10060 BY CHALLENGER AC9000 SERIES Residential Vehicular Garage Door Operator MODEL NUMBERS AC9300, AC9500, and ACJ9500 I N S TA L L AT I O N A N D O W N E R ’ S M A N U A L INSTALLER: Place this manual in the plastic envelope provided and permanently attach to the wall near the pushbutton.
TABLE OF CONTENTS Product Features ................................................... 3 Component Identification/Tools Required ........... 4 Section A: Assembly Instructions ....................... 5 Section B: Important Installation Instructions .... 6 Section C: Installing the Operator ....................... 7 Identify Your Door Type .................................... 7 Mounting the Front Bracket .............................. 8 Mounting the Power Head .................................
PRODUCT FEATURES The purpose of this booklet is to provide assembly, Sensing System: A built-in sensing system detects installation and operation information concerning the Challenger AC9000 Series (Models AC9300, AC9500, and ACJ9500) Residential Garage Door Openers and related Accessory Products. NOTICE IT IS IMPORTANT THAT THIS INSTRUCTION MANUAL BE READ AND UNDERSTOOD COMPLETELY BEFORE INSTALLATION OR OPERATION IS ATTEMPTED.
COMPONENT IDENTIFICATION TRANSMITTER OPTIONAL WALL BRACKET POWER HEAD/DRIVE RAIL ASSEMBLY DOOR ARM TUBE SECTION DOOR ARM ROD SENSOR ‘L’ BRACKET MANUAL RELEASE TAG DOOR BRACKET BELL WIRE SPOOL (when supplied) ! SAFE FINISH PHOTOSYSTEM SENSORS SENSOR ‘U’ BRACKET W AR N I N G Child can be pinned under automatic garage door. Death or serious injury can result. • Never let child walk or run under moving door. • Never let child use door opener controls. • Always keep moving door in sight.
A: ASSEMBLY INSTRUCTIONS If Your Opener Is Supplied Fully Assembled, Please Disregard This Page. NOTE: The Rail/Chain Assembly is packaged separately from the Power Head Unit. The trolley, front idler/ tension adjustment assembly, chain, drive gear and limit cams are assembled to the Rail/Chain Assembly at the factory. Follow the steps outlined below to complete assembly prior to installation. Refer to the component identification illustrations on the previous page.
B: IMPORTANT INSTALLATION INSTRUCTIONS IMPORTANT INSTALLATION INSTRUCTIONS WARNING TO REDUCE THE RISK OF SEVERE INJURY OR DEATH: READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS! ALUMINUM AND STEEL DOOR TOP SECTIONS TO AVOID DAMAGE AND TO INSURE PROPER OPERATION OF THE SAFETY REVERSE SYSTEM. CONTACT YOUR DOOR MANUFACTURER FOR A REINFORCEMENT KIT. WARNING: AN UNBALANCED DOOR OR ONE THAT STICKS OR BINDS MAY PREVENT THE SENSING SYSTEM FROM WORKING PROPERLY, CAUSING INJURY OR DEATH.
C: INSTALLING THE OPERATOR IMPORTANT! IDENTIFY YOUR DOOR TYPE FROM THOSE ILLUSTRATED BELOW AND FOLLOW INSTRUCTIONS FOR THAT TYPE OF DOOR 104367 104368 SECTIONAL DOOR CURVED TRACK HIGH ARC OF DOOR TRAVEL ONE PIECE DOOR HORIZONTAL TRACK JAMB HARDWARE ONE PIECE DOOR NO TRACK JAMB HARDWARE HIGH ARC OF DOOR TRAVEL HIGH ARC OF DOOR TRAVEL TRACK DOOR TRACK DOOR ONE PIECE DOOR NO TRACK PIVOT HARDWARE HIGH ARC OF DOOR TRAVEL DOOR DOOR JAMB HARDWARE FOR THESE TYPES OF DOORS USE 1/3 HP MODEL AC9300 OR 1/2
C: INSTALLING THE OPERATOR WARNING FRONT MOUNTING BRACKET MUST BE INSTALLED TO A STRUCTURAL SUPPORT (STUD) ON THE HEADER WALL. FAILURE TO DO SO COULD CAUSE SENSING SYSTEM TO MALFUNCTION, RESULTING IN ENTRAPMENT, INJURY OR DEATH. REINFORCE HEADER USING 2 x 6 WOOD STUDS AND LAG SCREW OR ANGLE IRON AND LAG SCREWS AS NECESSARY (NOT PROVIDED). STEP 1A: Mounting the Front Bracket — One Piece Doors Without Track: Mark a vertical centerline on the header above the door.
C: INSTALLING THE OPERATOR STEP 4: Mount Power Head to Ceiling: Since there is such variety in ceiling structures, all the mounting possibilities for the Power Unit cannot be illustrated here. The main concern is mounting the Power Unit securely to the ceiling joists for operational strength, rigidity and safety. Although there are a series of mounting slots provided on the power unit, try to secure the mounting straps in the slots closest to the front.
C: INSTALLING THE OPERATOR Step 8: Connecting Door Arm to Trolley (THIS IS FOR SECTIONAL DOORS ONLY - FOR ONE PIECE DOORS PROCEED TO STEP 10) The door arm assembly consists of the door arm tube section and door arm rod which are packaged separately. To assemble, screw the door arm rod into the the door arm tube in a clockwise direction approximately ten turns. Connect the door arm assembly into the trolley with the open end of the rod hook facing the power head unit (away from the door).
C: INSTALLING THE OPERATOR 6” Step 10: Connecting the Door Arm to the Door - ONE PIECE DOORS (USING OPTIONAL ONE PIECE DOOR ARM ASSEMBLY) Door Brackets Attach door arm brackets to the top surface of the door on the center line. Reposition Open and Close limit stops so trolley stops in locations as shown. Assemble the door arm by screwing curved rod into straight tube section. Allow approximately 6” of rod to project outside of the straight tube.
D: CONTROL AND AUXILIARY EQUIPMENT INSTALLATION OF A STANDARD WALL PUSH BUTTON OR DELUXE WALL STATION CONTROL A standard wall push button is included in your hardware package, an optional A CHILD OPERATING THE DOOR CONTROLS Deluxe Wall Station may be purchased RISKS INJURY — OR DEATH — TO HIMSELF AND from your installing dealer. The operatOTHERS. DO NOT ALLOW CHILDREN TO ing parameters for the standard wall OPERATE ANY DOOR CONTROLS.
D: CONTROL AND AUXILIARY EQUIIPMENT SAFE FINISH™ PHOTOSYSTEM INSTALLATION Identify which side of the garage door opening (if any) the sun is “likely” to shine into. As sunlight may cause undesirable operation, mount the sending unit (black button below the window) on the side of the door opening exposed most to the sun. STEP 1: 12 Inches From Door Opening #8 Hex Head Screw 110052-1 Mounting the Photosystem Wall Brackets Select a mounting position 5 inches above the floor to the center line wall bracket.
D: CONTROL AND AUXILIARY EQUIPMENT INSTALLATION OF RADIO CONTROLS: The following instructions detail installation of Model 9931 Radio Controls. For other Radio models, see instructions packaged with product. TRANSMITTER: To gain access to the Transmitter Coding Switches, remove the Battery Cover from the front of the T ransmitter by sliding it toward the bottom of the Transmitter as illustrated.
E: OPERATION AND ADJUSTMENT INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS WARNING TO REDUCE THE RISK OF SEVERE INJURY OR DEATH: READ AND FOLLOW ALL USER / SAFETY INSTRUCTIONS! • NEVER let children operate or play with door controls. Keep the Remote Control away from children. • ALWAYS keep a moving door in sight and keep people and objects away from the door area until the door is completely closed. NO ONE SHOULD CROSS THE PATH OF A MOVING DOOR. • NEVER GO UNDER A STOPPED, PARTIALLY OPEN DOOR.
E: OPERATION AND ADJUSTMENT INSTRUCTIONS HOW THE DOOR MOVES WHEN THE OPENER IS ACTIVATED Always keep moving door in sight and away from people and objects until it is completely closed NO ONE SHOULD CROSS THE PATH OF A MOVING DOOR. IF THE DOOR IS... ...FULLY OPEN, then pushing the standard wall Push Button or the radio control will cause the door to begin MOVING DOWNWARD. ...FULLY CLOSED, then pushing the wall Push Button or the radio control will cause the door to begin MOVING UPWARD. ...
E: OPERATION AND ADJUSTMENT INSTRUCTIONS OPTIONAL THREE FUNCTION DELUXE WALL STATION When the Wall Station is connected to the operator per instructions supplied with the wall station, it will provide the following features: 1. “OFF-ON” will prevent inadvertent operation of the door from any other push button, radio or keyless entry device. It will also as additional protection from unwanted operation during absence of the owner.
E: OPERATION AND ADJUSTMENT INSTRUCTIONS Adjustment #3: Setting Door Close Limit 9”to10” Confirm trolley close position 9” to 10” between the inside face of the door and the point where the door arm connects to the trolley (see illustration). Trolley (Close Limit Position) If adjustment of the close trolley position is necessary, activate the opener and move the trolley 12” to 18” to provide access to the “Limit Stop” devices (mounted on the chain).
E: OPERATION AND ADJUSTMENT INSTRUCTIONS Adjustment #5: Alignment and Initial Test of Safe Finish Photosystem A. Keep a portable transmitter with you to control the garage door opener. The red light on the receiver unit should now be on. If not, recheck that the mounting screws are tight then, if necessary, align the photosystem by slightly bending the wall bracket until proper operation is obtained. B.
SAFE FINISH WIRING DIAGRAM / MAINTENANCE SCHEDULE SAFE FINISH PHOTOSYSTEM WIRING - SERIES AC9000 109985 MAINTENANCE OF YOUR OPENER Once a Month: 1. Test for reversal on a 1-1/2 inch high object or a 2 x 4 board laid flat on the floor (see “Important Test: Opener Obstruction Sensing Feature”, page 18). If adjusting either the force or the limit of travel, retest the opener. Failure to adjust the opener may cause serious injury or death. 2.
INSTALLATION CHECKLIST BEFORE PLACING DOOR OPERATOR IN REGULAR SERVICE, MAKE SURE THAT: 1. THE FRONT AND REAR MOUNTS FOR THE OPENER ARE SOUND AND SECURE AND THE RAIL IS POSITIONED CORRECTLY ABOVE THE HIGH ARC OF THE DOOR, AND THAT THE OPENER IS POSITIONED OVER THE DOOR ACTION CENTERLINE. 2. FOR SECTIONAL DOORS AND ONE-PIECE DOORS WITH TRACKS, THE POSITION OF THE DOOR ARM, WITH THE DOOR CLOSED, IS SUCH THAT ITS CONNECTING POINT ON THE TROLLEY IS 5" TO 8" BEHIND ITS CONNECTING POINT ON THE DOOR BRACKET.
TROUBLESHOOTING GUIDE USE EXTREME CAUTION AT ALL TIMES WHEN ATTEMPTING TO DIAGNOSE WARNING AND RECTIFY PROBLEMS WITH YOUR GARAGE DOOR OPENER. BEFORE ATTEMPTING ANY SERVICE ON UNIT, DISCONNECT OPENER FROM POWER SUPPLY. YOUR GARAGE DOOR IS THE LARGEST MOVING OBJECT IN YOUR HOUSE, AND THE SPRINGS, PULLEYS, CABLES AND MOUNTING HARDWARE UTILIZED TO BALANCE ITS OPERATION ARE UNDER EXTREME TENSION AT ALL TIMES AND CAN CAUSE SERIOUS PERSONAL INJURY, EVEN DEATH, IF DISTURBED.
PARTS BREAKDOWN & LISTING # 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 22 23 24 25 Part # 109874 260587 260584 109938 005320 260572 260570 109948 109947 109845 220981 157149 229863 221012 220992 109843 157501 109932 249257 102618 102641 109369 109370 Description Frame Motor,1/3HP,AOS F42C55A29 Motor,1/2HP,AOS F42C56A29 Motor Control Board Power Supply Cord Capacitor,43-52 MFD,250V Capacitor,53-64 MFD,250V Wire Harness, Low Voltage Wire Harness,High Voltage Lamp Socket Light Diffuser MCB Spacer Limit Switch N
Manufacturer’s Limited Warranty Allstar warrants its AC9000 Series Challenger residential vehicular garage door operators as follows: A. The drive train to be free from defects in materials and workmanship for: Models AC9300/AC9500/ACJ9500: for 10 years from the date of purchase by the original purchaser. The drive train includes the motor, rails, frame and chain. B.
