Page 2 - TABLE OF CONTENTS; READ THESE STATEMENTS CAREFULLY AND FOLLOW THE
2 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...
Page 3 - PRODUCT FEATURES; The purpose
3 110044 PRODUCT FEATURES The purpose of this booklet is to provide assembly, 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 INSTRUCTI...
Page 5 - Recheck; ASSEMBLY INSTRUCTIONS
5 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...
Page 6 - FT OR MORE ABOVE THE FLOOR. MOUNT; IMPORTANT INSTALLATION INSTRUCTIONS
6 WARNING TO REDUCE THE RISK OF SEVERE INJURY OR DEATH: READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS! WARNING: AN UNBALANCED DOOR OR ONE THAT STICKS OR BINDS MAY PREVENT THE SENSING SYSTEM FROM WORKING PROPERLY, CAUSING INJURY OR DEATH. ENSURE DOOR IS PROPERLY BALANCED AND ELIMINATE ANY STICKING OR...
Page 7 - INJURY OR DEATH IF DISTURBED. DO NOT ATTEMPT ADJUSTMENT.; IDENTIFY YOUR DOOR TYPE FROM THOSE ILLUSTRATED BELOW AND FOLLOW; INSTALLING THE OPERATOR; FOR THESE TYPES OF DOORS USE 1/3 HP; REINFORCE THE HEADER WALL; Vertical Center; Mounting the Front Bracket — Sectional Doors and One-; with Track
7 WARNING WARNING WARNING WARNING SPRINGS, PULLEYS, CABLES AND MOUNTING HARDWARE USED TO BALANCE YOUR GARAGE DOOR ARE UNDER EXTREME TENSION AT ALL TIMES AND CAN CAUSE SEVERE INJURY OR DEATH IF DISTURBED. DO NOT ATTEMPT ADJUSTMENT. IMPORTANT! IDENTIFY YOUR DOOR TYPE FROM THOSE ILLUSTRATED BELOW AND F...
Page 8 - INCHES; Mounting the Front Bracket — One; Without; FRONT MOUNTING BRACKET MUST BE INSTALLED TO A STRUCTURAL SUPPORT; WARNING; — Sectional Doors and One Piece Doors; with; STEP 3A; — One Piece Doors; without
8 HIGH ARC RISE HIGH ARC RISE HORIZONTAL LINE 4 INCHES 8 INCHES 4 TO 8 INCHES 13 INCHES 8 TO 12 INCHES 18 INCHES STEP 1A: Mounting the Front Bracket — One Piece Doors Without Track: Mark a vertical centerline on the header above the door. Manually raise the door to its high arc position and temporar...
Page 9 - Mount Power Head to Ceiling:; STEP 7: Door Bracket Installation
9 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, rigi...
Page 10 - Step 8: Connecting Door Arm to Trolley; Type 1: Door Mounted Bracket
10 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 th...
Page 11 - Install a; Rough Service; STEP 11: Connecting The Electrical Power; A GFI Type receptacle is recommended.; Permanent Wiring Connection; (USING OPTIONAL ONE PIECE DOOR ARM ASSEMBLY); IMPROPER WIRING COULD CAUSE
11 Step 12: Install a Rough Service lamp bulb (75 Watt maximum) firmly in the light socket. Light bulbs in Door Openers are subject to vibration during normal operation which may shorten their life spans. Rough Service bulbs, available at most hardware stores, are recommended. Fit Light Diffuser tab...
Page 12 - CONTROL AND AUXILIARY EQUIPMENT; WARNING: SOME LOCAL BUILDING CODES DO NOT ALLOW; ANY; CONTROL BUTTON WARNING LABEL
12 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 Deluxe Wall Station may be purchased from your installing dealer. The operat- ing parameters for the standard...
Page 13 - CONTROL AND AUXILIARY EQUIIPMENT; SAFE FINISHTM PHOTOSYSTEM INSTALLATION; unmarked wire ends together. See wiring diagrams on page 20 .; Final Installation of Photosystem Units; and the solid color wire to the operator
13 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 ...
Page 14 - Setting The Coding Switches:; When setting the Coding Switches THE FACTORY; Mounting The Receiver:; After setting the Coding Switches, mount the Receiver on; POINTED STRAIGHT DOWN; toward the; INSTALLATION OF RADIO CONTROLS:; The
14 D: CONTROL AND AUXILIARY EQUIPMENT WARNING WARNING WARNING WARNING TO PREVENT THE RISK OF PERSONAL INJURY, DAMAGE TO DOOR OR PROPERTY, ONLY OPERATE DOOR CONTROLS WHEN DOOR IS IN CLEAR VIEW. KEEP REMOTE CONTROL AWAY FROM CHILDREN IN SECURE AREA. 104386 Setting The Coding Switches: When setting the...
Page 15 - OPERATION AND ADJUSTMENT INSTRUCTIONS; IMPORTANT SAFETY INSTRUCTIONS; children.; TURNING ON POWER TO THE OPERATOR; HOW TO ACTIVATE THE OPENER
15 E: OPERATION AND ADJUSTMENT INSTRUCTIONS IMPORTANT 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....
Page 16 - HOW THE DOOR MOVES WHEN THE OPENER IS ACTIVATED; MOVING; HOW THE LIGHT WORKS AND WHAT IT MEANS WHEN IT FLASHES; Problems with the safety system; HOW TO OPERATE THE DOOR MANUALLY -; MANUAL RELEASE DISCONNECT
16 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 P...
Page 17 - Adjustment #2: Opening and Closing Force; CLOSE; labeled “; OPEN; hex nut to decrease force until the door reacts properly.; OPTIONAL THREE FUNCTION DELUXE WALL STATION; This feature is to be activated only when the door is
17 E: OPERATION AND ADJUSTMENT INSTRUCTIONS Adjustment #1: Opening Travel Your opener is assembled at the factory with the trolley in the forward position with the open limit stops snapped in place on the chain, set for a standard door. If you door is non-standard, move BOTH open limit stops, locate...
Page 18 - Adjustment #3: Setting Door Close Limit; REPEAT THIS TEST MONTHLY!
18 Adjustment #3: Setting Door Close Limit 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). If adjustment of the close trolley position is necessary, activate the opener and move the trolley 12” ...
Page 19 - There may be a slight delay in; LED should go OFF; If; Important Test: Photoelectric Obstruction Test; Adjustment #7 :Resetting the Travel Timer
19 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. I f not, recheck that the mounting screws are tight then, if necessary, align the photosystem by sli...
Page 20 - SAFE FINISH PHOTOSYSTEM WIRING - SERIES AC9000; MAINTENANCE OF YOUR OPENER; SAFE FINISH WIRING DIAGRAM / MAINTENANCE SCHEDULE
20 SAFE FINISH PHOTOSYSTEM WIRING - SERIES AC9000 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 trave...
Page 21 - INSTALLATION CHECKLIST
21 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 S...
Page 22 - TROUBLESHOOTING GUIDE; spring
22 TROUBLESHOOTING GUIDE USE EXTREME CAUTION AT ALL TIMES WHEN ATTEMPTING TO DIAGNOSE 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, ...
Page 23 - PARTS BREAKDOWN & LISTING
23 PARTS BREAKDOWN & LISTING # Part # Description 1 109874 Frame 2 260587 Motor,1/3HP,AOS F42C55A29 260584 Motor,1/2HP,AOS F42C56A29 3 109938 Motor Control Board 4 005320 Power Supply Cord 5 260572 Capacitor,43-52 MFD,250V 260570 Capacitor,53-64 MFD,250V 6 109948 Wire Harness, Low Voltage 109947...
Page 24 - Manufacturer’s Limited Warranty; The drive train includes the motor, rails, frame and chain.
24 c.p. Allstar Corporation Downingtown, PA 19335 This garage door operator is built in the USA and complies with all requirements of Underwriters Laboratories Standard UL-325. P/N 109987 Rev. C April 2003 Manufacturer’s Limited Warranty Allstar warrants its AC9000 Series Challenger residential vehi...