Your new CSI
®
Classic Sectional Garage Door
has been designed to provide security, attractive appearance and smooth, low effort operation. Your door will not provide optimum
performance unless it is installed correctly. No guarantee will be given or responsibility accepted by the manufacturers if the door is not installed as instructed. For satisfactory door
operation please follow the instructions carefully.
DISCLAIMER THESE INSTRUCTIONS ARE INTENDED FOR PROFESSIONAL GARAGE DOOR INSTALLERS. NOTE: ALL REFERENCES ARE TAKEN FROM INSIDE LOOKING OUT.
PART NO. MS0070
>
REvISION 3
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JULY 2017 V2
The following hazards and hazard controls have been identified for installers during the installation of this door.
HAZARD CONTROL
• Housekeeping - risk of slip trip or fall
• Housekeeping - risk of injury to other people or
animals in the installers work area
• Tidy up site prior to start work as a minimum area should be at least the area of the installation back into the garage and 2 metres in front
• If the Site housekeeping is deemed to be unsafe do not install the door
• Keep all people well clear of installers work area with appropriate signage and discussion with owner
• Manual handling when moving the door from the Trailer
or Ute to the installation area - risk of musculoskeletal
injury
• Manual handling when installing Doors &
Openers particularly above head height - risk of
musculoskeletal injury or twisting
• Manual handling when installing tracks and torsion bars
- risk of musculoskeletal injury
• Pack sizes
• Use of 2 person lifts
• Use of mechanical aids
• Avoid twisting (Practice correct lifting techniques)
• Correct use of ladders while installing tracks
• Working at heights and working with ladders, scissor lifts,
scaffold - risk of fall from height
• Ladder check
• Ladder placement
• Do not work off the top rung
• Sharp edges on door, tracks or related jewellery -
risk of laceration
• Wear appropriate PPE (Dyneema cut off Gloves)
• Follow instruction explicitly particularly for the installation of windows in some panel doors as the unrolled cut out edges presents a very sharp
edge
• Pinch points - risk of cut, puncture or crush injury • Wear appropriate PPE and keep hands well clear of pinch points
• Ensure hands well clear of the panels
• Use of hand tools - risk of eye injury, laceration, cut,
stab or puncture injuries (Tools checklist)
• Use of Electric/ Battery or pneumatic tools - noise
hazard
• Use of cutting tools creating sparks - risk of fire
• Wear appropriate PPE and utilise operators manual
• Use appropriate noise/hearing protection in the form of ear plugs or ear muffs
• Ensure appropriate fire protection available and housekeeping to ensure that flammable liquids or materials are removed from the area of work
• Tension spring - risk of release of stored energy
(striking installer on the head or body)
• Ensure correctly fitting winding bar is used
• Ensure the correct length winding bar is utilised
• Ensure winding bar is placed appropriately in the torsion socket plug
• Ensure correct bolts are tightened or loosened (or clamp pliers) to ensure there is no release or controlled release of energy from the spring
either through the torsion bar or the winding bar
• Keep hands clear of the torsion plug at all times
• Keep head clear of the tensioning bar at all times
• Position the door on the brackets, there is a risk of the
door striking a person
• Ensure the door is immediately fastened to the bracket with the “U” Bolt
• Ensure no-one ever walks under a door sitting on a bracket
IMPORTANT INFORMATION THE INSTALLER mUST SELECT AND USE FASTENERS APPROPRIATE TO THE mATERIAL INTO wHICH THEy ARE bEING FIxED.
GENERAL ASSEMBLED VIEW
InstallatIon InstructIons V2
PART NO. MS0070
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REvISION 3
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JULY 2017 V2
STEP 1
Select door panel with weather seal pre-installed to bottom edge. Place this
panel face down on a soft support (eg, two padded saw horses) (FIGURE 1).
STEP 1A/B
Select from FIGURE 1A the bottom cable bracket and fit to each bottom
corner of the panel using 5 x 1/4” metal screws. Attach one cable over steel
extrusion either end (FIGURE 1B).
STEP 1C
Using the 2 x end hinge (FIGURE 1C) attach 1 hinge to each end stile of the
panel and fit the centre hinges to all intermediate stiles. Ensure hinge pivot
point is level with top edge of the panel. Fit 4 wheels and axles to each outer
hinge (FIGURE 1D).
LUBRICATION: Ensure that all roller shafts are dipped in grease
before installation. Lubricate all hinges in holes provided.
STEP 2
Stand door panel upright and central to garage door opening and ensure it is
level by placing spirit level on top edge of door panel (FIGURE 2). If panel is
not horizontally level it is important to use suitable packer underneath
door panel to achieve level. Ensure there is an even overlap on either side.
Mark a point 10mm past either end. Using a straight edge pencil mark a vertical
line on both sides of the opening (place a temporary prop against the panel).
STEP 3
Cut the vertical tracks from the bottom as a pair. They are cut door height
minus 280mm for std head single track and 405mm for low head
double track. Loosely fasten the wall fix brackets to each vertical track
using the 1/4” x 5/8” screws and nuts as shown. The screw heads must be
inside the track (FIGURE 3A). The smaller wall bracket is fixed to the bottom
of the track, with the larger bracket above.
IMPORTANT: Ensure the flat edge of the track is facing the wall.
Attach the flag brackets to the top of the track with the 1/4” x 5/8” screws
and nuts, once again screw heads must be inside the track (FIGURE 3B & C).
STEP 4
Install each vertical track by passing it over the bottom panel wheels already
in the opening. Using suitable fixings align inside edge of each track with
pencilled line as detailed in STEP 2 and FIGURE 4 and make sure tops of
tracks are level with each other.
STEP 5
Attach end hinges first to each end of the next door panel then attach
the centre hinges to each vertical rigid section between the two outer end
hinges by working your way towards the centre (FIGURE 6). Place a piece
of cardboard on top of the bottom panel where it mates with the
next panel to maintain the required gap between panels. Lower this
panel on top of the bottom panel (FIGURE 7).
STEP 6
Repeat STEP 5 to the third panel. NOTE: If your CSI
®
Classic has more
than 4 door panels it will be necessary to repeat the process again
using end hinges and centre hinges before proceeding.
STEP 7
Place the last section (top panel) face down, attach the top corner brackets
to the door panel as shown in FIGURE 8. The top brackets are secured
using four tek screws. Do not install final panel until STEP 12.
STEP 8
Adjust wheel and axle carriers so that the panels are in a vertical alignment
without scraping the wall or binding in the tracks.
IMPORTANT: Do not force the track too tightly against the rollers as
this will cause the door to bind when in operation.
Check that all door panels are level, make necessary adjustment if required
Once satisfied secure all wall mounted brackets to eliminate any further
track movement (FIGURE 9).
HORIZONTAL TRACKS
STEP 9
Use a suitable support to hold the back of the horizontal track in position
(FIGURE 10). NOTE: the 22” reinforcement angle always goes on the
lower track in Low headroom installations.
STEP 10
Attach the curved section of the horizontal track to the flag bracket using the
1/4” x 5/8” screws and nuts. Ensure that the screws are on the inside of the
track. Attach the end of the horizontal angle to the top of the wall mounted
flag bracket, the 3/8” x 3/4” carriage bolt and nut (FIGURE 11). Make sure
the horizontal and vertical tracks are aligned when joined.
Door
Wall
Side
Top
View
Centre
Hinge
End
Hinge
FIGURE 4 FIGURE 6
FIGURE 1A
End
Hinge
Bottom
Cable
Bracket
Top
Corner
Bracket
FIGURE 2
FIGURE 3B FIGURE 3C
Bottom
Top
FIGURE 3A
FIGURE 1C
FIGURE 1B
FIGURE 1
Bottom
Top
End Hinge
Centre Hinge
FIGURE 1D
Centre
Hinge
PART NO. MS0070
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REvISION 3
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JULY 2017 V2
STE P 11
Secure the rear of the horizontal track with steel angle brackets supplied, if
not suitable it will be necessary to fabricate from other material. Make sure
that the track is level and square with the opening. Due to the fact that the
horizontal tracks are weight bearing, when the door is fully opened ensure
that adequate fasteners are used into solid fixings (FIGURE 12). Repeat this
step for the second horizontal track.
STEP 12
Fit the top panel by removing the sliding section from each top hangar and
placing the panel in position with cardboard between the joint to the panel
below, refit the sliding section with the axle into the track fit bolts and nuts
do not tighten, fit fixings to the hinge below.
The sliding section on the top door panel bracket should be loose. Push
roller to the front of the front of the guide and adjust top panel leaving
enough clearance between head and jamb. Once satisfied that the roller is
correctly positioned in the track then tighten the slide bracket (FIGURE 13).
REINFORCING BRACING
STEP 13
These are placed as follows:
When fixing reinforcing ensure 2 fixing are placed at each end and to every
intermediate stile (FIGURE 8).
SPRING AND SHAFT ASSEMBLY
STEP 14
Attach the bearing plate to each horizontal angle on both tracks using
carriage bolts and nuts (FIGURE 11).
STEP 15
Secure the spring anchor plugs to the centre bearing. Locate the left wound
spring to the right side of the plate and the right wound spring to the left of
the plate. If your door only requires one wound spring locate it to the left or
right as detailed above. Slide the completed spring assembly over the shaft
and slide into place the cable drums at each end. Ensure that the correct
drums are on the right ends as marked (FIGURE 14 and 15 also ATTENTION
INSTALLERS diagram on following page).
STEP 16
Place the shaft assembly over the horizontal tracks and slide one end
through the bearing plate with the greatest side clearance, then insert the
opposite end into its bearing plate (FIGURE 15).
STEP 17
Take hold of the spring bearing plate and raise it until the shaft is level.
Position the bracket near the centre of the header so that the opener can be
fixed in the centre and securely fix to the wall (FIGURE 16).
STEP 18
Pull the cables up in the space between the tracks and the door. Align the
cable over the back of the cable drum and insert in the cable slot. Lay the
cable over the highest outside groove of the drum and tighten cable drum
onto the shaft place a clamp onto the shaft and against the lintel to prevent
the cable unwinding (FIGURE 17). Repeat for the second cable and drum
making sure both cables and drums are evenly aligned.
FIGURE 13
FIGURE 10
FIGURE 12
FIGURE 8
FIGURE 14 Two spring arrangement
Left
wound
spring
Right
wound
spring
Spring
Anchor
Plug
L.W.S R.W.S
FIGURE 15
FIGURE 17
FIGURE 16
FIGURE 18
Guide only
2100mm high
- approx 7.5 turns
2400mm high
- approx 8.5 turns
+/- 75mm
Door
centre
line
Centre line
between bearing
holes
Line B
FIGURE 9
FIGURE 7
DOOR WIDTH
PANEL
QTY
REO QTY FIT TO
0 - 3,570mm 4-6 0 n/a
3,575 - 4,600mm 4-6 1 top
4,605 - 4,900mm 4-6 2 top + bottom
4,905 - 5,250mm
4 2 top + bottom
5-6 3 top + bottom + middle
5,255 - 5,510mm
4 2 top + bottom
5 3 top + bottom + middle
6 5 miss the middle panel
5,515 - 5,930mm 4-5 3 top + bottom + middle
5,935 - 6,100mm
4 3 top + bottom + middle
5 4 miss the middle panel
5,515 - 6,100mm 6 6 all the panels
6,105 - 6,500mm 4-6 reo all panels
all the panels
FIGURE 11
PART NO. MS0070
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REvISION 3
>
JULY 2017 V2
TORSION SPRING
WARNING: Springs under tension may cause damage or injury if
handled incorrectly and should only be attempted by a person with
sound knowledge of springing mechanisms.
IMPORTANT: Door must always be in closed position when
adjusting tension.
STEP 19
Draw or texture a central horizontal line along the length of the springs. This
line is used to easily identify the amount of tension you have put on the door,
each spiral reflects one turn of tension.
Springs must be tensioned in the direction they are wound (FIGURE 18).
Insert a winding bar into the hole of the spring block and wind 1/4 of a turn,
now insert a second winding bar and continue turning. Repeat this process
until desired tension is achieved. Once you have completed the desired
number of turns secure the set screws on the spring block to the shaft.
Remove the winding bars.
WARNING: Always ensure that your body and face are to the side of
the winding bars.
FINAL ADJUSTMENT
IMPORTANT: Door must always be in the closed position when
adjusting the tension.
•Openandclosethedoortochecktension.
•Ifspringisovertensionedthedoorwillnotclosefully(Remedy–reduce
spring tension, 1/4 decrements advised)
•Ifspringisundertensionedthedoorwillbeheavytolift(Remedy–
increase spring tension, 1/4 increments advised)
NOTE: Always ensure the torque is taken up on the winding bar
prior to releasing spring set screws.
•Withthedoorinclosedpositionloosenthetrackwallbracketsandmove
vertical tracks to adjust clearance from the wall.
•Checkallnutsandboltsforsecurefastness.
Congratulations! You have now successfully commissioned your CSI
®
Classic sectional overhead garage door. If installing an automatic opener,
please refer to the opener installation instructions.
AFTER INSTALLATION CARE
COLORBOND
®
& COLOURED STEEL FINISH
Your CSI
®
Classic Sectional Door has been pre-painted with a modified
polyester formulation, which is one of the best paint films commercially
available today. However, all exposed surfaces require some attention to
guard against the premature onset of corrosion and any other harmful
atmospheric effects. In our atmosphere there are harmful deposits that
gather on the door surface and if not removed regularly, will seriously affect
the appearance and life of the door Washing of the door with clean water
andaclothevery14daysisrecommended–particularcareshouldbetaken
to clean areas of the door not normally washed by rain.
LOCK (if fitted)
Your lock does not require special maintenance, however, if the keyway
becomesstiff,theapplicationofpowderedgraphiteisrecommended–do
not grease or oil the lock.
WARNING: Do not disassemble the lock mechanism and do not
allow paint to enter the lock keyway.
HINGES & HANGERS
If the hinges and hangers squeak and squeal during operation, then the
hinges haven’t been greased or the grease has dried up. Please apply some
grease to the shaft to minimise this
CABLES
Check the cables regularly for corrosion, fraying or tangling, if any of these
are evident call your service provider.
REGULAR MAINTENANCE REQUIRED
We recommend that you check the operation of your CSI® Classic
Sectional Door at least every six months (more regularly in extreme
environments or frequent use). The effort required to manually open and to
manually close the door should be about the same (if door has an automatic
opener, put into manual mode before testing door). If the door is difficult to
operate in either direction (up or down) then check that the inside surfaces
of the guides are clean and free of obstructions. If the door is still difficult to
operate, then your door will need a service to adjust the spring tension and
possibly other operational parts of the door.
This service should only be carried out by an experienced door technician,
using the correct tools.
If you have an automatic opener fitted to your door, it is particularly
important that you ensure the optimum operation of the door, otherwise you
may reduce the effective life of the opener.
To keep your door running well, it is recommended that your door be
serviced, by an experienced door technician, every 12 months (more
regularly in extreme environments or frequent use), or earlier if required.
SPRING TENSION
It is natural for springs to lose tension over time. When spring tension is
adjusted or when your door is first installed it is usual to apply a little more
tension than is required for balanced operation, to allow for the normal
“settling in” of the springs.
WARRANTY
The CSI
®
Classic Sectional Door in normal residential use is covered by a
12-month warranty, 12 months on surface (excludes salt corrosion), all other
parts 12 months.
Warranty conditional on proper care as recommended above. Full details
of your warranty are available on the Owners Handbook/Warranty Card
attached to this door.
ATTENTION INSTALLERS!
NEw COLOUR CODING STANDARD FOR ALL b&D SECTIONAL DOOR SPRINGS
Springs & drums are now colour
coded based on winding direction
to match international standards.
INSIDE GARAGE LOOKING OUT
red cable drum black cable drumblack plug red plug
LEFT HAND SIDE RIGHT HAND SIDE
These springs are right hand wound
and can be identified by the direction
of the curled fingers of the right hand
when the thumb is pointing left,
matching the same direction of the
spring end and pointing to the red
cable drum. The plugs in these springs
are painted black and go on the left
hand side of the door.
NOTE: Red cable drum mounted on
the left side (standard headroom).
These springs are left hand wound
and can be identified by the direction
of the curled fingers of the left hand
when the thumb is pointing right,
matching the same direction of the
spring end and pointing to the black
cable drum. The plugs in these springs
are painted red and go on the right
hand side of the door.
NOTE: Black cable drum mounted on
the right side (standard headroom).
/
