CSI Classic Installation guide

Brand: CSI

Model: Classic

Type: Installation guide

CSI Classic is a sectional garage door, designed to provide security, attractive appearance and smooth, low effort operation. It features:

Pre-installed weather seal on bottom edge of door panel
2 x end hinge and center hinges to attach end stile of the panel
4 wheels and axles to each outer hinge
Vertical tracks cut to door height minus 280mm for std head single track and 405mm for low head double track
Wall fix brackets to fasten vertical track
Flag brackets to attach to the top of the track
Top corner brackets to secure top panel
Wheel and axle carriers to adjust vertical alignment of panels

CSI Classic is a sectional garage door, designed to provide security, attractive appearance and smooth, low effort operation. It features:

Pre-installed weather seal on bottom edge of door panel
2 x end hinge and center hinges to attach end stile of the panel
4 wheels and axles to each outer hinge
Vertical tracks cut to door height minus 280mm for std head single track and 405mm for low head double track
Wall fix brackets to fasten vertical track
Flag brackets to attach to the top of the track
Top corner brackets to secure top panel
Wheel and axle carriers to adjust vertical alignment of panels

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

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

REvISION 3

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

REvISION 3

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

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.

•Openandclosethedoortochecktension.

•Ifspringisovertensionedthedoorwillnotclosefully(Remedy–reduce

spring tension, 1/4 decrements advised)

•Ifspringisundertensionedthedoorwillbeheavytolift(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.

•Withthedoorinclosedpositionloosenthetrackwallbracketsandmove

vertical tracks to adjust clearance from the wall.

•Checkallnutsandboltsforsecurefastness.

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

andaclothevery14daysisrecommended–particularcareshouldbetaken

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

becomesstiff,theapplicationofpowderedgraphiteisrecommended–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).

CSI Classic Installation guide

Brand: CSI

Model: Classic

Type: Installation guide

CSI Classic is a sectional garage door, designed to provide security, attractive appearance and smooth, low effort operation. It features:

Pre-installed weather seal on bottom edge of door panel
2 x end hinge and center hinges to attach end stile of the panel
4 wheels and axles to each outer hinge
Vertical tracks cut to door height minus 280mm for std head single track and 405mm for low head double track
Wall fix brackets to fasten vertical track
Flag brackets to attach to the top of the track
Top corner brackets to secure top panel
Wheel and axle carriers to adjust vertical alignment of panels

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CSI Classic Installation guide

CSI Classic Installation guide

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