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 tRACKSStEp 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 Hingeend

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

StEp 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 bRACInGStEp 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 ASSEMbLYStEp 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 wIDtHpAnEL

QtYREo 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 - 5,250mm4 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 - 6,100mm4 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 SpRInGWARNING: 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 ADJUStMEntIMPORTANT: Door must always be in the closed position when adjusting the tension.

•Openandclosethedoortochecktension.

• Ifspringisovertensionedthedoorwillnotclosefully(Remedy–reducespring 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.

•Withthedoorinclosedpositionloosenthetrackwallbracketsandmovevertical 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 CARECoLoRbonD® & 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–particularcareshouldbetakento 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–donot 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 REQUIREDWe 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.

wARRAntYthe 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 SIDEThese 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).