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 1 > JAnUARY 2016

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

pARt no. MS0070 > REvISION 1 > JAnUARY 2016

StEp 1 Stand door panel upright central to garage door opening and ensure it is level by placing spirit level on top edge of door panel. If panel is not horizontally level it is important to use suitable packer underneath door panel to achieve level. ensure that 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.

InStALLInG vERtICAL tRACKSStEp 2 Cut the vertical tracks from the bottom as a pair. they are cut door height minus 300mm for std head single track and 385mm 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. 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.

StEp 3 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. refer Figure 3.

StEp 4 Install each vertical track to garage wall using suitable fixings, align inside edge of each track with penciled line as detailed in SteP 1 and make sure tops are level.

SEttInG Up tHE DooR pAnELSStEp 5 Select door panel with weatherseal pre-installed to bottom edge. Place this panel face down on a soft support (eg, two padded saw horses).

StEp 6 Attach the bottom cable bracket to each bottom corner of the panel using 1/4” metal screws. Hook one cable over steel extrusion either end.

StEp 7 using the end hinge attach a hinge to each rigid vertical section of the panel. ensure hinge is face down and level with top edge of the panel. refer Figure 7b.

StEp 8 As each door section is completed, the rollers must be placed in the brackets and hinges as shown in Figure 8. once complete slide bottom panel into vertical tracks, refer Figure 9. ensure rollers are engaged in track and moving freely.

LUBRICATION: Ensure that all roller shafts are dipped in grease before installation. Lubricate all hinges in holes provided.

StEp 9 Check that door panel is level by placing spirit level on top edge of door panel. If panel is not horizontally level it may be necessary to use suitable packer underneath door panel to achieve level. Make sure vertical tracks are level.

StEp 10 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. 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 door panel on top of the bottom panel.

StEp 11 repeat SteP 10 to the third door panel. ensure centre hinges are used on each internal vertical rigid section. 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 to SteP 12.

StEp 12 Place the last section face down, attach the top corner brackets to the door panel as shown in Figure 12. the top brackets are secured using four tek screws. If the door is supplied with reinforcement, attach as shown (inset). Do not install final panel until SteP 17.

NOTE ON REINFORCING BRACING: If your door is over 4.451m wide it will be supplied with reinforcing. these are placed as follows:

Doors 4.451m to 4.950m one reinforcing to the top panel and one to the bottom panel.

Doors 4.951 and over supplied with reinforcing for all panels.

FIGURE 1

Door

Wall Side

top View

FIGURE 10

FIGURE 3

FIGURE 5

FIGURE 7a

FIGURE 8

FIGURE 4

FIGURE 6

FIGURE 7b

FIGURE 9

Bottom

top

Bottom

top

Bottom Cableend Hinge Centre Hinge

Centre Hinge

end Hinge

end Hinge

Bottom Cable Bracket

top Corner Bracket

Centre Hinge

FIGURE 2

FIGURE 11Centre Hinge

end Hinge

Centre Hinge

end Hinge

pARt no. MS0070 > REvISION 1 > JAnUARY 2016

StEp 13 make sure front face of panels do not touch the wall and 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 and make necessary adjustment with temporary packers. once satisfied secure all wall mounted brackets to eliminate any further track movement.

InStALLInG HoRIzontAL tRACKSStEp 14 loosen the slide on each top bracket enabling easy roller adjustment.

StEp 15 use a suitable support to hold the back of the horizontal track in position. refer Figure 14.

StEp 16 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. refer Figure 15. Make sure the horizontal and vertical tracks are aligned when joined.

StEp 17 lower the final door panel into the vertical tracks. Fasten the hinges to the bottom of this panel. that is in a four panel door secure the hinges from the top of panel three to the bottom of panel four. this is done to prevent the top panel from falling out of the vertical track.

StEp 18 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. refer Figure 16. repeat this step for the second horizontal track.

ADJUStInG tHE top pAnELStEp 19 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 accordingly leaving enough clearance between head and jamb. once satisfied that the roller is correctly positioned in the track then tighten the slide bracket. If an opener is to be installed tighten bracket to leave clearance between panel and lintel. refer Figure 17.

FIttInG SpRInG ASSEMbLYStEp 20 Attach the bearing plate to each horizontal angle on both tracks using carriage bolts and nuts. refer Figure 18.

StEp 21 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.

StEp 22 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. refer Figure 20.

StEp 23 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 automatic GtS can be fixed in the centre and securely fix to the wall. refer Figure 21.

StEp 24 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. Both cables must be even.

FIGURE 13

FIGURE 15

FIGURE 17

FIGURE 14

FIGURE 16

FIGURE 18

FIGURE 12reinforcing Strut

FIGURE 19 two spring arrangement

left wound spring

right wound spring

Spring Anchor

Plug

l.W.S r.W.S

FIGURE 20

FIGURE 22

FIGURE 21

FIGURE 23

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

pARt no. MS0070 > REvISION 1 > JAnUARY 2016

AFtER InStALLAtIon CARECoLoRbonD® & CoLoURED StEEL FInISH

Your CSI® Classic Sectional Door has been pre-painted with a silicone 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

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.

toRSIon SpRInG ASSEMbLYWARNING: 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 25 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.

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. Refer Figure 23.

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.

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.