Henderson TRACKED Installation Instructions

Installation Instructions
For
TRACKED
Unframed Single
GRP Garage Door
(where the door is to be fitted to a timber garage door frame)
Always read the care and maintenance label thoroughly.
Part No. 002440
Issue No. 04 December 2004
PC Henderson Limited
Durham Road, Bowburn, County Durham DH6 5NG
Telephone: 0191 377 1441 Fax: 0191 377 2972

UNFRAMED TRACKED DOOR

Familiarize yourself with the terms for the door components before starting the installation. The door and
components must be installed by suitably trained and qualified persons, in accordance with the instructions
provided. If in doubt contact a professional installer. It is important that the installation does not deviate from the
instructions provided such that all requirements of EN 12604 and EN 12453 are met and if necessary verified
(from May 2004). Once installed the door should be labeled in accordance with EN 13241 (from May 2004).
Slam-latch
Door bracing
bracket
(each side)
Roller bracket
(each side)
Top
weatherstrip
(each side)
Middle
weatherstrip
(each side)
Strap
Ceiling
support
Pull rope
Door
bracket
(each side)
Inside handle
Note: The door bracing differs with
each door style
Illustration shows pattern for vertical and
Slam latch
Lock arms
horizontal type panels. bracket
(each side)
NOTE: Two inner handles are provided to make
the door easier to lift during transit. They are
Inner handle
attached by ropes to the bottom sides of the door
2 off
chassis and should be removed once the door is
secured in position. They will be used in step 12.
IMPORTANT
Check that all contents are included in the packs and that the door size is correct for the opening
(see label on side of door - the label refers to the size of opening and not size of door).
The following parts are supplied separately and must be checked before starting installation: -
Gear Pack 'C' track assembly 1 off - see contents list
Weatherstrip pack 1 off - see contents list
Fittings pack 1 off - see contents list
Pre-Pack 1 off - see contents list
Installation is carried out from inside the garage. Ensure that you have adequate lighting and that
all tools and fittings are inside the garage BEFORE you start.
Ensure you have the outer handle with you before leaving the garage during installation. Whilst
operating the door be aware of the area it moves through. Keep people and objects out of the
way. When manually operating the door, control the leading edge of the door by hand throughout
the opening and closing cycle. When the door is in the open position, always ensure it is fully
open/as far back as possible.
Ensure that good safety practices are employed during installation. Use good quality tools and take
appropriate care if using any electrical equipment. Always check for dangerous features in the
workspace such as sharp edges, protrusions or concealed or damaged electrical wiring

CONTENTS OF THE FITTING / PRE PACK

Outer handle - 1 off
(includes screw and
washer)
Roller spindle Slam-latch keep
- 2 off - 2 off
Strike plate - 2 off Pivot block - 2 off
(One Left hand and one right hand)
Hook - 2 off Adjustment strap - 2 off
Note: If you are short of any of the items mentioned, please contact your supplier.

CONTENTS OF THE GEAR PACK

'C' track
assembly
(each side)
Slam-latch keep
(each side)
Roller bracket
- 2 off
Keys (attached
to lock body)
Arm
assembly
(each side)
Spring
assembly
(each side)
Spring anchor
bracket
(each side)
'C' track assembly Bottom Ceiling Strap
- 2 off weatherstrip support - 2 off weatherstrip
(not boxed) - 2 off - 2 off

CONTENTS OF FIXINGS PACK

ITEM A - Qty - 24
38mm x 8mm self-tapping screw
Pilot hole diameter - 4.5mm
USE IN STEPS - 3,4,5,7 and 8
ITEM C -
Qty - 4
M8 x 40mm hexagonal slotted
machine screw
USE IN STEP - 5
Washers - 6 off
ITEM E -
Qty - 12
M8 shakeproof washer
USE IN STEP - 5
Door bracket
- 2 off
ITEM: G QTY: 8
Rawlplugs. Pilot 8mm diam.
USE IN STEP - 5
Stop - 2 off
ITEM I
- Qty - 4
32mm x 8g Posidrive screws
Pilot 1.5mm diam.
USE IN STEP - 11
1
CHECK EXISTING FRAME DIMENSIONS
Before installation ensure a suitable good quality
frame is fitted, ideally hardwood or softwood timber
76mm x 76mm.
Timber of different sizes may be used:-
Head 38mm minimum
Side 70mm minimum
The frame may be between or behind the reveals,
must be secure, square and upright. It is important
that the back surfaces of the frame are flush.
Note: All doors include the necessary clearances.
Spring Anchor bracket
- 2 off
2
PLACE THE DOOR IN POSITION
You should carefully remove the fittings pack and other
loose items attached to the door.
Remove the protective wooden batten from the bottom of
the door (where fitted). Handle the door carefully to avoid
damage.
At this stage ensure that all equipment and fittings are
inside the garage.
Position the door within the frame, ensuring that the top
weatherstrips are flush against the frame legs.
Temporarily secure the door in position. Place 2 x 10mm
packers in the top of the door, lift and wedge the door on
both sides until it is in contact with the packers at the top.
Ensure that the following clearances are established
between the door and frame.
Top
Each Side (Premier Door)
Middle Spring Door arm Each Side (Castle Door)
Assembly Assembly
Bottom
- 2 off - 2 off - 2 off
3
FIT THE ROLLER BRACKETS AT THE TOP WEATHERSTRIP
SHOWN ACTUAL SIZE
Secure the cast alloy roller brackets over the top
weatherstrips using 38mm x 8mm self-tapping screws A
using the 3 large holes in the bracket. Ensure that the
roller brackets are aligned squarely with the top of the
door and insert the roller spindles into the roller brackets.
When all installation steps have been completed, the
ITEM B Qty - 8 rollers must still be able to be turned by hand.
38mm x 6.3mm self-tapping screw
Similar to artwork as figure 2 tracked single unframed
Pilot hole diameter - 4.5mm
USE IN STEPS - 5 and 6 GRP doors - but remove head of fastener shown securing
the top weatherstrip and outer profile of roller bracket
base is changed - photograph available
4
'C' tracks are supplied pre-
assembled to the front track brackets.
ITEM D - Qty - 12
Support the rear end of the 'C' track
M8 steel nut
and place the front over the roller as
USE IN STEP - 5
shown.
Using 38mm x 8mm screw A, fit front
track brackets to the side frames, first
through the top vertical slotted hole
as shown and then through the lower
vertical slotted hole. Note - a third
fastener is added to each track
bracket later (see step 5).
ITEM F- Qty - 2
Ensure the roller spindle clearance
M8 plain washer
between the cast roller bracket and
USE IN STEP - 5
spindle washer is 3mm as shown.
Note: The rollers are not required to
support the weight of the door. It is
important that the rollers can be
moved by hand once the temporary
door supports used in step 2 are
removed.
ITEM H - Qty - 2
5
Saftey fasteners
USE IN STEP - 6
Slide the adjustable ceiling support over the rear of
the 'C' tracks and raise the tracks. Ensure the 'C'
tracks are parallel and angle downward from the
face of the door to the back of the garage by
approximately 53mm
ITEM T - Qty - 14
Secure ceiling support and fixing straps into the
Tack
USE IN STEPS - 6,8 and 9 ceiling using fixings B, C, D and G (not required if
secured to timber). Ensure 'C' tracks are square to the
opening. Diagonal measurement of the tracks from
corner to corner should be equal. Check the position
of the roller at the front of the track. Position the front
track brackets to provide a small clearance at the
bottom of the roller (1mm). Now fix 50mm x 8mm
screws A in the remaining bottom hole of the 'C'
track front bracket (see step 3).
Reveal
Insert the track roller stop into the end of the track. Fix
Frame using M8 x 40mm hexagonal slotted machine screw
C, nut D and washers E and F.
Door
Between
reveals
Important: Correctly fitted 'C' tracks will be rigid and
parallel and will not require intermediate supports.
70mm min.
6
Behind
LOCATE PIVOT BLOCKS & MIDDLE WEATHERSTRIPS
reveals
The pivot blocks are handed. Line up the edge of the pivot block with the inside edge of the frame
leg, ensuring there is a gap of approximately 3mm between the top of the pivot block and the
bottom edge of the top weatherstrip guide, as shown.
Secure using two 38mm x 6.3mm screws B through the holes provided. Repeat the holes provided.
Repeat for the other side.
13mm max. 13mm max.
Slide the middle weatherstrip under the rebate at the bottom of the pivot block, ensuring that the
rubber edge overlaps the door edge and the plastic edge is level with the inside edge of the pivot
block. Secure to the frame through the top hole in the weatherstrip using a tack T. Repeat for the
other side.
Weatherstrips
= 10-13mm 13mm
= 8 -11mm
= 10-13mm
= 10-15mm
Cast roller
bracket
Roller
Top weatherstrip
ATTACH THE'C' TRACKS
Front track
bracket
Cast roller
bracket
'C' track
Transit
bracket
3mm
'C' track
Cast roller bracket Spindle
washer
ALIGN THE 'C' TRACKS
53mm
Ceiling
Fixing strap
support
'C' track
Stop
Inside of frame
top
L/H R/H
weatherstrip
guide
3mm
top
weatherstrip
guide
Pivot
Pivot
block
block
Middle
weatherstrip
Middle
weatherstrip