Door Lifting Gear AP100 Multi Springs

This door gear has been designed for quick and easy installation. Through careful design it is possible to adjust the door after installation for very smooth operation. To obtain these benefits read the instructions RIGHT through BEFORE installation.

CAUTION ALWAYS raise and prop the door in the open position before fitting, adjusting or removing the springs.

All instructions are given from within the garage.

Please Note. Although a confident D.I.Y person should be able to carry out this work we recommend that you engage the services of a specialist installer.

Firstly unpack and identify the parts (right hand assembly shown).

a.	Track stabiliser	2 off
b.	Track support bracket	2 off
c.	Track with end bracket	2 off
d.	Rubber buffer	2 off
e.	Top roller	2 off
	Top roller bracket	2 off
	Roller retaining clips	4 off
f.	Top weather strip	2 off
g.	Spring anchor bolt	2 off
h.	Spring yoke	2 off
i.	Spring	6 off
j.	Spring clip	2 off
k.	Door arm assembly C/w post bracket, door bracket and spring adjustment	2 off
l.	Rubber weather strip	3 Metre roll
m.	Door/ latch striker plate	2 off
	Screw pack

STEP 1 FRAME DETAILS

Recommended timber frame size 70mmx 70mm. Minimum frame size 50mm x 70mm. Frame must be square, check diagonals. Frame must also be square with opening.

STEP 2 FIT TOP ROLLER BRACKETS & WEATHER STRIPS

GO STRAIGHT TO STEP THREE IF TOP ROLLER BRACKETS AND WEATHER STRIPS ARE PRE-FITTED. Locate the top roller bracket flush with the top of the door matching the same overhang as the top weather strip. On doors OVER 50mm (2") thick; lower the top roller bracket by the same amount. ie door thickness 62.5mm (2 ½") lower the bracket by 12.5mm (½"). Fix the roller bracket and weather strip using No. 12 x ¾" self tapping screws. TAKE GREAT CARE NOT TO DRILL RIGHT THROUGH THE DOOR FACE.

STEP 3 POSITION DOOR IN OPENING

Wedge the door in to the opening allow 10mm side clearance, 10mm clearance between the top of the door and the header and allow at least 10mm ground clearance.

STEP 4 INSTALL THE TRACKS

Locate the track over roller, support rear of the track allowing between 25mm and 40mm fall to the rear. With the track JUST TOUCHING the bottom of the roller drill 2 x 6mm pilot holes in the middle of the slots in the track brackets. Fix 2 x M8 x 60 coachscrews.

Slide on track support bracket and fasten to a suitable support using 1 x M8 x 40mm coachscrews and washer ensuring track is square to door and allowing fall as above. Fit rubber buffer by drilling 9mm hole in track and secure with M8 x 30mm bolt / nut / washer as fitted. Position rubber buffer towards rear of track but not so far as to allow door arm to hit spring anchor bolt. Door must stop against rubber buffer not arm against anchor bolt.

STEP 5 INSTALLATION OF ACTIVATING ARMS

Fit Door arm onto the 50mm or 70mm wide post allowing 3mm gap between the top weather strip and the door arm bracket, with the door arm bracket protruding past the post into the opening by 20mm. Drill 3 x 6mm pilot holes as indicated and secure with 3 x M8 x 60mm coachdscrews and M8 washers, ensuring arm is vertical and parallel to door edge. Fit bottom arm bracket to door with M8 x 20 Hex bolts.
TAKE CARE NOT TO DRILL RIGHT THROUGH THE DOOR.

STEP 6 INSTALLATION OF DOOR / LATCH STRIKER PLATE

Position bottom of striker plate on floor with vertical edge projecting past post into opening by 20mm. Mark holes with bradawl and secure plate to post using 4 no 12 x 19mm self tapping screws.

STEP 7 INSTALLATION OF SPRINGS

Open the door and prop it firmly in the fully open position. Assemble spring onto retaining plates as shown ensuring that slots at each end are in line. It is important that the springs are balanced on the retaining plates.
Attach spring clip to spring bar pull the springs down and locate over the spring anchor bolt The door should glide up and down with the minimum of effort. If the door is HEAVY on LOWER half of its travel, RAISE the spring anchor bolt until the bottom half of its travel is satisfactory To complete the balance of the door in the TOP half of its opening operation, adjust the spring on the adjusting bar When complete ensure the spring anchor bolt is fully tightened IMPORTANT Springs must be under tension at all times when in the open position - failure to do so could result in injury and/or damage to the door/ door gear.
NOTE: ALL ADJUSTMENTS MUST BE CARRIED OUT WITH THE DOOR FIRMLY PROPPED IN THE FULLY OPEN POSITION.

STEP 8 INSTALLATION OF BLACK WEATHER STRIP

Unroll weather strip, position top end immediately beneath door arm allowing 10mm to overlap the door and nail onto post using 6 x 25mm clout nails. Cut off excess at bottom and repeat for the other side.

STEP 9 OILING THE DOOR

For smooth running of the door it is important to oil the moving parts.

1. The six pivots on the activating arm assemblies
2. The roller wheels
3. The top spring attachments

IMPORTANT SAFETY PRECAUTIONS

Adjust springs only when the door is in the open position.

Before removing springs or spring anchor bolts use a prop to securely keep the door in the open position.

NEVER ADJUST OR REMOVE THE SPRINGS WITH THE DOOR IN THE CLOSED POSITION.