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COOLWHIP T4 Installation Instructions Manual

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YOUR INSTALLATION INSTRUCTIONS

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  • Page 1 YOUR INSTALLATION INSTRUCTIONS...
  • Page 2 T4/T5/T6 FLAT PACK FURNITURE INSTALLATION INSTRUCTIONS...
  • Page 3 STOP & READ Please ensure you briefly read over this instruction manual before attempting to assemble and fit your units. Once you have an understanding of the process, please then read and follow each page step by step, failure to do this can result in mistakes and the process taking much longer. Please note some pictures contain our Premium range and VW T5/6 furniture, however all principles of the instructions remain the same.

  • Page 4: Table Of Contents

    CONTENTS Overview 6-16 T Trimming 17-22 Hanging doors 23-26 Drawer assembly 27-28 Floor assembly 29-59 Assembly 99-106 Fitting 107-110 Fitting the table...
  • Page 5 THE PROCESS Read instructions and Tambour doors The floor prepare work space and tools T Trimming Hang all doors and fit catches Assemble...

  • Page 6: T Trimming

    T TRIMMING TOOLS • Mallet • Stanley knife • Curved Stanley knife • Mitre shears...

  • Page 7: Quick Overview

    QUICK OVERVIEW Staring the Trim Trimming corners Ending the join Removing Trim from hinge holes Tips and hints Do not T trim perimeter of wardrobe front, wardrobe upright (L) and wardrobe upright (R) until slide 51 Do not T trim the floor until slide 44...
  • Page 8 STARTING THE TRIM Cut the trim square before Ensure the lip is on the surface Start and finish on the starting every piece denoted by the piece sticker black line...
  • Page 9 CORNERS Keep the Trim tight Use the inside of the mallet to avoid gaps to trim door apertures* *ensure you use masking tape...
  • Page 10 CORNERS Remove the inner trim to avoid bobbled corners...
  • Page 11 ENDING THE TRIM Mark and cut the Trim a few Mallet the join flush. Butt the two Trims together (mm) past the start point...
  • Page 12 ENDING THE TRIM Where there is no join simply cut the edge straight with a Stanley...
  • Page 13 REMOVE THE HINGE Remove the inner Trim from the hinge hole to allow the hinge to sit flush. Failure to do this will result in bulging...
  • Page 14 TOP LOCKER Leave some excess trim on the top right of the Top locker face, this will make sense later on...
  • Page 15 FRIDGE PODS Remove the rear trim lip from both fridge pods...
  • Page 16 TIPS AND HINTS Always keep the trim taught Always hit down onto a surface, use Heat the trim to stretch to avoid gaps and bobbles the edge of a bench if necessary and manipulate...

  • Page 17: Hanging Doors

    HANGING DOORS TOOLS • Drill Driver • Stanley knife • Cross head Screw driver...
  • Page 18 HANDLES Place the correct door into the Using 16mm screws, fix the Place the handle catch correct aperture ensuring the back of the catch into place into the hole door is orientated correctly ensuring the catch is straight...
  • Page 19 HINGES Turn the adjustment all the Fix the hinges to the door only Clip on the cover plates way to the rear before fixing using 16mm screws and the to the aperture pilot holes provided...
  • Page 20 (CONT.) HINGES HORIZONTAL ADJUSTMENT OVERLAY ADJUSTMENT CLIP-ON MOUNT Once both hinges are fitted, Remove wide screws and adjust the door to fit flush with replace with 16mm screws to fit equal spacing the plate to the aperture...
  • Page 21 STRIKE PLATE Remove the trim lip from the door and the Mark out the width of the strike plate aperture allowing the strike plate to sit flush onto on the door and the aperture parallel the wood, then fit using 2 x 16mm screws* to the catch using a Stanley knife *adjust before tightening...
  • Page 22 HANGING DOORS CHECK & MAKE SURE… The doors sit flush and open and shut correctly Now follow the same process of hanging all the doors before continuing to page X...

  • Page 23: Drawer Assembly

    SOFT CLOSE DRAWER ASSEMBLY...
  • Page 24 (CONT.) SOFT CLOSE DRAWER ASSEMBLY Attach the mounting clips Fit the drawer rear using Fit the drawer base using 16mm screws 16mm screws, ensure the base is flush to avoid gaps...
  • Page 25 (CONT.) SOFT CLOSE DRAWER ASSEMBLY Fit the drawer face catch Screw the drawer face mounts Clip the face into the into the pilot holes with the 4 x side runners large head screws provided with the drawer box...
  • Page 26 FRIDGE POD ASSEMBLY 4 x screws in each plate (provided with drawer box) Ensure the block sits flush Align the Drawer fixing blocks and Fit the runners to the blocks using before screwing, some fit using 5 x 25mm screws into the the pilot holes provided, ensure you sanding may be required same pilot holes as the picture, do...

  • Page 27: Floor Assembly

    (CONT.) FLOOR ASSEMBLY OVERVIEW The integrated floor design allows you to build the units in the comfort of a workshop or garage then simply lift them into the van. This allows for any electrical work to be carried out before the units have been fitted.
  • Page 28 (CONT.) FLOOR ASSEMBLY Glue the biscuit join, do Screw the floor together with Now finally Trim the floor not over glue the fixing plates using 16mm as a one screws...
  • Page 29 WARDROBE ASSEMBLY TOOLS • Drill Driver • Mallet • Stanley knife • Sand paper • Cross head Screw driver • Tape Measure • Set Square...
  • Page 30 (CONT.) WARDROBE ASSEMBLY OVERVIEW The wardrobe is the most time consuming part of assembly Its important you follow each step in order of instruction Use 16mm screws unless directed otherwise This is a two person job You will need a large clean flat surface Do not counter sink 25mm screws...
  • Page 31 TAMBOUR APERTURE Always remove the rear trim lip from any tambour door aperture, failure to do so will result in a noisy and rough tambour opening, if you have no upgraded tambour ensure to do this on the large standard tambour...
  • Page 32 (CONT.) WARDROBE ASSEMBLY Firstly, stick the wardrobe LED into the profile and re attach the cover case...
  • Page 33 (CONT.) WARDROBE ASSEMBLY Remove the T Trim lip Remove the T Trim lip from the Fix the wardrobe bottom shelf from the underside of the underside of the bottom shelf inner to the underside of the bottom shelf inner shelf using 25mm screws...
  • Page 34 (CONT.) WARDROBE ASSEMBLY Place the wardrobe face down Slot the bottom shelf, divider Fit the wardrobe upright (L) and lid shelf into the rebates first, align all rebates and start DO NOT SCREW from the base working up to the top using the blocks and pilot holes...
  • Page 35 (CONT.) WARDROBE ASSEMBLY Fit the wardrobe upright (R) Ensure all rebates are flush Ensure the bottom shelf is align all rebates and start from and fit together nicely seated correctly before fixing the base working up to the top using chock blocks and pilot holes...
  • Page 36 (CONT.) WARDROBE ASSEMBLY Screw the bottom shelf together using the blocks and pilot holes provided, ensure the joins are tight and flush...
  • Page 37 (CONT.) WARDROBE ASSEMBLY FLUSH Fit the lid shelf to the upright (R) Screw through the bottom Secure top of divider with a ensure the joins are tight and flush shelf into the divider using a block 25mm screw* *You may countersink...
  • Page 38 (CONT.) WARDROBE ASSEMBLY Repeat the process with Now screw the lid shelf to the face. the left upright Please note, your blocks may be underneath the lid shelf...
  • Page 39 (CONT.) At this stage you have two choices, you can continue to assemble outside the van or begin to build inside. Building outside the van is easier, however requires an awkward three-man lift of the fully built units when finished. If you do not have three strong people available to lift, we recommend placing the floor base in the centre of the van and continuing inside...
  • Page 40 (CONT.) WARDROBE ASSEMBLY Continue Stand the wardrobe up click into the Fix the wardrobe to the floor floor rebates. using 16mm screws, and pilot holes provided...
  • Page 41 (CONT.) WARDROBE ASSEMBLY Screw the large tambour door Repeat the process with the Insert the tambour door into the wheel (R) to the bottom shelf opposite wheel on the lid shelf wheel runners from the rear using 25mm screws...
  • Page 42 (CONT.) WARDROBE ASSEMBLY Glue the bottom track 14b onto the bottom Close tambour door, Slide the Wardrobe tambour shelf butt up to the tambour wheel. door upper shelf into rebates, then fit using chock Repeat the process for the top track blocks underneath with the pilot holes provided...
  • Page 43 (CONT.) WARDROBE ASSEMBLY Repeat the process for the Fit the blocks for the Fit the Wardrobe rear shelf Wardrobe tambour door lower shelf Wardrobe rear shelf flush with the rear...
  • Page 44 (CONT.) WARDROBE ASSEMBLY T Trim the Wardrobe T Trim the Wardrobe T Trim the Wardrobe upright (L) starting on the face starting on the upright (R) starting on the arrow. Trim lip outside arrow. Trim lip outside arrow. Trim lip outside...
  • Page 45 (CONT.) WARDROBE ASSEMBLY Finally slide the cubby hole insert into place...

  • Page 46: Assembly

    ASSEMBLY 25mm Fit the Kitchen unit face Fit the shelf blocks Ensure the face is flush from the rear with the wardrobe...
  • Page 47 ASSEMBLY Fit fridge pod (R) from Fit the Kitchen unit shelf behind, if you have the new twin door design fit with 1 x block at the top using the pilot holes...
  • Page 48 ASSEMBLY Now fit the rear support Fit blocks to the flap Now fit the fridge pod into place, be sure to divider and fit to shelf upright (L) and click rear have it the correct way using the rebate support into place, note your panel will be worktop height unlike the picture above...
  • Page 50 ASSEMBLY Mark and cut away the Screw the strike plate with Fit the two chock blocks to overhanging Trim on the inside 16mm screws the drawer upper support of the drawer upper support...
  • Page 51 ASSEMBLY Adjust the drawer to fit perfect, Fit the drawer to the runners, Now you can fit the ensure both fridge pods are equally there is an audio click when drawer upper support 15mm from the base front the runners are pushed in above the drawer correctly Please see drawer box manual for...
  • Page 52 ASSEMBLY Fit the fridge upright (L) to the Continue to screw the units Fit the right side table floor using 2 x small L brackets to the floor, ensuring the storage holder to the on the inside of the aperture, face is inline with the outside front of your do not use blocks as they...
  • Page 53 (CONT.) REAL OAK STOP! Before screwing through any real oak please ensure you pilot drill first, failure to do this may result in The oak splitting...
  • Page 54 WORK TOP Using the alignment rebates, drop the worktop into place. Start by offering the right of the worktop into the wardrobe rebate, then simply find the rebates at seat correctly. Do not forget to fix down with blocks and 16mm screws, we advise pilot hole drilling the rear oak first...
  • Page 55 ASSEMBLY Now you can screw your flap Fit the drawer cover caps divider to the worktop and insert your chopping board...
  • Page 56 ABOVE UNITE SHELF/ LOCKER ASSEMBLY...
  • Page 57 TOP LOCKER ASSEMBLY fit the blocks to the top locker If you have not done so fit both end panels using the face first, then screw into the already, fully prep your top pilot holes and chock blocks base to attach locker for installation.
  • Page 58 TOP LOCKER ASSEMBLY Finally, if you choose to do so, fit the rear and add the divider...
  • Page 59 If you have purchased furniture only skip to slide 109 for fitting...
  • Page 60 ELECTRIC PACKAGE INSTALLATION INSTRUCTIONS...
  • Page 61 STOP & READ Please ensure you briefly read over this instruction manual before attempting to fit the electrical components and looms to your units. Once you have an understanding of the process and feel confident carrying out the install, please read and follow each page step by step, failure to do this can result in mistakes and the process taking much longer.

  • Page 62: Fitting The Table

    CONTENTS 67-69 Electrical diagrams 70-74 Sink/ grill combo 75-84 Electrical component installation Van earth point 86-88 Unit installation 89-90 Leisure battery 92-98 Split charge & 240 hook up connection 99-102 Securing the units 103-106 Splashback, Top locker and Control panel 107-110 Fitting the table...
  • Page 63 THE PROCESS Read instructions, Connect to Lift unit into Fit earth cables to prepare workspace Vehicle battery & the van van earth point and tools 240 hook Fit electrical Secure the Sink/ grill Connect to components combo units Leisure battery and loom...
  • Page 65 See left VW T5, the Ford transit custom differs here; the top locker, splashback and control panel are fitted separately towards the end...
  • Page 66 DISCLAIMER Please note, this instruction manual is a guide to how we recommend the following stages are carried out. Although the looms and components are prewired and labelled, you will require a basic understanding of electrics. If you are not confident in this process, we recommend seeking advice or help from a professional.
  • Page 68 Top locker Fuse C-line Wardrobe board controls Vehicle battery connection CTEK split charger 240 hook up BATTERY FRIDGE EARTH POINT Consumer Water Smart battery unit pump Charger 240 socket...
  • Page 69 TOP LOCKER MAIN MAIN LIGHT/ DIMMER LIGHTS SPARE LIGHT SWITCH PLUGH WARDROBE SOCKET CTEK SPLIT CHARGE MAINS CONSUMER UNIT FRIDGE EARTH POINT FUSE LEISURE BATTERY WATER PLUG - BATTERY - CHARGER PUMP SOCKET VEHICLE - BATTERY +...
  • Page 70 SINK/ GRILL COMBO TOOLS • Mallet • Stanley knife • Curved Stanley knife • Mitre shears Fit the screw inserts, pre-drill Remove the protective Fit the rubber edging, cut on any oak material masking tape completion and butt together...
  • Page 71 SINK/ GRILL COMBO TOOLS • Mallet • Stanley knife • Curved Stanley knife • Mitre shears Fit the plug rubber seal Screw into the worktop Fit the black screw caps using the screws provided with the appliance...
  • Page 72 SINK/ GRILL COMBO TOOLS Feed the rubber seal then Screw the drain into place Feed the tap through the fixing thread over the water tap hole pipe and cables from behind and tighten...
  • Page 73 SINK/ GRILL COMBO TOOLS Heat one end of the Manipulate the pipe to give a Fit the pipe to the freshwater pipe in hot water wider berth water pump...
  • Page 74 SINK/ GRILL COMBO TOOLS Fit the 20mm waste pipe to the Fit the other end to the tap grey outlet under the sink, fasten inlet, push firmly, there will be with jubilee clip, heating in water an obvious audio clip may be required...
  • Page 75 STOP & READ Always use 16mm screws unless stated otherwise, failure to do so will result in screwing the furniture board...
  • Page 76 FUSE BOARD AND MAIN LOOM TOOLS Fridge Using the cut outs in the Screw the fuse board into For FTC simplymasking tape furniture, run the fridge and place using the pilot holes the switches here on the tap cables into place and p provided worktop, the control panel will clip into position...
  • Page 77 TAP WIRING DIAGRAM WATER PUMP...
  • Page 78 TOOLS Feed the cable and fresh pipe through hole on the water tank lid before installation Connect the tap and water P-clip and cable tie the waste, pump using the labelled water pipe and tap cable into wago connectors, then P-clip the shelf notch or cable tie away...
  • Page 79 CONSUMER UNIT & SOCKET TOOLS Remove the consumer unit face Remove the 240 socket face Finally refit both faces and fit into position, ensure the and fit on the square below short single 3 core blue cable and earth exits the bottom...
  • Page 80 CTEK/ BATTERY CHARGER AND TRAY TOOLS Screw the CTEK split charge Before fitting the battery tray Screw the smart charger into into position, you will require remember to feed the strap possition and connect 25mm screws underneath...
  • Page 81 BATTERY TRAY WARDROBE LED TOOLS Fit the battery tray using the Clip the Wardrobe LED into the pilot holes provided, have the Qijie joiner, ensure the fit is cut-out entry point over the correct positive side...
  • Page 82 P-CLIP CABLE TIDY Tidy up all wires and P-clip into place, it’s important to have tidy and organised cables, here are a few pictures of how we do it. Where possible clip AC, DC and water separate...
  • Page 83 P-CLIP CABLE TIDY TOOLS...
  • Page 85 VAN EARTH POINT TOOLS TOOLS Your electrical kit will need earthing to the vehicle, therefore locate a suitable earthing point and attach the earth cables. You can do this now then attach to the battery later, or attach to the battery then earth when in the vehicle...
  • Page 86 INSTALL PREP TOOLS TOOLS Lay some protection to the Tape the 240 hook up and Repeat the process with the van floor to prevent any vehicle battery cable inside water tank pipes scratches the fridge aperture...
  • Page 87 INSTALL PREP TOOLS TOOLS Feed the top locker LED through the Align the units square and Do not attempt to lift with the splashback hole and connect to the close to the van fridge or leisure battery installed, Qijie joiner, ensure the fit is correct the units will be too heavy...
  • Page 88 Lift the units straight up and place just • inside the rear of the van Allow the front person to now enter the van • and regrip Tilt the units anti clockwise from the rear • perspective Whilst on tilt, lift the units into the centre of •...
  • Page 89 CONNECTING THE LEISURE BATTERY TOOLS TOOLS Pull all live red cables and the Attach the battery terminals Fit the battery to the stary and CTEK thermometer through secure with the strap the rubber terminal...
  • Page 90 CONNECTING THE LEISURE BATTERY TOOLS TOOLS Attach the consumer unit Fit the studs over the terminal Fit the rubber terminal and earth with the wago clip positive, then firmly tape the repeat the process for the thermometer to the terminal negative, include the black earth cable...
  • Page 91 Offer the units into position but do not fit into place...
  • Page 92 CONNECTING TO THE VEHICLE BATTERY Locate and access the Connect the red split charge Reattach the battery cover vehicle battery beneath cable stud to the vehicle and p-clip cables neatly the driver's seat battery live...
  • Page 93 SMART ALTERNATOR From 2015 the customs are fitted with variable voltage charging systems that help to reduce emissions, this means conventional VSR relays are no longer appropriate to use. If you have this smart alternator, you will have a third 1mm red cable with a ‘piggyback fuse’...
  • Page 94 SMART ALTERNATOR TOOLS TOOLS...
  • Page 95 FITTING THE 240 PLUG If fitting inside we also recommend We recommend simply wind deflectors, allowing the Locate the position you fitting on the B pillar extension to feed through the want the plug and cut the (see next slide before fitting) window when hooked up.
  • Page 96 FITTING THE 240 PLUG NEUTRAL LIVE EARTH Please double check Wire the 3 core artic 240 terminals match the picture cable to the hook up as newer designs may differ...
  • Page 97 FITTING THE 240 PLUG Alternative methods include passing the cable through the fire wall and mounting under the bonnet, or fitting externally.
  • Page 98 TEST Before securing the units to the van, we advise running an electrical test. Check all components are working correctly, if there are any issues, please see page 72. Make sure your consumer unit is on with the breakers in the off position.
  • Page 99 FITTING THE UNITS TOOLS TOOLS Firstly, fit the rear into position, you Repeat the process with two chock Secure the battery rear with 2 x will need to pilot drill through the blocks as seen in the picture chock blocks, screw into the van metal work before fixing, 16mm base only with 16mm screws screws is surfiest...
  • Page 100 FITTING THE UNITS TOOLS TOOLS Continue to secure the units to the Ensure the units are pushed back Finally, the fridge pod area, van ply lining, 16mm screws only into and as flush as possible. Key tip, remove the drawer for easier the furniture, however 25mm can be attach the block to the unit first, access...
  • Page 101 FITTING THE UNITS TOOLS TOOLS Remove the battery access flap Now screw into the floor Continue in the main in the rear wardrobe to locate using 25mm screws. compartment. the two pilot holes, be mindful of the electrics...
  • Page 102 FITTING THE UNITS TOOLS TOOLS Offer the fridge into position and Remove the fridge fixing point caps, connect the feeds using the screw though into the aperture, use Finally, the fridge aperture . wago connectors, check the 30mm screws, be mindful not to fridge is working before fixing screw through the ply...
  • Page 103 SPLASH BACK Once you have installed and fitted your units, offer your splash back to the recess of the van, you can fit by screwing through the splashback into the ply lining where the top locker will sit. You will also need to attach to the worktop, we advise marking exactly where it sits and screwing from the underside of the...
  • Page 104 TOP LOCKER & CONTROL PANEL Once the splash back is in place, you can hang the top locker, please note the end panels may need scribing to suit. If you have a pop top you can hang by screwing directly into the metal work, if you have a low roof, you can hang from the headliner, please just ensure your headliner is...
  • Page 105 C-LINE CONTROL PANEL Finally fit the control panel box, this is over sized due TOOLS to different variations in roof heights and will need trimming to suit for a perfect fit. Ensure to feed all controls though the C-line cut outs before fixing Remove the back cover of the 240 C-line socket...
  • Page 106 C-LINE CONTROL PANEL TOOLS Clip the controls into the fixing plate Re attach the back cover of Clip the finishing cover plates then screw into place aligning with the 240 C-line socket over the top into position the pilot holes provided...
  • Page 107 FITTING THE TABLE LEG AND RAIL...
  • Page 108 FITTING THE TABLE LEG AND RAIL Screw the table leg into Fit the rail brackets 40mm Align the rail central and the underside of the table from the table edge with 4 x 30mm from the unit top with 4 x 20mm screws 16mm screws in each bracket provided, ensure central...
  • Page 109 FITTING THE TABLE LEG AND RAIL 25mm 25mm 25mm 30mm Rail 30mm from top of Fit the rail using a 25mm screws Fit the center support using a unit face 25mm screw...
  • Page 110 TABLE STOWAGE Now fit the stowage clips Offer the table in and fit the using 30mm screws left side storage holder, ensure its not too tight...
  • Page 111 FIND US CONTACT INFO Unit 2 Mon - Sat 07399 637 083 9am - 5pm Gallows Park info@coolwhipcampers.co.uk Sunday closed Millbrook PL11 3AX coolwhipcampers.co.uk...

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T5T6

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