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ORANGEBOX Campers & Dens CD01ALS Assembly Instructions Manual

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888.STEELCASE (888.783.3522)
www.steelcase.com
2024 Steelcase Inc.
©
Grand Rapids, MI 49501 U.S.A.
Orangebox - Campers & Dens
CD01ALS Assembly Instructions
8mm
6mm
5mm
x2
Page 1 of 44
P/N: 1499234001
Doc # 163398 Rev B

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Summary of Contents for ORANGEBOX Campers & Dens CD01ALS

  • Page 1 Orangebox - Campers & Dens CD01ALS Assembly Instructions 888.STEELCASE (888.783.3522) Page 1 of 44 www.steelcase.com P/N: 1499234001 2024 Steelcase Inc. © Doc # 163398 Rev B Grand Rapids, MI 49501 U.S.A.

  • Page 2: Table Of Contents

    Table of Contents Warnings & Statement Fixing Kit Base Track 1.1. Door threshold Service Hoop Vertical posts Base alignment Service Hoop External Covers Support fabrications External Panels Plywood, Laminate & Whiteboard - External Location Acoustic Cassettes Interior Panels Whiteboard - Internal Location Glass panels Door Roof...

  • Page 3: Warnings & Statement

    “The UL certification for Campers and Dens does not cover tables and other furniture options in the pod, please refer to individual documentation provided for more information. The hoop fire management system has been tested for electrical safety only and has not been tested to any official fire safety standards.

  • Page 4: Base Track

    Base Track Locate the base track packaging. Lay out the base track assemblies. Remove central cover if present. Page 4 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 5: Door Threshold

    Door threshold Assemble door threshold to the side base track using a T20 Torx screwdriver. M4x6mm Button Hex M/C Page 5 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 6 Assemble door threshold to the front base track. Remove central cover if present, unscrew door post and leveling screws to bring foward base track. Use a T20 Torx screwdrive for M4x6mm Button Hex M/C (2). Page 6 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 7 Base Track Assemble the base track corners (3) using an 8mm allen key for M10x25mm screws. 1G. Remove cover to reveal screws. Slide back the rubber window extrusions if present, remove the screws, and then remove the corner end piece. 1H.
  • Page 8 1K. Slide into position the rubber window extrusions. Cut to length if needed. 1L. Repeat steps for other corners. 01272952 M10x25 Door threshold Page 8 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 9: Service Hoop

    Service Hoop Locate the service hoop component packaging. Lay down the hoop horizontal. Align the hoop verticals. NOTE: Lay protection to prevent scratches to hoop. Page 9 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 10 2B. Remove hoop covers to gain access. 2C. Connect ground wires to hoop verticals on left and right hand sides. Page 10 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 11 2D. Assemble beam and vertical posts together. Use a 6mm socket head drive for M8 x 30mm thread forming screws. 2E. Remove hoop-fixing bolts from the base track. M8x30 15Nm Door threshold Page 11 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 12 Align hoop to base track ensuring the switch is on the same side as the door, and facing the door. Secure hoop M10 fixings. p a n i t c h M10x25 Page 12 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 13 Connect hoop internal electrics. Place back the covers on hoop’s vertical. Page 13 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 14: Vertical Posts

    NOTE: Support corner post until top track is fitted. Vertical Posts Locate the vertical post component packaging. Assemble corner post to base track with a 6mm socket head M8 x 20mm machine screws. M8x20 Page 14 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 15 3c 3d. Connect top track side to hoop and corner post. Use a 6mm socket head drive for M8 x 25mm thread forming screws(4). NOTE: Support corner post until top track is fitted. 3e. Repeat steps for opposite corner. M8x25 NOTE: Use a ratchet Page 15 of 44 driver when access is limited.
  • Page 16 3f. Connect top track side to hoop post. Use a 6mm socket head drive for M8 x 25mm thread forming screws(2). 3g. Assemble top track rear to corner casting. Use a 6mm socket head drive for M8 x 25mm thread forming screws(4).
  • Page 17 3h. Remove bolt from the base track if present. Assemble sliding door post assembly to base track with M10 x 25mm machine screw. M10x25 NOTE: Support vertical post until top track is fitted. Page 17 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 18 3i. Assemble top track front to corner casting. Use a 6mm socket head drive for M8 x 25mm thread forming screws(2). 3j. Connect top track side to hoop post and top track front. Use a 6mm socket head drive for M8 x 25mm threadforming screws(4).

  • Page 19: Base Alignment

    Base alignment Release the levelling screws with 6mm allen key. Ensure the corners are square and make sure the base track is level. M10x40 Page 19 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 20: Service Hoop External Covers

    Covers Ensure power cables are routed correctly and refit covers. Door threshold Page 20 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 21: Support Fabrications

    Support fabrications Use soft mallet to attach. Note: Ensure vertical D posts are fully seated in extrusion. Page 21 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 22: External Panels

    Corner Panel (wider - 745mm) Flip panel 180 left or right External Panels Up arrow variation for indicator corner panel. Narrow Panel (670mm) Fit top 2 fixings only for hooking feature. Fit top 2 fixings only for hooking feature. M6x16 M6x16 ~10mm ~10mm...
  • Page 23 7b. Using the 2 exposed M6 fixings, hook exterior panels in place. 7c. Fit remaining M6 fixing to secure panels to frame. Note: Ensure an even spacing between panels when tightening fixings. 7d. Dress fabric when completed. 2 fabric panel sizes: - 670mm wide - 745mm wide (LH or RH option).

  • Page 24: Plywood, Laminate & Whiteboard - External Location

    Top fixings for opposite corner post. Plywood, Laminate & Whiteboard - External Location Change fixing position to suit left or right hand corner post. Fit top 2 fixings only Up arrow 8b. Using the 2 exposed M6 fixings, for hooking feature. indicator hook exterior panels in place.

  • Page 25: Acoustic Cassettes

    Acoustic Panels Locate the acoustic panel packaging. Push acoustic panels into place between extrusions. Pull tab for removal. Page 25 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 26 Assemble Clip L-Plates (4). Per bracket M6x16 Page 26 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 27 Reference level line Applies only for CD01CLS and CD01DLS Place in position Clip L-Plates (6). Align corner L-Plates(2) with opposite corner L-Plates using a spirit level. Fix in position. Align middle L-Plates(4) with corner L-Plates using a spirit level. Fix in position. Per bracket M6x16 Reference...

  • Page 28: Interior Panels

    Clips L bracket Interior panel Interior Panels Locate Interior panel packaging. Locate top corner of fabric panel in place with L bracket. Firmly engage fabric panel in place with clips. Clips L bracket Use soft mallet to attach. Interior panel Page 28 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 29: Whiteboard - Internal Location

    Whiteboard - Internal Location Clips L bracket Locate top corner of whiteboard panel in place with L bracket. Use soft mallet Firmly engage whiteboard to attach. panel in place with clips. Up arrow indicator Interior whiteboard Whiteboard Panel Vertical Whiteboard Location - Internal Location Whiteboards can be specified...
  • Page 30 Glass Locate the glass packaging. Ensure the correct PPE is being worn. 12a. Place glass carefully into the base track channel. Protection sleeves required. Page 30 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 31 12b. Trim and fit plastic glazing extrusion. Place glass carefully into final position. 12c. Temporary fit the top track glazing cover. Secure in place M8 x 16mm machine screws. M8x16 Page 31 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 32 Important to clean glass edge prior to bonding. Fix the 90 degree glass seal to glass edge. Page 32 of 44 P/N: 1499234001 Top View Doc # 163398 Rev B...

  • Page 33: Glass Panels

    90 degree glass seal standard glass seal Proceed to fit the remaining glass panels. Refer to Appendix for glazing locations. Trim and Fit plastic glazing extrusion to cover both glass panels. Fix temporary glass cover to hold glass in place. M8x16 Page 33 of 44 P/N: 1499234001...
  • Page 34 Use a combination of glass packers and base track adjustment to achieve the correct glazing levels. Use the 90 degree angle suction lifter to align the corner glass. NOTE: Leave 90 dergree angle suction approximately 30 minutes to set, depending on environment temperature.
  • Page 35 Fit the external vertical cover with 6mm socket head M8 x 16mm machine screws. Remove the temporary glazing cover. Fix the top external glazing cover with 6mm socket head M8 x 16mm machine screws. Slide and fix the external glazing cover flush to the corner with 6mm socket head M8 x 16mm machine screws.

  • Page 36: Door

    Door 13a. Locate the door component packaging. 13b. Remove the 2.7m Top track internal cover if present by removing the 4 M8x16 Hex M/C screws. 13c. Place the bottom of the door in the door pocket extrusion. 13d. Hook door runner in the top track.
  • Page 37 Wall mounted sliding mechanism with softbrake - set for glass door - 13D. Hook door runner in the top track. See detail below. NOTE: Ensure wheel in sliding mechanism fits onto upper extrusion and can be moved easily. (x2) Glass thickness setting screw Allen key 2,5mm Anti-derailment screw Top track profile...
  • Page 38 13e. Adjust door aligment in the top track using the height adjustment screw. 13f. Check the open door width and adjust Door stops locations door stops where necessary. Keep in mind position of door handles. 13g. Secure the door stops if they have been adjusted.
  • Page 39 M6x95 Fix door handle with 4mm socket head drive. Ensure the Orangebox logo on the handle is on the outside of the pod. Fix the acoustic seal extrusion to the rear of the glass door. Page 39 of 44 P/N: 1499234001...

  • Page 40: Roof

    Roof Locate roof cassette component packaging. Fix roof linkages(4) to the roof cassette(4) for the correct left hand-right hand orientation. Use T15 Torx head to fit 4mm x 25mm Plastite screws. Torx T15 Page 40 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 41 Insert roof cassettes into pod. Ensure the roof linkages are placed closest to the central hoop and the roof blades open outwards. Page 41 of 44 P/N: 1499234001 Doc # 163398 Rev B...
  • Page 42 Open the roof blades and connect roof cassettes to the roof motors. Use the linkage bolts and spanner provided. Repeat for all connections. Page 42 of 44 P/N: 1499234001 Doc # 163398 Rev B...

  • Page 43: Fascia

    Fascia Locate the Fascia component packaging. Clip fascia panels into the outer extruded covers. Place covers on corner tops and top ends of the central hoop. Page 43 of 44 NOTE: Do not fit front Fascia P/N: 1499234001 panels if pod is specific with a kink. Doc # 163398 Rev B...

  • Page 44: Base Track Trims

    Base Track Trims Door threshold Glass Panel Page 44 of 44 P/N: 1499234001 Doc # 163398 Rev B...

Table of Contents