Assembly Instructions

LS7000 - Small box body

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Table of contents

Assembly hatches ................................. Fel! Bokmärket är inte definierat.

Assembly floor............................................................................................ 5

Assembly roof ............................................................................................ 6

Assembly sub frames ................................................................................. 7

Assembly wall panels ............................................................................... 10

Assembly cross beam to sub frame ......................................................... 13

Assembly hatches to the box body ........................................................... 14

Delivery overview ..................................................................................... 15

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Assembly hatches

Start by pulling the rubber seal in to the edge profiles. Cut the rubber seal even with the profile edge of the

ends where the profile is cut in 45 degrees. (You can also mount the rubber seal afterwards but then you

have to grind an opening in the pillar for the foot of the rubber seal.)

Cross measure carefully before the edge profiles is fixed with rivet (40213-00) on the inside.

(If necessary the edge profiles can be riveted on the outside also.)

Let the rubber seal (70040-00)

extend 3mm of the straight cut

part of the edge profile. Cut away

the foot of the rubber seal.

The hinge profile is placed

so that the joint is on the

outside of the hatch.

Put some superglue on the inner part of the

rubber seal, approximately 50mm on each

side.

Apply adhesive to both sides of the

edge profile before mounting them to

the sandwich panel.

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Mount rubber seal 70090 in the hinge profile. Let the

rubber strip extend approximately 5mm on each side.

Do NOT glue this rubber seal.

Join the outer hinge profile on the hatch. Install the stop screw (40164-00) in the hinge track and adjust

so that the outer hinge profile has the same measure on both sides of the hatch (about 11mm). The

screw must be tightened but it should be easy to ”turn” the hinge profile. Secure the screw by

applying adhesive (type Sikaflex) in the hinge groove outside of the screw.

Apply adhesive outside of the screw.

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Assembly floor

Start by mounting frame profiles, corner joints and reinforcement angles on the floor panel. Glue

the frame in the same way as the edge linings for the hatch. Carefully measure the diagonal measure

and then secure the profile’s location with rivet 40213-00 on the inside.

The reinforcement angles is used where there are no sandwich panels (hatch openings).

Step 1 Step 2 Step 3

Apply adhesive for the corner

joint, it is important that there

is adhesive on the surfaces

that is marked and that there

is adhesive the whole joints

length, about 50mm.

Apply adhesive to both

sides of the edge

where the floor panel

is to be placed.

sandwichskivan.

B = A±1

A

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Assembly roof

Start by mounting frame profiles and corner joints (02525-00) on to the roof panel. Glue the frame in the

same way as the edge linings for the hatch. Carefully measure the diagonal measure and then secure

the profile’s location with rivet (40213-00) on the inside.

Step 1 Step 2

Apply adgesive to both

sides of the edge where

the roof panel is

to be palced.

B = A±1

A

Apply adhesive for the corner

joint, it is important that there

is adhesive on the surfaces

that is marked and that there

is adhesive the whole joints

length, about 50mm.

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Assembly sub frames

Start by mounting the sub frames to the front cross beam, use the supplied screws 40159-00 and

washers 40146-00. Put adhesive between the sub frame and the floor before they are riveted, use

the supplied rivet 40504-00. Make sure that the front end of the sub frame is connecting to the

front edge profile.

Put adhesive between the

profile and the floor panel.

Rivet c/c 300 mm

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Also secure the front cross beam with

two rivets 40504-00.

Attach the two corner angles 50395-00 to

the rear end of the sub frame, use the

supplied rivet 40504-00.

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Assembly the rear light beam to the sub frame, using the supplied rivet 40504-00.

Use supplied rivet 40504-00 to attach

the rear light beam to the floor panel.

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Assembly wall panels

Mount u-profiles to the floor section where the front and side walls are placed. Assembly the vertical

corner profiles and wall profiles and then assembly the roof section. Use the u-profile with equal flange

length to the front and the u-profile with unequal flange length to the sides.

U

Put a thin layer of adhesive between the

frame profile and the u-profile. Use the

supplied rivet 40213-00 to secure the

u-profile to the frame.

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Mount the panels and the

vertical corner profiles.

Put adhesive on the inside

of the both flanges of the

u-profiles and the corner

profiles.

Apply adhesive for the corner

joint, it is important that there

is adhesive on the surfaces

that is marked and that there

is adhesive the whole joints

length, about 50mm.

Apply adhesive to both

sides of the edge

where the roof panel is

to be placed.

Mount the roof section.

Put adhesive on the

inside of the flanges of

the u-profiles and the

corner profiles.

(See above)

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Secure the vertical corner profile

to the reinforced corner angle,

use the supplied rivet 40501-00

to the wall and 40506-00 to

the floor.

Mount the reinforced corner angle

to the roof-/wall connection where

there are no sandwich panels, use

the supplied rivet 40501-00.

Mount the u-profile on the

side panel, put adhesive on

the inside of both flanges.

Mount the cover strip

to the front and the

rear corner profile.

Adhesive

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Assembly cross beam to sub frame

Mount the cross beams to the sub frame, make sure that the box body is centered when the cross beams

is mounted.

Mount the chassis bracket

to the sub frame, use

supplied screws 40159-00,

washers 40146-00 and

nuts 50428-00.

Mount the chassis bracket to

the cross beams, use the

supplied screws 40157-00,

washers 40143-00 and

nut bar 02438-00.

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Assembly hatches to the box body

Lock, gas springs and other details can then be pre-mounted on the hatch.

Before the hatch is mounted in to the frame, adhesive should be applied to the hinge profiles leg

(see picture below).

When the hatch is pressed into place, the protruding rubber strip is pressed into the profile.

Secure the hatch with the rivet 40213-00 on the inside with a c/c about 300mm.

Adhesive

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• 2 pcs frame profile, for the roof side

• 2 pcs frame profile, for the roof front/back

• 2 pcs frame profile, for the corner pillar

• 3 pcs rectangular tube

• 1 pcs u-profile, for the front

• 4 pcs cover profile

• 2+1 pcs hinge profile, frame

• 2+1 pcs hinge profile, hatch • 2+1 pcs edge profile, cut 2 x 45 degrees

• 4+2 pcs edge profile, cut 1 x 45 degrees

Delivery overview

• 2 pcs edge profile, for the side

• 2 pcs edge profile, for the front/back

Profiles

37010-10 37018-10

37015-10

37014-10 37011-10

37012-10 37013-10

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• 2 pcs sub frame

• 1 pc cross beam • 1 pc rear light beam

• (1+1 pcs) U-profile, short

• (1+1 pcs) U-profile, long

36129-10

Only if fixed wall is ordered.

37016-10

36132-10 36032-10

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• 8 pcs corner joints • 2 pcs corner angles

• Rubber strip, hatch

• Rubber strip

• 6 pcs screw SK6SS M8x8 • 8 pcs reinforced corner angles

• 24 pcs rivet • 8 pcs rivet

Accessories

50395-00 02525-00

40164-00 50390-00

40501-00 40506-00

70090-00 70040-00

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• 24 pcs rivet • 100 pcs rivet

• 6 pcs nut bar • 6 pcs end cap

• 6 pcs chassis bracket • 16 pcs screw M6S M8x30

• 16 pcs washer BRB 8,4x16x1,6 • 12 pcs nut M6MF M8

40504-00 40213-00

02438-00 02424-00

40159-00 50503-00

40146-00 50428-00

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• 6 pcs screw M6S M10x35 • 6 pcs washer BRB 10,5x20x2

40157-00 40143-00