PP Fitting instructions-04.30.2xx and 3xx series · Fitting instructions opening windows 04.30.2xx Series 04.30.3xx Series May 2007

Fitting instructionsopening windows04.30.2xx Series04.30.3xx Series

May 2007

Fitting instructions May 2007 3 piece Frontset

Please check if You use the latest version.

Stays/Dim: C D E F: Product specification list

C 1

C 2

DW

A -

he

igh

t

WA - width

FF E

04.30.3xx

C 1

C 2

D

WA

- h

eig

ht

WA - width

FF E

04.30.2xx+

/- 0

.5 m

m

T



Wall Aperture

RectangularWall Aperture size:Width x Height (mm)

Wall Aperture Radius:4 x R75 mm

SpecialWall Aperture size:see Product specification

Wall Aperture Radius:≥ R75 mm

GeneralWall thickness (T):20mm < T < 40mm

Wall aperture tolerance: +3mm / -1mm

Extra space around the Wall Aperture:Space used for screws ≈ 40 mm

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•

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- 00 - Reinforcements around the Wall Aperture.

To mount the 04.30.2xx and 04.30.3xx series on the wall, se-veral other parts are used. The parts are mounted in the Wall aperture and on the wall using screws. Around the contour of the Wall Apertures a rubber profile is fitted and fixed with staples.To make sure that the required parts are fixed correctly around the Wall Aperture, the wall has to be reinforced with a material (such as wood) which is suitable for holding screws, staples and mastic.



- 2 - Positioning the hingebar.

Polyplastic supplies the upper hingebars in the right length and provided with countersunk holes.

Position the hingebar on the wall and make sure that the middle of the hinge-bar aligns with the center of the wall aperture.See product specification for measurements X (= 1/2 length upper hingebar).

- 1 - Preparing the hingebar.

Clean front & hingebar with cleaner*. Stick the butyl tape* on the back of the hingebar.

••

* Clearify with supplier if the used product is suitable for its function and tolerant for all involved materials.

X X

23

76.5 76.5



- 2 - Positioning the hingebar

Suggestion 1: use a jigPlace jig in the Wall Aperture before fitting the rubber profileMark the positions for the upper hingebar.

Suggestion 2: Marks in toolingIn case the wall aperture is positioned accurately in the front / back:

Add marks in the mould for making the front. the marks will be copied in the front / back.

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- 3 - Screw the hingebar to the wall.

Place the upper hingebar on the marks of the WA and fix it with screws. The countersunk holes in the upper hingebars are dimensioned for the use of ‘Cross recessed countersunk head tapping screws’ DIN 7982 - ST 3,5 x L*.

* The length of the screws are to be specified by the screw supplier.

Deviation:Use the hingebar as jig to drill holes Ø4,5mm in the front. Place grommets in the holes and mount the upper hingebar to the wall with matching screws to the grommets.



- 4 - Rubber profile

To make sure the right type from the 66x rubberrange is chosen for your wall thickness contact the Polyplastic sales department. The 66x rubberrange is available with mastic.

- 5 - Pre cutting the rubber

Measure each wall aperture and add an extra 50mm to determine the length of the rubberprofile.

For a square WA that is:2x width + 2x height - 8R + 2πR + 50 = rubber length

R75: 2x width + 2x height - 79 = rubber length

Cut the rubber in a straight line and perpendicular to the profile. While cutting keep the rubber to the rulers on the scissors.

Polyplastic special rubberscissors are available. (art. no. 09.00.887)

50 mm



- 6 - Fitting the rubber

Fit the rubber profile into the Aperture, starting at the bottom. The joint should be positioned where it can be covered by one of the lockplates of a bottom catch.

The distance to the center of the locking plate is shown in the product specification list (Y).

Always clean the wall first with a cleaner* before fitting the rubber into the wall aperture.


Deviation I:Adding extra butyl tape under the joint is allowed. To keep the lockplate at its normal height, the joint with butyl tape should not correspond with the position of the lockplates.

Deviation II:Adding an extra butyl tape on the wall is allowed with a maximum thickness of 2mm.



- 7 - Fit the corners tightly

Press the rubber tightly into the corners of the wall aperture.



- 8 - Connect the ends

The final length of the rubber is cut with an overlap of 10mm (8.1). Cut the rubber in a straight line and perpendicular to the profile. While cutting keep the rubber to the rulers on the scissors. (8.1a)

Apply some powerglue on one of the ends of the rubber profile with the excep-tion of the bubble (8.2) and put both ends together to fit the joint. Make sure the ends are connected neatly (8.3)

8.1a

8.3

8.1

10 mm

Polyplastic sells special rubber-scissors (art. no. 09.00.887)

8.2



- 9 - Flattening the rubber

Press the bump down firmly and flatten the rubber in the wall aperture (9.1). Make sure that the joint stays at the position where the lock plate comes. (9.2)

9.1 9.2



- 10 - Push the mastic to the wall

Press the outer lip of the rubber tightly against the wall to make sure that the mastic sticks everywhere on the wall and the bulb is positioned correctly.

Suggestion: Rolling pressing tool

A rolling tool can be very helpfull to press the rubber firmly against the wall.



- 11 - Staples

Staple the rubber profile on the wall. Use a staple on every 80mm for the bottom and the sides. On the top side a staple on every 40mm.

At the joint 2 extra staples are placed for reinforcement.

Deviation I: Instead of stapling the rubber on the top, staples can also be used at the bottom of the inner lip of the rubber profile.

Deviation II: The two staples are not necesarry when butyl tape is used under the joint.



- Stapling the corners

At least 3 staples are used for fixing the corners.

In case of using a plastic corner fix this to the wall first with at least two staples.

Art. No. Plastic Corners

R75: 09.00.850.00.00.00.000



12.1

- 12 - Cuts in the bulb

Make 2 holes at the bottom of each Wall aperture to prevent a vacuüm in the bulb. The diameter of the hole is 5 mm. The picture (12.1) shows the position of the cuts on the wall apertures.



Plastic inserts for the rubber profileare supplied in two colours:

White: (09.00.819)Grey: (09.00.829)

Fitting tool for Insertion: (09.00.886)

- 13 - Soap

A bit of soapy water* will make it easier to apply the insert in the channel. Make sure the bulb stays dry. A brush is a helpfull tool to apply the soapy water.

- 14 - Fitting the insert

Start fitting the insert where it can be covered by one of the lockplates of a bottom catch or start in the middle on the top side. Easiest is to use the fitting tool for inser-tion (09.00.886)




- 15 - Clipping in the windows.

Position the 04.30.2xx or 04.30.3xx window in front of the upper hingebar.‘open’ the window in an angle of approximately 125 degrees so the hingebar on the window can clip in the upper hingebar. Look at both hinge ends and at the middle of the hingebars to make sure the hinge-bar is clipped in completely before closing the win-dow.

≈125˚



- 16 - fixing the stays.

From the inside of the caravan the stays can be connected with the vertical polyfix adapters on the windows. The product specification shows which tubular or clic clac stay is used for each window.

Shut the windowSlide stay 3mm openPush ‘stay-wall connection’ against the wallOpen the windowMount the bottom screwMount the top screw

••••••



- 17 - Fixing the catches (09.05.451)

Slide the catches on the horizontal Polyfix adapters.



- 18 - Mounting the lockplates

Place the lockplate on the insert in the rubber with the B facing towards the window. Center the lockplate with its catch. Make sure that the distance between the inner sheet of the window and the wall is 12mm. Fix the lockplate to the wall aperture with two screws.

When mounting the lockplates pay attention to the following points:

- The distance between the innersheet and the wall is 12mm.- The lockplate is centered with the catch.- The overlap of the catch and the lockplate is at least 5mm.

Min

. 33

T



Polyfix adapter as shown in the standard position

3,4 mm

To lower the position of the adapter remount the Polyfix adapter using the upperholes.

Absorbing assembly tolerances

Option 1

Lockplate (09.00.811) The lockplate is mounted standard on the insert with the B facing towards the window.

Lockplate (09.00.811)+ spacer 4,5mm (09.00.814)

Add the spacer under the lockplate.

Option 2

Documents

PP Fitting instructions-04.30.2xx and 3xx series · Fitting instructions opening windows 04.30.2xx Series 04.30.3xx Series May 2007