Assembly instructions BR 133-3 to 139-3
Status 03/2022
Former instructions lose their validity.
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2. Preparatory work / Human resources
AluTeam kits can be assembled in any well-
equipped workshop! Implement the following
preparations beforehand:
2.1 Human resources, preparations
For the assembly of the box kits 133-3 to 139-3, 1-2 fitters are required
with training as a vehicle and car body constructor, or equivalent
training, are required depending on the size of kit.
•
Check that delivery & order agree (1.1) and the lower chord of the
walls, as well as the floor profile, are undamaged. Damage can com-
plicate assembly or make assembly impossible!
•
Secure the overall kit against tipping over, as well as its individu-
al module assemblies. These are stored on the pallet in the order
they are required for construction. With extraction, first cut the red
straps which secure a component in each case (see 1.2!).
•
Provide
enough free surface
(min. 3 m) on both sides, as well as be-
hind the vehicle, including the
required tools and equipment
(2.2).
•
The ambient temperature for components, as well as adhesives and
sealants must be at least 15°C.
Attention:
The final strength of the sealant is reached after 24
hours at 20°C.
2.2 Required tools and equipment
Gather the following equipment before assembly:
•
Tape measure (10 m)
•
Precision compressed-air or cordless screwdriver (e.g. Fein
Accutec ASM12-12)
•
Screwdriver bit Tx 30 according to ISO 1173, hard and tough
version, ¼" drive, min. 70 mm long (MH 170107), po
extension for screwdriver bits
•
Torque wrench up to 200 Nm
•
Carrying belts with double-stud fittings
•
10-/13-/17-/19 open-jaw spanner or ratchet and small ratchet
with matching nuts, possibly impact screwdriver and extension
•
Hammer (500 gr.), Punch/Mandrel d = 3 mm and d = 4 mm
•
Air or manual mastic gun for 310 ml sealant cartridges
•
2x glue pliers for doors
•
Rivet gun for rivet diameter 5 mm
•
Crane, forklift
•
2 straight ladders or erection scaffolding
•
HSS drill Ø 5.0 mm (shorter than the wall-thickness!)
•
Commercial painter's spatula (blades approx. 50 mm wide)
•
Small ratchet (1/4 inch with adapted screwdriver bit receptacle)
•
Inside hexagonal wrench or nut size 5
2.3 Tightening torques of the screws
The settings for the screws must be checked by appropriate measuring
equipment. The torques apply in case of dry screw thread.
Adjust the
following tightening torque in each case:
•
assembly screw M6 x 21
(
MD100224)
10 Nm ± 1 Nm
•
assembly screw M6 x 25
(
MD100318
)
5 Nm ± 1 Nm
•
Flat-head screw M10 x 20
(
MD100332
)
52 Nm ± 5 Nm
•
frame screw M10 x 60
(
MD1003)
65 Nm ± 2 Nm
•
Substructure screw M12
80 Nm ± 5 Nm
Fig. 21
Fig. 22
Fig. 23
