Assembly instructions BR140-2 / BR141-2 / BR142-2 / BR143

Assembly instructions BR140-2 / BR141-2 / BR142-2 / BR143-2 / BR144-2 / BR145-2 / BR146-2

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Please read through these assembly instructions carefully before starting the work. Damage caused by failure to follow these instructions during assembly cannot be recognised as the basis of a complaint. 1. Scope of delivery • Front wall assembly • Side wall assemblies, left and right incl. tailgate posts and, depending on the design, with doors attached • Roof assembly with integrated doorframe cross support incl. doorframe connectors • Alternatively, steel tailgate doorframe e.g. for kits with roller shutter • Depending on the design, tail lift flap with safety bracket right and left plus pneumatic spring and mounting screws for lift flap. • Depending on the design, lower doorframe cross support • Assembly screw M6*21 Tx30 self-locking, AluTeam part no.: MD100224 • Countersunk screw M10x30 galv., MD100268 – connection of aluminium columns to roof • Door screws M12x45, MD100307 – connection of aluminium columns to lower doorframe cross support • Blanking plugs for drilled screw holes in the doorframe posts • Handle with self-tapping fixing screws • 1K sealant, adhesion area cleaner and assembly instructions • Depending on the design, rear position lights (see circuit diagram on Page 14) • Depending on the design, side marker lights with an assembly kit (see circuit diagram on Page 13) • Depending on the design, a connection cable for truck chassis as per order (see circuit diagram on Page 13) 2. Tools and equipment required (not included in delivery) • Precision cordless screwdriver with torque setting up to 12 Nm (e.g.: FEIN AccuTec ASM12-12) • Screwdriver bit Tx30 to DIN 3126 / ISO1173, tough flexible design, ¼“ drive, 50 or 70 mm length (AluTeam part no.: MH170107) • With kits of series BR 140-2 to BR 142-2, the use of a screwdriver bit extension is necessary. • Pneumatic or manual sealant gun for 310 ml sealant cartridges • 4 wooden panels about 300x300 mm (thickness min. 20 mm) or similar


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• 4 single-stud fittings (LOAD-LOK 5018 or Allsafe JUNGFALK 7105 / 75018) • A crane and min. 1-tonne cross-beam with lifting gear are recommended 3. Staff • Depending on the kit size and the firm’s equipment, 1-2 staff may be required for the assembly of an AluTeam kit. 4. Safety precaution • Only use the screws supplied! If you use third party screws, the operational safety of the kit will be put at risk and the guarantee is then void. • To permanently guarantee safety of operation, screws may be used only once. Repeated screwing in of the screws is not permitted. In the event of a repair, it is essential to use new original AluTeam MD100224 screws. • It is essential to observe the stated torques. Screws that work loose on their own because of failure to observe the torque specifications cannot form the basis of a complaint. • During cleaning and sealing work ensure adequate ventilation and venting. The processing, safety and disposal specifications of the adhesive and sealant manufacturers are to be observed. (If necessary request safety sheet and working guidelines directly from the adhesive and sealant manufacturers, see label on cartridge or by telephone on 0049 -521 -41 73 11 10 or by fax 0049 -521 -41 73 11 90.) 5. Safety instructions • Pay attention to your own safety and the safety of your employees. • When offloading or transporting the kit in the transport cradle with a crane, a cross-beam must be used. • When offloading or transporting with a forklift truck, transport cradles are to be secured against tilting and tipping. The transport cradle is to be pushed all the way on to the forklift truck forks. • Transport/handling units may only be lowered on level surfaces and are to be secured by appropriate means against tipping or falling over. • Only lift assemblies upright and not angled! Never walk under raised loads! The suspension point from the crane must always be located above the assembly’s centre of gravity! • Remove all packaging strips only when assembling the box, in the prescribed sequence, always the white packaging strips first. • Each component is individually secured with a red packing strip. Before cutting through the red packing strap secure the component to be removed against tipping e.g. by attaching the assembly aids to the crane. • The roof assembly bars (Airline tracks) are used exclusively as assembly aids. Lifting may only be done with a cross-beam. Do not lift or transport assembled boxes using the roof assembly bars. Risk of them being torn out! • Continue to observe the following regulations: The vehicle manufacturer’s assembly guidelines, UVV (Accident Prevention Guidelines), StVZO (road traffic licensing regulations), BGV D 29, BGV A1, BGG 915, BGG 916 (trade association regulations on accident prevention). • The vehicle constructor is responsible for the suitability of the materials and surface properties used in the kit, as AluTeam is not aware of the purpose of use as a rule. The vehicle constructor is obliged to adapt the order to its customer's requirements before placing it with AluTeam. Negative influences on surfaces or components caused by transport goods such as aggressive chemicals in the construction are not a basis for complaint with regard to our warranty conditions. • Only clean the construction after 6 weeks with a steam-jet cleaner. When doing so, always keep the nozzle at a minimum distance of approx. 300mm.


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Water temperatures over 60°C are not permitted. Highest work pressure 100 bar. Cleaning agents must not exceed a ph value of 10. Rinse off immediately with plenty of clean water after cleaning. No guarantee or warranty is assumed for paintwork damage caused by not complying with these instructions. Flash rust on the stainless steel tailgate doorframe and stainless steel components can be removed with standard stainless steel cleaners. Door seals: Treat the sealing profiles with rubber cleaner after each cleaning process. Locks and locking cylinders:

This involves maintenance parts. These must be kept in working order with lubricants as necessary. Frozen locks due to lack of maintenance are no basis for complaint. 6. Tightening torques of the screws • The torque settings on the screwdriver for the M6 assembly screws are to be checked by appropriate measurement devices. The type of screwdriver mentioned by us under 2. possesses a constant and precise tightening torque after the torque has been set. • The tightening torque of the M6 assembly screws is 10 ±1 Nm. • The tightening torque of the M10 countersunk screws is 72 ±5 Nm • The tightening torque of the M12 door screws is 125 ±5 Nm 7. Preparation work • The elements should be assembled on a level surface. To protect the painted components and for easier alignment place wooden panels about 300x300 mm (thickness min. 20 mm) or similar underneath the corners of the front wall/side wall and side wall/tailgate doorframe. Here you should ensure that the front corner post does not get enclosed from underneath since cables may still have to be fed out. • Have to hand the screwdriver set to the torque of our assembly screws with a TX 30 bit inserted and the MD100224 assembly screws. • The contact surfaces of the assembly joints must be free of impurities and foreign objects. • The sealing strips fitted in the profiles must not show any damage. Damaged sealing strips allow water to get into the assembled box. • The individual components are only to be connected directly to each other. The insertion of third party materials at the joins will lead to the lapse of the guarantee of strength and good seal. • With box kits in the batten by batten design, before assembling the side walls/ front wall, the bottom two or three rows of battens should be removed to allow the wood floor to be easily fitted. 8. Kit assembly • Position the front wall ready for assembly. • Take the side wall out of the transport/handling unit with the crane and lay it on the plywood panels. The side wall remains secured by the crane. • Push the front wall up to the side wall at right angles. • One worker secures the components from outside whilst the second one screws in 3 - 4 screws inside the box, starting from the bottom and working up to about ¾ of the height of the box, until the profiles are pressed together and the required torque has been reached. With kits with inside wall cladding or BR 141 kits we recommend the use of a bit extension with a length of about 100 mm or a flexible bit holder.


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• Place the second side wall in the same way and position it at right angles to the front wall. Then once more screw in 3 - 4 screws, starting from the bottom and working up to about ¾ of the height of the box, until the profiles are pressed together and the required torque has been reached. • With kits with front marker lights, the cables for the lights are to be fed down through the post. This step is omitted with pre-assembled cable sets. • Recheck the angle and diagonal measurements of the parts assembled so far and if necessary correct them. • Take the doorframe cross support from the transport cradle and position it between the two doorframe posts. Attach from the outside of the posts with 4 M12x45 screws each but position the screws initially without tightening them.

• If the kit is equipped with doors, before putting on the roof, the securing straps for the doors must be released but the doors should nevertheless still be secured against tipping. • Take the roof from the transport cradle and lay it horizontally and fit the single-stud fittings to the roof assembly bars. 2 or 4 fittings are required depending on the length of the kit. Make sure that the fittings are securely seated.


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• If the kit is equipped with a tailgate top flap, the flap which is fixed to the transport cradle has to be removed and mounted by using the screws 6,3x22mm at intended holes on top roof profile. • Now lift the roof with appropriate lifting gear on to the single-stud fitting using a cross-beam.

Do not walk under raised loads. Only lift it upright and not angled! • The top doorframe connectors have been pushed sideways into the doorframe cross supports and attached. These attachments are to be detached. The pushed-in doorframe connector is now to be turned 90° so that the tip points downwards. Then attach the connectors to the doorframe posts with two horizontally positioned M10x30 countersunk screws per side. • If the kit is equipped with marker lights at the back, the cables are now to be fed through the large drill holes visible towards the back. Marker lights are now pushed into the drill holes and thereby attached. The cables for the lights are to be fed down through the post. • With pre-assembled cable sets, the rear position lights must be inserted into the doorframe cross support and the plug-in connectors connected according to the diagram.

• Clean front roof panels, seal surfaces on the tailgate doorframe and roof edging with adhesion area cleaner, air for about 5 minutes and apply sealant as shown in drawing IVI00083 below. • Lift the roof into place and, starting from the front, centre it on the top flange of the front wall. The roof caps should protrude over the corner posts. Orient the roof to the wall profiles. Now attach the roof to the front wall with 3 screws evenly spaced across the width of the front wall, making sure that the screws go in straight.


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• Depending on the design, internal lights and/or marker lights are fitted in the roof. Before the final fixing of the roof, the cables must be fed down through the doorframe post for later cabling. To this end the doorframe posts have an opening in the direction of travel through which the cables can be fed out forwards. • Slowly lower the roof so that the downward-pointing tips of the doorframe connectors can be centred in the doorframe posts. Then attach the connectors in the doorframe posts with 3 vertically positioned M10x30 countersunk screws each. With pre-assembled cable sets, the cable laid in the roof edging must be placed into the cut-out in the roof edging when lowering the roof. Otherwise there is a risk of the cable being crushed. • Tighten 3 - 4 screws, depending on the kit length, into the side wall-roof join lengthwise until the required torque is reached. • Measure the diagonals of the doorframe and if necessary correct them. • Tighten the screws of the top doorframe connectors (M10x30) with a torque of about 72 Nm and tighten the screws of the bottom doorframe cross support with about 125 Nm. Here you should make sure that the rear surface of the cross support forms one level area with the rear surface of the posts. • Remove the single-stud fittings from the roof assembly bars. Screw down the post joins from bottom to top, the front wall/roof join crosswise and the side wall/roof join from front to back until the required torque is reached. • If the kit is equipped with doors, the doors should now be closed and the accuracy of the fit should be checked and if necessary corrected. On aluminium doors, the adjustment is done using the screws in the hinge leaves and on integral doors using the door stops on the top and bottom doorframe cross support. The screws should be thoroughly checked again to make sure they are secure. • On kits with an aluminium flap in conjunction with a doorframe post without integrated seal, the flap should be secured from shifting sideways during operation using the two brackets as shown in the sketch.


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• On aluminium doorframes with plywood flap in conjunction with a doorframe post with integrated seal, the flap should be secured from shifting sideways using the hexagonal screws supplied as shown in the sketch.

• With each version of a top flap, the flap’s gas springs are to be seated in the ball heads. • Depending on the flap design, a flap with leaf hinges can also be supplied. In this case, the hinge pieces are fixed to the roof, the hinge leaves must be fitted into the hinge pieces and the hinge pins must be pushed in and secured. If the roof has a built-in tail lift seal, then the end of seal is to be glued to the doorframe posts and also fixed in place with a screw. • With kits with a roller doorframe or doorframe made of high grade steel, the doorframe will be supplied as a separate part. In this case you should proceed as follows. Take the tailgate doorframe out of the transport/handling unit. For this purpose there is a strap fitted in the middle of the top head piece for lifting the frame with lifting gear. Position the tailgate doorframe, push it completely into place, orient it at right angles and begin to tighten 3 - 4 screws starting from the bottom up to about ¾ of the height of the box until the profiles are pressed together and the required torque has been reached. Here too beware of the marker light cables coming out of the posts – risk of damage. On kits with roller shutters, the enclosed roller shutter assembly instructions should be used.


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• The handle can optionally be screwed on inside on the right on the tailgate doorframe post. • The screw holes positioned on the sides of the tailgate posts are to be stopped with the stops supplied with the fitting accessories. • If a sticker about structural strength has been attached to your kits, the blue protective film is to be removed from this after the structure has been painted at the latest. Structural strength stickers are only valid in combination with a structural strength certificate issued by AluTeam from an independent inspection organisation.


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9. Sealing in accordance with drawing IVI00194 • Remove any sealant that has escaped from the corners of the box assembly. • Clean the external sealing surfaces with the adhesion area cleaner supplied. • After airing for 5 minutes, seal as follows: • Around the front corner of the roof • Around the back corner of the roof and the roof edging / doorframe post join both at the top of the doorframe post and the areas of contact top left and right of the doorframe post to the doorframe cross support. • It is only with kits with roller doorframes or doorframes made of high grade steel that the doorframe is to be sealed to the roof along the entire width of the kit. • The seals should only be pressed in and smoothed out with water, without the addition of soap. 10. Fitting the box onto the chassis • The box is to be fitted onto the chassis in accordance with the drawing, see Page 12. Any damage resulting from failure to observe these screwing instructions cannot form the basis of a complaint and therefore will not in principle be recognised. • The substructure or chassis onto which the box is fitted must be positioned horizontally and free of deformation on a level base. In the case of trailers with a step, the low bed must be positioned absolutely parallel and free of all deformation and tension relative to the high bed. • The condensation drainage holes of the bottom flange profiles in BR140-2 and BR142-2 and the water drainage holes in the case of side doors must remain free even after fitting onto a chassis outer frame! • With kits with side sliding doors, the chassis cross supports in the area of the side sliding door’s track are to be disconnected over a width of 60 mm. The remaining cross support height in this area should be at least 45 mm. Ensure adequate strength in the cross supports. With side sliding doors, the vehicle constructor must ensure that the vehicle wheels have enough clearance in the area of the sliding door rails. • With kits of series BR 140-2 and BR 142-2, the doorframe posts are to be supported at the back against the chassis or the chassis cross supports against the direction of travel so that no deformation is caused in the metal sheeting when in contact with the ramp. The support should be arranged so that forces are transferred to the chassis structure or to the ground. Any damage resulting from failure to observe this cannot form the basis of a complaint and therefore in principle will not be recognised. • Fitted boxes must not be handled by the roof eyelets. Risk of them being torn out! • With box superstructures with multiple-leaf side doors, the chassis in the area of the side doors and about 1 m to the right and left of them is to be reinforced as necessary. The responsibility for this lies with the vehicle builder. • With box kits with coupé doors, the chassis in the area of the coupé doors and about 1 m to the right and left of them is to be reinforced as necessary. In particular, the area of the step is to be strengthened in the outer frame area to the rest of the chassis e.g. with junction plates. The responsibility for this lies with the vehicle builder. • With the fitting of the floor panels, the expansion behaviour of the panels is to be taken into account. You can request information on this from your floor panel supplier. The floor panels should always be sealed to the superstructure. The responsibility for this lies with the vehicle builder.


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• With box kits in the batten by batten design, the bottom two or three rows of battens must be screwed back in place after fitting the floor panels. The vehicle constructor is responsible for the correct assembly of the battens. 11. Finishing-off work • After completion of the fitting of the box onto the chassis, the cover panel can be snapped into the bottom flange profile by hand. The cover panel is first placed in the clean lower channel and, starting from one side, pressed or knocked in above. Depending on the kit length, this work should be done with two workers. • Our components with finishing coats and coil coated and powder coated parts are normally to be coated with traditional wet paints. The correct paint composition to achieve secure adhesion should be agreed with the vehicle builder’s paint supplier. Paint suppliers are technically in a position to state whether/which primers must be used. It is essential to treat untreated and galvanised profiles with an appropriate primer before painting. As pre-treatment for the painting process, the parts with finishing coats supplied by AluTeam need only to be buffed (sanding pad) and removed from dust and grease. The temperature in the paint booth must not exceed 60°C. • If attached parts are subsequently assembled or changes are made to the components by AluTeam, adequate corrosion protection must be ensured. Contact corrosion caused by different materials must be ruled out. In case of non-compliance, the guarantee and warranty on the paintwork and coating lapses. • With unpainted boxes it is recommended that the cover panel be fitted only after painting so as to prevent corrosion damage. • After the cover panels have been fitted, the remaining vertical gaps between the bottom flange or cover panel and the front and back posts are to be cleaned with adhesion area cleaner and sealed with 1K sealant in accordance with the sketch. • Once the box has been assembled on the substructure, the connection cable must be pulled out of the doorframe post and connected to the respective vehicle manufacturer's connection cable. • In the case of pre-assembled cable sets with side marker lights for Iveco chassis, the side marker lights must be connected with an “SML chain” connection lead and the cable must then be connected to the SML connection lead.


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Documents

Assembly instructions BR140-2 / BR141-2 / BR142-2 / BR143