AluTeam BR 13x-3 User manual

Assembly Instructions BR 13x-3
Box kits
Please be sure to read these instructions carefully
ad completely before commencing the installation.
MA13X3.ENGL_032019
AluTeam Fahrzeugtechnik GmbH
Brockhagener Str. 88, D -33649 Bielefeld
Tel. [phone], Fax + 49 (0)521 -41 73 11 -90
E-Mail: [email protected], www.aluteam.de 03.22

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 2 / 14
Table of Contents
1. Safety and warning instructions 2
1.1 Checking the scope of delivery 2
1.2 Warning instructions 2
1.3 Safety instructions 3
1.4 Copyright 3
2. Preparatory work / Human resources 4
2.1 Human resources, preparations 4
2.2 Required tools and equipment 4
2.3 Tightening torques of the screws 4
3. Assembly of the kit 5
3.1 Assembling of the longitudinal supports (sub-structure) 5
3.2 Assembling connection of floor and front wall 5
3.3 Assembling of the side walls 7
3.4 Placement and fastening of the roof 8
3.5 Connection of the attached electrics 8
3.6 Assembly of the frame, doors, top gate or sliding door 9
3.7 Placement of the rear roof corners and sealing the kit 10
3.8 Optional additional equipping 10
3.9 Completion work 11
4. Maintenance 13
5. Service, Spare parts 13
6. Waste disposal of used boxes or component parts 13
7. Scope of delivery 14
This manual explains the assembly of kits 133-3 to 139-3. In order to
generate a fault-free structure, absolutely adhere to the work instructions
described here, particularly the following warning notes, the guarantee
otherwise expires. Coloured representations serve for illustration only.
Get in touch with us immediately in case of uncertainties.
1.1Checking the scope of delivery
• Check the shipment against the enclosed packing list for com-
pleteness. Notify any damage incurred during transit immediately
to the delivering forwarding agent. Please understand that we must
reserve the right to make changes to the delivery in form, equipment
and technology. Please find the general scope of delivery on page 14.
1.2Warning instructions
AluTeam does not normally know how the kit is going to be used. As the
vehicle constructor, you must co-ordinate the order and processing
of the kit to the needs of your customer, as well as to the installa-
tion guidelines of the vehicle manufacturer. This also applies to the
related materials and surface conditions. Damage caused by transported
goods such as aggressive chemicals, do not represent a reason for
complaint.
• Store the kit dry and clean (not outside).
• To ensure that no (splashed) water penetrates into the structure,
the sealing cords in the panels must not show any signs of damage.
1. Safety and warning instructions
Please read these instructions completely before commencing the installation!

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 3 / 14
• The seating faces of the module assemblies must be free from
contamination and dirt.
• Never apply screws diagonally, they must not tilt. Consider the tor-
ques (2.3). Undershooting weakens the strength of the system, a
clear overshooting can lead to damage to component parts!
• Connect the component parts directly with the supplied screws.
They may be used one-time only. External or used screws endanger
operational safety. Always use new AluTeam screws also for repairs.
1.3 Safety instructions
Pay attention to your own safety and to that of your employees.
Working with kits involves hazards. Therefore caution is always advised,
in particular you should absolutely:
... Use a lifting beam when unloading or transporting of the packed kit
with a crane.
... Secure the kit against inclination, tilting and toppling over when
unloading/transporting the packed kit with a forklift.
... Only place transportation frames onto flat surfaces, and secure them
against inclination, tilting and toppling over (Fig. 132).
... Always wear a helmet during crane work and only lift module assem-
blies vertically and not at an angle. Never step under raised loads.
The suspension in the crane must always be above the centre of
gravity of the assembly.
... Remove all the packaging straps at the time of installation in the
specified sequence, and remove the white packing straps first. The
individual components or groups are attached with a red packing
strap. Secure the part to be taken out against tipping over before
cutting the packing strap (Fig. 133/134).
... In case of utilisation of an assembly carriage, secure it against
rolling away.
... Provided that you raise the floor over the airline rails, using a mini-
mum of 2 double-stud fittings for that with sufficient load-bearing
capacity.
... Only lift the roof with a lifting beam or vacuum suction-unit! The mount-
ing brackets (airline rails) are used for this purpose only as an assembly
aid. Assembled boxes may not be lifted with them. Riskof pullingout!
... Comply with the legal specifications, such as StVZO, BGV D 29, BGV
A1, BGG 915, BGG 916. This is the responsibility of the vehicle manu
facturer.
... For cleaning and sealing work, make sure there is sufficient aeration
and ventilation, and observe the processing specifications and the
safety and disposal regulations of the adhesive/ sealant manu-
facturer. Please request the safety sheet and the processing
specifications from the manufacturer printed on the cartridge or under
[phone].
1.4 Copyright
The copyright of these instructions belongs to AluTeam.
They are only intended for the professional assembly company and its
staff and, either in total or in parts, may not be:
•
reproduced
•
disseminated or
• disclosed in any other way.
Contraventions can have civil and criminal legal consequences!
Excessive torque
1
2
Fig. 122
Suspended loads
on the crane
Falling
objects
Hazardous
substances
Tumbling parts or
module assemblies
Hazard from
high-pressure
cleaners
Risk of scalding
Fig. 131
Fig. 132
Fig. 133
Fig. 134
Fig. 14

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 4 / 14
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), possibly +
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

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 5 / 14
3. Assembly of the kit
I n case of the kit BR13x-3, the sub-structure and the floor are component
part of the kit and must be assembled professionally.
3.1 Assembling of the longitudinal supports (sub-structure)
• Place both longitudinal supports with the vehicle-specific, pre-as-
sembled brackets on the vehicle chassis. The V-Shaped section must
point in the driver cab direction (Fig. 311) and the upper leg sup-
ports to outside.
• Align the longitudinal supports according to the diagonal dimen-
sion y and hole separation dimension x. Consider absolutely the
measurement dependencies x1 = x2, as well as y1 = y2 (Fig. 312). The
difference between the diagonals must not exceed 4 mm!
The supports should rest on the longitudinal stringers flush with the
outer edge of the vehicle frame (Fig. 313) and keep the same sepa-
ration distance to the driver cab in front in each case.
Attention: In case of iso-floor, the hole separation dimension x
listed in the type sheet is to be adhered to absolutely !
Observe the construction and modification instructions of the re-
spective chassis manufacturer, in particular the positioning and the
type of connection of the substructure, flexible or rigid. At a mini-
mum, the two front fastenings must be spring-supported. Otherwise
forces occurring during driving (e.g. with cornering, load changes
or uneven loading) are transferred to the structure. This can lead
to cracks in the sub-structure and in the set-up structure. Possible
adaptation work, such as e.g. bores, are the responsibility of the ve-
hicle constructor.
• Now measure again and check the hole separation dimension x and
the diagonal dimension y. If required , re-adjust. If the dimensions
are consistent, first screw the front and rear brackets securely and
after that the remaining brackets follow.
3.2 Assembling connection of floor and front wall
• Now place the floor onto the longitudinal supports (Fig. 321) by
means of a crane and suitable belts with double-stud fittings. (Fig.
321). Latch the fittings into the integrated airline rail in the cen-
tre of gravity of the floor. As an alternative, you can possibly use a
forklift with sufficiently long prongs.
• A foam strip protects the side floor profile and the subordinate seal-
ing cord. Now pull these strips carefully out in order not to damage
the seal.
• Align the floor centrally to the longitudinal chassis beams and the
driver cab. There must be a separation distance of approx. 1.20 m to
the front wall, so that you can attach the front wall later (Fig. 322).
Danger: Toppling module assemblies endanger life and
limb. Secure the floor against tilting and falling,
where you fix it with four screws at the longitudi-
nal supports.
• If the kit is equipped with side marking lights, a cable runs in front
crossways within the floor. Ensure that the plug connectors hang
down freely on the side (Fig. 323).
Fig. 311 Fig. 313
Fig. 312
Fig. 323
Fig. 321
Fig. 322

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 6 / 14
• Take the front wall from the transport unit with crane and
lifting tackle or vacuum cross beam. Insert the wall with
the lower chord diagonally into the floor profile at an
angle of 10 - 15° (Fig. 324).
Danger: Crane-work involves hazards to life and limb. Never
step under raised loads! Always wear a helmet. Lift loads
only vertically and not diagonally! The suspension in the
crane must always be above the centre of gravity of the
assembly.
• Ensure that the front wall and the floor have a flush transition on
the side (Fig. 325).
• Raise the front wall to the second or upper latch point and the
"nose" latches into the floor profile clasps with a clearly audible
noise ("click") (Fig. 326). Test visually whether the nose has en-
gaged in the profile and whether a gap dimension still exists.
• Danger: Toppling module assemblies endanger life and limb.
Screw the right and left two screws (MD 100318) into the
rivet-down nuts so that the front wall does not topple
over (Fig. 327). Check the side profile transition for flush
finish.
• Then fix the front wall over the entire width with the delivered mod-
ule assembly screws (MD 100318) and the gaskets (MD 110044). In
difficult to access areas, use the small ratchet.
• Loosen the four floor screws fixed at the beginning and push floor
and assembled front wall carefully to the driver cab up to reaching
the parallel driver cab separation distance (Fig. 328). In order to
place the module assembly centrally and to prevent a side misalign-
ment of the floor, one fitter per vehicle side must push.
Danger: Protect the driver cab against damage with suitable
means.
• Position the floor in longitudinal and transverse direction for the
screwed connection with the longitudinal supports. In this case,
the separation distance to the driver cab is to be adjusted in
accordance with type sheet (parallel).
• Then measure the separation distance of the exterior frame of the
floor to the longitudinal supports in front and behind as well as to
the left and right, and adjust the dimensions.
According to floor variant, now proceed as follows:
• In case of a standard module assembly with steel longitudinal
supports insert the supplied threaded plates into the cross beams
and screw the longitudinal supports (Fig. 329-3212) with the floor
using screws MD100354.
In so doing, insert the clamping claws into the cross beams, always
with the nose toward the middle of the vehicle (Fig. 3211).
• On the front and rear support, implement the screwed connection in
accordance with the exploded view (Fig. 3212).
10 -15 °
Latching point 2
Latching point 1
MD 120015
MD 110020
MD 100354
Front/Rear support
Longitudinal support
Fig. 3212
•
Take the front wall from the transport unit with crane and
Fig. 324
Fig. 326
Fig. 325
Fig. 328 Fig. 327
Fig. 329
Fig. 3210
Fig. 3211

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 7 / 14
• Align an iso-floor with steel longitudinal supports so that the
screw thread inserts in the floor are located over the elongated holes
of the longitudinal supports (distance according to type sheet). The
separation distance to the driver cab is absolutely to be adhered to.
Tip: Use a mandrel (Fig. 3213) in order to bring the bores of the
longitudinal supports in line with those of the floor.
• Insert the screws MD100354 into the bores and screw them down
with several turns of the thread. If they can be screwed down with-
out impairment of the freedom of motion, tighten them crosswise
with the required torque (Fig. 3214).
• Align the rear longitudinal support close-off to the hole pattern in
the floor. Use a mandrel to check whether the hole pattern in the
longitudinal support is in line with the bore in the floor (Fig. 3215).
3.3 Assembling of the side walls
• Lift with a suitable lifting aid (crane with appropriate hoisting
gear, vacuum cross beam or lifting plate) the 1st side wall in the
centre of gravity (Fig. 331). Observe the safety instructions!
Tip: It is best to fix the rear walls with glue pliers in order to prevent
damage to the side wall.
• Ensure that no cables are present between connection points (dan-
ger of crushing of the cables). They must hang down freely on the
beginning and end of the wall (Fig. 330 a/b).
• As with the front-side wall assembly, set the lower chord of the wall
diagonally (approx. 10-15°C) into the floor profile (Fig. 331/324).
• Rotate the module assembly screws MD 100318 into the appropriate
bores in order to fix the latching point (with MD 110044), and tighten
them by several turns of the thread (Fig. 332). With the bedding of the
side wall, the corner pillar touches the frame cross beam (Fig. 333).
Further assembly is not hindered by this.
Attention: Before the raising of the side wall, the front wall
should stand vertically and the corner pillar overlap
the front-side wall panel.
• Raise the side wall up to the second latching point until it engages
with a noise ("click") (Fig. 334/336).
• Visually check whether the nose has engaged in the profile and
whether a clearance still exists, in particular in the side door area.
Where appropriate, press down in order to ensure engagement. Once
again, check for a flush line and gap dimensions (Fig. 334/327).
• The frame pillar should now fit flush with the frame cross beam and
both are at right angle to each other below (Fig. 335). Now tight-
en the screws used at the beginning securely with the appropriate
torque.
• In the interior of the box, fix all walls with the module assembly
screws for the interior area MD 100224 (Fig. 337).
Attention: Unlike those for the outer area (MD100318), these screws
have no gasket and are provided with a cylindrical
head.
• Proceed with the assembly of the 2nd side wall just like with
the 1st side wall (Fig. 338 /339).
•
Proceed with the assembly of the 2nd side wall just like with
the 1st side wall (
•
Lift with a suitable lifting aid (crane with appropriate hoisting
gear, vacuum cross beam or lifting plate) the 1st side wall in the
centre of gravity (
Fig. 3213 Fig. 3214
Fig. 3215
Fig. 330a Fig. 330b
Fig. 332
Fig. 331 Fig. 333
Fig. 339
Fig. 334
Fig. 336 Fig. 337
Fig. 338
Fig. 335

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 8 / 14
3.4 Placement and fastening of the roof
• Push the upper frame nodes laterally into the roof edge. Fix these
hand-tight with 2 flat-head screws M 10x20 MD 100332 each (Fig. 341).
• Lift the roof with a crane or with of a vacuum cross beam over
the transport lugs and carrying straps (Fig. 342/343). Set it
down over the structure (Fig. 344).
Danger: Crane-work involves hazards to life and limb. Never
step under raised loads! Wear a helmet. Lift loads only
vertically and not diagonally! The suspension in the
crane must be above the centre of gravity of the assembly.
• Keep the roof in the balance while an employee secures the centre
of gravity of the component. Now carefully set the roof down be-
ginning at the front on the front wall (Fig. 344).
• Centre the roof on the top boom of the front wall. The roof caps
catch on the corner pillars. Align the roof with the wall profiles. Fix
it to the front wall with screws distributed over the entire width.
Attention: The screws must not tilt and cable and plug not get
squeezed!
• Lower the roof slowly. The tips of the frame nodes pointing down
should be centred on the frame pillars. Fix the nodes in the pillars
hand-tight with flat-head screws M 10 MD 100329 (Fig. 344/345).
• Screw the side wall/front wall to the roof with the module assem-
bly screws MD 100224, until the required torque 10 Nm ± 1 Nm is
reached (Fig. 346).
3.5 Connection of the attached electrics
• The cable connections of the kits BR13x-3 can be mounted very
simply as follows:
• For the cabling of the navigation lights and the third stop
light , just connect 1. the plugs and slide 2. the plug connec-
tion (to the right) into the right frame pillar (Fig. 351).
Attention: The cables and connectors must not be crushed.
• Now connect the different lights and the reversing camera:
• For the cabling of the LED strips with motion detector (infrared
sensor), just connect 1. the plugs and slide 2. the plug connec-
tion downward into the left frame pillar (Fig. 352).
Remark: The illustration indicates a cabling with LED strips on the
right and left.
•
Lift the roof with a crane or with of a vacuum cross beam over
the transport lugs and carrying straps (
Adapter
MA 350147
Adapter
MA 350148
MA 350151
MA 350151
3. Brake
light
MA 350143
MA 350081
MA 350149
2
Molex pin
Molex bushing
Roof edge
MA 350114...19, MA 350141
MA 350114...19, MA 350141
MA 350127
MA 350081
Power IN cable
MA 350081
MA 350126
2
Driving direction
Fig. 341 Fig. 342 Fig. 343
Fig. 345 Fig. 346
Fig. 344
Fig. 351
Fig. 352
1
1
Driving direction

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 9 / 14
• For the cabling of the LED strips without motion detectors (in-
frared sensor), just connect 1. the plugs and slide 2. the plug
connection downward into the left frame pillar (Fig. 353).
Remark: The illustration indicates a cabling with LED strips on the
right and left.
• For the cabling of the preassembled side marking lights (SML), just
connect 1. the plug on the left side with the connection cable in
the floor profile and 2. connect the plug on the right-hand side
with this cable as well.
Now insert the plug connections no. 1 and 2 into the floor profile
on the front or on the side (Fig. 354); see also 3.9 (Fig. 396).
• For the reversing camera MA 350172 or MA 350173, connect 1. the
camera cable in the frame pillar with that of the camera and slide
the plug connection into the pillar (Fig. 355). Then 2. route the
cable MA 350174 into the driver cab in order to connect it to an
external monitor or via an adapter cable to the vehicle display.
Attention: Be sure to follow the assembly instructions of the
camera manufacturer, as well as the specifications of
the chassis producer.
3.6 Assembly of the frame, doors, top gate or sliding door
• Fix the lower cross beam from the outer side of the corner pillars
each with 2 screws M 10 x 60 mm. Do not tighten the screws yet!
Measure the diagonals of the frame and correct these as appropri-
ate until they are in full alignment (Fig. 361).
• Tighten the screws of the frame nodes M 10 x 20 (MD 100332) and
the bottom frame cross beam screws M 10 x 60 (MD 100328) with
the correct torque (no impact screwdriver!). The cross beam and
the rear surfaces of the pillars must be flush (Fig. 362).
• Take the fittings out of the roof assembly strips.
• Close the tailgate in order to check the fit accuracy.
Set these up as appropriate, according to the door design, over the
brace supports on the frame cross beams.
• Fix an upper flap to the frame using the holes provided in the hinge
with the screws MD 100058. Then seal the transitions (Fig. 363).
Take the gas pressure springs (piston rod must point down) and
engage the spherical heads.
• In the case of a frame pillar with integrated seal, secure the flap
against lateral displacement with the assembly screws A (Fig. 364).
• In the case of a frame pillar without integrated seal, secure the flap
against lateral displacement with 2 brackets B (Fig. 365).
• Mount a sliding door according to the current instruction included
with the assembly material for sliding doors.
MA 350081
MA 350081
MA 350120
MA 350081
MA 350120
Power IN cable
Power IN cable
Roof edge
MA 350114...19,
MA 350141
MA 350114...19,
MA 350141
LED strip rightLED strip left
SML MA 350135
Connector cable MA 350 0 81
Connection cable MA 350161
Blind cap pin MA 350093
Connection
cable
Connection cable
Connection cable
SML
Blind cap pin
on the cable end
SML
SML
Connection cable
SML
1
2
MA 350172
MA 350173
in the frame
pillar
MA 350174 in
side-wall profile
MA 350081
Fig. 353
12
1
2
3
Fig. 354
1+2
Fig. 355
Fig. 361 Fig. 362
Fig. 363
Fig. 364 Fig. 365
AB
Driving direction
Driving direction
Driving direction

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 10 / 14
3.7 Placement of the rear roof corners and sealing of the kit
• The ambient temperature for component parts, as well as adhesives
and sealants, must be 15°C minimum.
Attention: The final strength of the sealant is reached after
24 hours at 20°C.
• Provide the contact surfaces of the rear roof corners (internal) with
sealant on the side and top (Fig. 371).
• Place the corners onto the roof. Where appropriate, drill from above
through the roof corners and the frame cross beam into the existing
bores with a diameter of 5 mm. Please be sure to not damage existing
cables.
• Place 2 blind rivets MD 150051 d = 5 mm (Fig. 372). Remove sealant
mass leaking from the corners.
• Clean the sealing faces with the adhesive cleaner of the kit (Fig. 373).
• After approx. 5 minutes flash-off time, seal on the outside:
• The front roof corners from below (Fig. 374),
• The circumference of the rear roof corners (Fig. 375),
• The roof edge connection and frame pillar at the upper end ,
• The contact surfaces top right and left from the frame pillar to
the frame cross beam,
• The rivets fixing the roof corners from above (Fig. 372)
• In each case, seal the vertical gap in the front wall between the
lower chord and the two front corner pillars (Fig. 376) with the
sealant included in the kit.
• Provide sealing in the interior of the box in the area of the frame
cross beam and the front-side corners (Fig. 377/378).
• Smooth off all sealing using only polishing agent or water without
soap additives.
3.8 Optional supplementary equipment
Unlike the model range 13x-2, we offer further additional options, such
as the preassembled tail pull-out ladder or the reversing camera. Those
options, which are described in the following, must still be attached
however.
• In case of a tail LBW, you may need to refit the rear lights. With
the rear light brackets (right-hand KM390010360R; left-hand
KM390010360L), the lights can be assembled both horizontally and
vertically. The brackets are pre-punched (Fig. 381 / 382) for the rear
lights of usual vehicles.
• After the attachment of the LBW, mount the rear light bracket to
the lower frame cross beam. The folded legs (Fig. 382) must point
backwards, against the direction of travel (TD). A bevel serves for the
screwed connection with the frame cross beam. The second bevel
points toward the centre of the vehicle (VC) (Fig. 381).
• Fix the bracket with the hexagon socket M 10 x 30 (MD100227) and
the washers (MD110002) to the frame cross beam (Fig.382).
Fig. 371 Fig. 372
Fig. 373 Fig. 374
Fig. 375 Fig. 376
Fig. 377 Fig. 378
Fig. 381 Fig. 382
TD
VC

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 11 / 14
• In case of the optionally supplied side rise MA 200373, first re-
move the nuts and washers A in the area of the side doors.
• Take the rise, fit it from below and screw it back with the wash-
ers and nuts. Tighten the nuts securely with the prescribed torque
(Fig. 383).
• With the fender bracket option KS 320185, the brackets are pre-
assembled to the sub-structure with cross beams (Fig. 384). Screw
off the brackets. The threaded inserts remain in the cross beams.
• Use fenders with flat assembly surfaces (not included in the scope
of delivery). Place the two parts of the brackets symmetrically in
longitudinal and transverse direction to each other on the assem-
bly surface of the fenders. The bevel must point upward.
• Use the holes in the brackets as a drill template and drill the
fenders. Screw the components together with the screws MD 100265,
washers MD 110001 & nuts MD 120001.
• Secure the fender bracket with the threaded inserts MD 100354
and the screws removed at the beginning to the cross beams.
Align the fenders centrally over the running-contact surface of the
wheel. Check if the tyre can move freely and correct as appropriate,
then tighten the screws with the appropriate torque (Fig. 385).
3.9 Completion work
• Where appropriate, screw the hand grip to the inner right portion of
the frame pillar (Fig. 391).
• Close the side screw holes on the rear pillar with the supplied plugs
MA150001 (Fig. 392).
• According to wall-thickness, shorten the inside brackets
MA100068/-69 at the markers. Arrange these according to the
illustrations and fix with the screws MD100057. At the rear, any
preassembled screws must be removed beforehand (Fig. 393-395).
AA
Fig. 383
Fig. 384
Fig. 385
Fig. 391 Fig. 392
Fig. 393 Fig. 394 Fig. 395
front rear rear

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 12 / 14
• Pull out the connection cable for the interior lights at the bottom
of the left frame pillar and connect to the vehicle electrics.
Attention: Follow the instructions of the vehicle manufacturers!
• Pull out the connection cable for the navigation lights and, if ap-
propriate, the connection cable of the side marking lights at the
bottom of the right frame pillar. Connect these connection cables
to the adapter cable for the respective vehicle.
• Connect the vehicle-specific adapter cable with the rear light
(Fig. 396).
• Check the roof corners, doors and the lighting for tightness e.g. by
a water test for structures, following EN 283.
For this, direct a water jet from a ½" nozzle (Ø 12.5 mm inner di-
ameter) at a pressure of over 1 bar onto the external sealed joints.
Hold the nozzle at a distance of approx. 1.5 m from the structure.
After the test, no water should have penetrated into the structure.
• You can generally paint over our coil coating and powder-coated
parts with traditional wet paints. For a secure adhesion, get in
touch with the paint supplier especially concerning the primer.
Untreated and zinc-coated profiles are to be treated with a suitable
primer before painting. The temperature in the painting cubicle
may not exceed 60°C.
• Pay attention in particular to the corrosion protection in case of
subsequently attached component parts or modified AluTeam com-
ponents. In particular, you must absolutely exclude contact corro-
sion through different materials (Fig. 398). Otherwise the guaran-
tee on the painting, coating and bond is voided.
Note that the final strength of the sealant is reached, at the
earliest , after 24 hours (at 20°C). The assembled box can be treat-
ed but not loaded.
Attention: You may only clean the structure with a steam
cleaner after 6 weeks. Please absolutely consider the
corresponding explanations under "4. Maintenance".
Stick-on labels related to the structure strength apply only in
connection with a certificate issued by AluTeam (Fig. 399).
Adapter
cable Suitable for motor vehicle type:
MA350158
MB Sprinter, VW Crafter, MAN TGE,
Opel Movano, Renault Master, Citro-
en Jumper, Fiat Ducato,
Peugeot Boxer
MA350159 Iveco Daily
MA350168
Ford Transit
Fig. 396
Attention: Paints, solvents
and dusts endanger health.
Protect yourself!
Fig. 397
Fig. 398
Fig. 399

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 13 / 14
For the maintenance of the structure, check all screws are tight (also in
case of sliding doors!) at regular intervals but at least once a year. Also
check the prescribed torque in the process.
• Locks and closing cylinders are maintenance parts. They must be
kept serviceable with lubricants when necessary. Locks seized due
to poor maintenance are not a reason for complaint.
• Clean the structure with a steam jet blower, at the earliest after
6 weeks. In order to avoid damage to the paint, keep
nozzle at a minimum distance of approx. 300 mm. The
maximum water temperature is 60°C, the maximum oper-
ating pressure is 100 bar, and the pH value of the clean-
ing agents is 4 - 10.
After that, flush immediately with sufficient amounts of clear wa-
ter. Remove rust film on stainless-steel parts (including the frame)
with normal household stainless steel cleaners.
• Treat all seals with a rubber care agent after every cleaning.
In case of questions related to the assembly, our Customer Service will
be glad to help you:
Tel: [phone], Email: [email protected]
If you require spare parts, please contact your responsible sales repre-
sentative or call us at: +49 (0)521 - 41 73 11 - 10
Please send e-mails to: [email protected]
• You can remove the metallic layers from the foam core and have
them recycled together with aluminium via the scrap trade. The
same applies to the steel and/or stainless steel components of the
frames.
• A PUR foam core can be burned in thermal waste treatment systems
without contaminating the environment. The energy contained in
the insulation material is converted into primary energy in this case.
• Plywood, too, can be used to generate energy. Odour nuisance due
to the ammonium additives in the binding agents are to be avoided.
Generally, they can be burned as chipboard in wood furnaces with
50 kW minimum nominal thermal capacity. They are subject to
significantly stricter carbon monoxide limit values than solid wood.
Mostly, only automatically fed systems comply with these values.
•It is essential that you also consider the proper disposal of the
foam in the floor area.
Tip: Information on this can be found in a leaflet published by the
„Fachvereinigung Polystyrol - Extruderschaumstoff (FPX)“,
Odenwaldring 68, 64380 Rossdorf (www.fpx-daemmstoffe.de).
4. Maintenance
6. Waste disposal of used boxes or component parts
5. Service, Spare parts
•
Clean the structure with a steam jet blower, at the earliest after
6 weeks. In order to avoid damage to the paint, keep
nozzle at a minimum distance of approx. 300 mm. The

Assembly instructions BR 133-3 to 139-3 Status 03/2022 Former instructions lose their validity. 14 / 14
Please understand that we must reserve the right to make changes to
the scope of delivery with regard to form, equipment and technology.
Included in the scope of delivery of a kit BR13x-3:
• Fully assembled longitudinal supports with prepositioned brackets
according to motor vehicle type
• Sub-structure hexagon screw M 12 with washer 3 mm MD 110020
and hexagon stop nut M 12 MD 120015
• Floor module assembly with airline rails, with pre-assembled door-
stops and tail pull-out ladders as appropriate
• Module assembly screw self-locking 6 x 25 MD 100318 with gasket
MD 110044 (connection floor / wall - external)
• Front wall module assembly
• 2 side-wall module assemblies right-hand and left-hand, incl.rear
pillars, as appropriate with preassembled side marking lights, pre-
assembled ramming buffer and attached doors according to the
version
• Roof module assembly with integrated frame cross beam,
including preassembled front roof corners and frame node
MA 430124 as appropriate, with pre-ass. reversing camera
MA 350172 or ..173
• Rear roof corners MA 100060
• Blind rivet MD 150027 for the riveting of the rear roof corners
• For LBW kits: tail top gate with gas pressure spring and mounting
screws MD 100058, and material to fix the flaps on the sides (de-
pending on the type of flap)
• Inside bracket front and rear for 14/31 mm walls MA 100068
MA 100069.R / MA 100069.L including fastening screws /
MD 100057
• Module assembly screw M 6 x 21.5 self-locking, geomet-coated
MD 100224
• Flat-head screws 10 x 20 with hexagon socket MD 100329
- connection aluminium pillars to roof
• Cylinder-head screw M 10 x 60 MD 100328 for connection of the
aluminium pillars to bottom of the frame cross beam
• Seal plug for screwed connection bores in the frame pillars
MA 150001
• Hand grip MA 200152 with self-drilling fastening screws 4.8 x 16 mm
geomet-coated MD 100167
• 1-component sealant and adhesive, AluSeal traffic-white MA 310115
• Adhesive cleaner Sika Activator / Cleaner 205 MH 240068
• According to the version, matching adapter cable for connection of
the electrics to the rear lights
• Paper tissues
• Stick-on label with structure number
• Assembly instructions
•Further options:
• Side rise MA 200373
• Rain water deflector (for side door)
• Preassembled fender bracket KS 320185
• Rear-light bracket KM 390010360L or KM 390010360R
• Stick-on label "Tested freight protection"
Attention: The stick-on label is only valid with a certificate
issued by AluTeam!
7. Scope of delivery