TITGEMEYER Tf1673GB(0517)1. GETO City Body Kit with a self-supporting base and without a base Assembly Instructions

Transcription

1 TITGEMEYER Tf1673GB(0517)1 with a self-supporting base and without a base

2 All rights reserved. The technical data quoted in this catalogue, performance descrip - tions, recommendations and instructions e.g. for the installation of the components available from us, are without liability. These are based on our experience. Claims against us as a consequence are expressly excluded as much of the application of our goods remains outside our direct influence. It is a fundamental obligation of the user to ascertain and to decide whether the goods provided by us are appropriate for a particular application. This catalogue is our intellectual property! Disclosure to third parties is prohibited. Reproduction even in part as well as use of our illustrations and TITGEMEYER part-numbering systems is only permitted with our express permission in writing. Subject to change. Supply of goods is in conformity with our delivery and payment conditions. Gebr. TITGEMEYER GmbH & Co. KG Osnabrück

3 Contents Instructions for assembly with a self-supporting base Pre-assembly work Assembly instructions Instructions for assembly without a base Pre-assembly work Assembly instructions Important information Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 3

4 Pre-assembly work Please read these assembly instructions carefully and from beginning to end before beginning the assembly work! To ensure the proper functioning and quality of the kits supplied by TITGEMEYER, the pallet containing the individual body kit components must not be directly exposed to the elements. Failure to observe this obligation will result in all damage and compensation claims becoming void! GETO City is suitable for chassis with a gross vehicle weight of 5t. Fitting materials (supplied with the kit) Drilling screws 4.8 x 13 mm TIBULB blind rivets 6.4 x 10.5 mm SPAX screws for sandwich roof to attach the roof / rear frame 1 cartridge of Körapur 125 adhesive Cleaner Körasolv WL Also supplied with self-supporting base version 2 aluminium longitudinal members Body mounting brackets to affix the longitudinal members to the floor panel Countersunk screws M 6 x 55 mm and lock nuts SPAX screws 5 x 50 mm to connect the side rave to the floor panel 3 Körapur 140 adhesive cartridges Special accessories Chassis brackets to connect longitudinal members to chassis Tools and materials (required for kit assembly) Machine screw tap M 10 Torque screwdriver, medium torque 4 Nm Type T 25 Torx bit or Phillips screws Vice-grip wrenches (2) Set of open-ended and ring spanners / Screw drivers Abrasive pad to clean glued surfaces Manual or pneumatic cartridge gun for 310 ml cartridges Rivet tool for 6.4 mm rivets C clamps 1 piece of lumber, approx mm long Installation Fit the brackets to the chassis Lay the longitudinal members on the chassis, then position and secure (only applies to self-supporting base version) Fit the self-supporting floor panel to the longitudinal members Fit the bulkhead to the floor panel Fit side wall 1 to the floor panel and bulkhead Fit side wall 2 to the floor panel and bulkhead Fit the rear frame to the self-supporting base and side walls Fit the roof Assembly preparation Ensure that the connections between the floor, bulkhead, side wall / side wall, rear frame and to the roof are clean and dry The kit should be assembled on an even surface and timber The self-supporting base version is assembled directly on the floor panel The kit components are supplied on a pallet and secured using cable ties When removing the parts / loosening the cable ties, ensure that the parts that are not yet needed remain securely positioned on the pallet Secure the pallet to prevent it from tipping The rear frame and bulkhead must first be removed from the pallet and then safely set to one side until they are to be installed. The supplied fixing materials can be found at the bottom of the pallet in the middle. To ensure accurate fitting in the contact areas between bulkhead / side walls and roof, we recommend applying adequate pressure during the assembly 4 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

5 with self-supporting base Assembly with self-supporting base Measure the length of the floor panel. This is needed to determine the length the alu - minium longitudinal members need to be cut to. The aluminium longitudinal members should be 25 mm shorter than the length of the floor panel. (Fig. 1) 25 Fig. 1 Align the subframe brackets on the chassis so that they are parallel and then bolt them to the chassis. Align the longitudinal members so they run parallel to the chassis and clamp them tight against the subframe brackets using C clamps. Now measure the resulting spacing between the longitudinal member flange surfaces (edge to edge). (Fig. 2) Spacing Fig. 2 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 5

6 with self-supporting base Place the floor panel underside up on e.g. supports. Mark the determined spacing between the longitudinal member flange surfaces (edge to edge) on the underside of the floor panel as well as on the areas where the crossmembers are located. (Fig. 3) Add another 10 mm to the outer edges of each mark. Now tap an M 10 mm thread at each of the determined points. Please note: Determining the position of the tapped holes: Width of floor panel - Spacing between longitudinal member flange surfaces (edge to edge) - 20 mm (2 x 10 mm spacing between right + left longitudinal members) : 2 = Distance from outer edge of floor panel to centre of drilled hole Fig Now drill 8.5 mm holes at the points marked on the cross-member and then tap an M 10 mm thread. (Fig. 4) Fig. 4 6 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

7 with self-supporting base Before laying the floor panel over the longitudinal members, roughen the area that will support the longitudinal members and floor panel using e.g. an abrasive pad and then clean the surface using Cleaner Körasolv WL. (Fig. 5) Apply adhesive to the glue ducts on the longitudinal member flange, by adding one adhesive bead per duct. (Fig. 5) The longitudinal members should already be resting on the chassis at this time. Fig. 5 Take the floor panel and position it on the longitudinal members so that the front is flush and then bolt together using the body mounting brackets supplied (torque: 40 Nm). (Fig. 6) Fig. 6 Slide the floor panel back about 1000 mm (required working space) and secure! Ensure that the floor panel is level. Using a marker pen, mark the centre of the floor panel on the front. (Fig. 7). Fig. 7 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 7

8 with self-supporting base Bulkhead / side wall Check that the rubber piping in the corner post profile is undamaged and correctly fitted. (Fig. 8) Fig. 8 Installing the bulkhead Drill 5.2 mm holes approx. every 300 mm into the upper fastener groove of the side rave profile. (Fig. 9) Please note: Only drill through the side rave profile! Using a marker pen, mark the centre of the bulkhead on the inside of the floor support. Clean the inside of the side rave using Cleaner Körasolv WL. Apply Körapur 140 adhesive to the inside of the side rave profile or alternatively to the front of the floor panel. Fig. 9 Place the bulkhead against the floor panel and centre (marking to marking). Then drill 3.2 mm holes through the holes on the side rave profile and into the floor panel. (Caution! Insert is 30 mm deep all the way round; must be drilled). Now bolt the side rave profile to the floor panel using the 4.8 x 50 mm self-tapping screws supplied. (Fig. 10) Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

9 with self-supporting base Attach the flashings around the bulkhead. (Fig. 11) Fig. 11 The assembly can now be brought into its final position on the driver's cab and aligned in keeping with the chassis manufacturer's assembly instructions. The longitudinal members and attached subframe brackets will need to be bolted to the chassis. (Fig. 12) Fig. 12 Installing the side wall Drill two holes each between the floor panel cross-members as shown in the illustration. The holes should be drilled into the upper fastener groove of the side rave profile that is attached to the side wall. Please note: Only drill through the side rave profile! (Fig. 13) Fig. 13 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 9

10 with self-supporting base Clean the inside of the side rave using Cleaner Körasolv WL. Apply Körapur 140 adhesive to the inside of the side rave profile or alternatively to the front of the floor panel. Position the side wall. (Fig. 14) Fig. 14 Check that the area around the roof supports is the same height. (Fig. 15) Fig. 15 Attach vice-grip wrenches to the top and bottom to lock the components in place. (Fig. 16) Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

11 with self-supporting base Affix both components by screwing the drilling screws provided into the installation holes from the inside. Check that, after installation, the gap on the outside is as narrow and even as possible. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig. 17) Fig. 17 Drill 3.2 mm holes through the holes on the side rave profile and into the floor panel. (Caution! Insert is 30 mm deep all the way round; must be drilled). Now bolt the side rave profile to the floor panel using the 4.8 x 50 mm self-tapping screws supplied. (Fig. 18) Fig. 18 Continue with the second side wall in the same way as for the first side wall. (Fig. 19) Fig. 19 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 11

12 with self-supporting base Rear frame In order to install the rear frame, we recommend that you detach the rear doors (if present). Hold the rear frame by the bottom member and slide the frame over the floor panel. Ensure that the C profiles on the rear frame correctly slide into the side wall guides. (Fig. 20) Fig. 20 Secure both components using C clamps. Affix the components by screwing the supplied drilling screws into the pre-drilled installation holes from the inside. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig. 21) Fig. 21 Drill the rear bottom member and fit the M 6 x 50 mm countersunk screws supplied to the pre-drilled holes. (Fig. 22) Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

13 with self-supporting base Roof Check that the sealing strip in the roof profile is undamaged and correctly fitted. (Fig. 23) Fig. 23 Using Cleaner Körasolv WL, clean the inside of all four roof corner caps as well as the top of the rear frame and the top corners of the bulkhead and side walls. Apply Körapur 125 sealant to the top of the rear frame and to the front and back of the corners of the body as well as the roof corner caps. (Figs ) Fig. 24 Fig. 25 Place the roof on the assembly. Make sure that the roof is properly positioned and secure it using C clamps. To ensure that the roof slots snugly onto the rear frame, place e.g. a piece of timber at the back and across the roof connection profile and clamp in place using C clamps. (Fig. 26) Fig. 26 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 13

14 with self-supporting base Affix the roof to the bulkhead and side wall by screwing the supplied drilling screws into the pre-drilled installation holes from the inside. Finally, bolt / rivet the rear of the rear frame to the roof. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig. 27) Fig. 27 Apply sealant all the way around the inside of the corner caps and then hand-tighten the bolts from the inside. Seal the front and/or rear corner caps. Seal the rear end plate on the rear frame from the outside. (Fig. 28) Fig. 28 Apply sealant front and back to the inside and outside corners of the floor panel. When sealing the outside front and back of the floor panel, leave the ends of the cover strip free to allow water to drain off.. 14 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

15 with self-supporting base Fit the flashings to the side walls. (Fig. 29) Fig. 29 Installation guidelines for mud guards, storage boxes, door retainers and side guards If the accessories described above need to be installed on the underside of the floor panel, it is imperative that the underside of the floor panel be reinforced by gluing on e.g. sheet aluminium. (Fig. 30) Please note our important guidelines on page 24. Fig. 30 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 15

16 Without a base Please read these assembly instructions carefully and from beginning to end before beginning the assembly work! To ensure the proper functioning and quality of the kits supplied by TITGEMEYER, the pallet containing the individual body kit components must not be directly exposed to the elements. Failure to observe this obligation will result in all damage and compensation claims becoming void! Fitting materials (supplied with the kit) Drilling screws 4.8 x 13 mm TIBULB blind rivets 6.4 x 10.5 mm SPAX screws for sandwich roof to attach the roof / rear frame 1 cartridge of Körapur 125 adhesive Cleaner Körasolv WL Special accessories (please order separately) Chassis brackets to connect longitudinal members to chassis Tools and materials (required for kit assembly) Torque screwdriver, medium torque 4 Nm Type T 25 Torx bit Vice-grip wrenches (2) Set of open-ended and ring spanners / Screw drivers Manual or pneumatic cartridge gun for 310 ml cartridges Rivet tool for 6.4 mm rivets C clamps 1 piece of lumber, approx mm long 4 pieces of lumber, approx. 600 mm long Installation Fit the bulkhead to side wall 1 Fit the bulkhead to side wall 2 Fit the rear frame to the side walls Fit the roof Assembly preparation Ensure that the connections between the floor, bulkhead, side wall / side wall, rear frame and to the roof are clean and dry The kit should be assembled on an even surface and lumber The self-supporting base version is assembled directly on the floor panel The kit components are supplied on a pallet and secured using cable ties When removing the parts / loosening the cable ties, ensure that the parts that are not yet needed remain securely positioned on the pallet Secure the pallet to prevent it from tipping The rear frame / bulkhead must first be removed from the pallet and then safely set to one side until they are to be installed. The supplied fixing materials can be found at the bottom of the pallet in the middle. To ensure accurate fitting in the contact areas between bulkhead / side walls and roof, we recommend applying adequate pressure during the assembly 16 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

17 Without a base Installing the bulkhead / side wall Check that the sealing strip in the corner post profile is undamaged and correctly fitted. (Fig. 31) Fig. 31 Place the bulkhead and one side wall on the timber and at right angles to each other. (Fig. 32) Fig. 32 Check that the upper intersection between the side wall / bulkhead is the same height. (Fig. 33) Fig. 33 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 17

18 Without a base Secure the components in place using vicegrip wrenches. Affix both components by screwing the supplied drilling screws into the pre-drilled holes from the inside. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig. 34) Fig. 34 Continue with the second side wall in the same way as for the first side wall. Measure the diagonals from front to back and align the body if necessary. (Fig. 35) Fig. 35 Installing the rear frame Place the rear frame on timber and position at the end of the side walls. (Fig. 36) Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

19 Without a base Ensure that the C profile on the rear frame rests directly below the profile support on the side wall. (Fig. 37) Also check the floor support is at the correct height. Fig. 37 Secure both components using vice-grip wrenches or C clamps. (Fig. 38) Fig. 38 Affix the components by screwing the supplied drilling screws into the pre-drilled holes from the inside. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig. 39) Fig. 39 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 19

20 Without a base Installation steps Check that the sealing strip in the roof profile is undamaged and correctly fitted. (Fig. 40) Fig. 40 Using the Cleaner Körasolv WL, clean the inside of all four roof corner caps as well as the top of the rear frame and the top corners of the bulkhead and side walls. (Fig. 41) Apply Körapur 125 sealant to the top of the rear frame and to the inside of the front and back roof corner caps. (Fig. 42) Apply an additional 80 mm bead of sealant to the area around the roof corners. Fig. 41 Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

21 Without a base Place the roof on the assembly. Make sure that the roof is properly positioned. Bolt the roof to the bulkhead starting at the top and working across. Use vice-grip wrenches to pull the cantrail profile onto the side wall profile and then bolt the side walls to the roof going from front to back. Attention: Do not screw the screws! Tightening torque 4 Nm. (Fig ) If installing a sandwich roof, no vice-grip wrenches can be attached from the inside. Before affixing the screws from the inside, check that the roof fits flush on the out - side. To ensure that the roof connection profile slots snugly onto the rear frame, place e.g. a piece of timber at the back and across and clamp in place using C clamps. On the rear frame version with upper tail-lift flap, close the tail lift and attach e.g. long C clamps across the closed flap. Finally, rivet the back of the rear frame to the rear of the roof using the supplied TIBULB rivets and moving from one side to the other. On the sandwich roof version, install using the Spax screws supplied. (Fig ) Fig. 43 Fig. 44 Seal the front and/or rear corner caps. (Fig ) Fig. 45 Fig. 46 Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 21

22 Without a base Seal the rear end plate on the rear frame from the outside. (Fig. 47) Fig. 47 The kit can be fitted directly to e.g. a GETO Van Frame base assembly. Once the body has been affixed to the base assembly and then been painted, the outer flashing will need to be fitted to the side rave. Lay the flashing on the bottom edge of the side rave and press down from above until it slots into the side rave profile. (Fig. 48) Fig L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com Tf1673GB(0517)1

23 Important Information Paintwork There are no downtimes or curing periods with this kit. Please note: If the kit is to be painted, the roof must be painted in a light colour. (Fig. 49) Bild 49 Storage / Installation Do not allow bare cut edges to come into contact with water. Cleaning GRP body end users (fleet operators) must be informed that special protective measures apply when cleaning sheeting. The use of a cleaner or detergent with an unsuitable ph value may result in the surface being damaged or even destroyed. Pressure cleaners with too much pressure or not held far enough away from the surface can also lead to the sheeting surface being destroyed. The following basic rules apply: Temperature: 70 C max Pressure: 80 atü max Minimum distance between sheeting and nozzle: 30 cm ph value: between 2 and 10. Pallet Returnable pallets remain the property of Titgemeyer and will be collected during a future delivery. Non-returnable pallets will be left with the customer. Tf1673GB(0517)1 L Phone: +49 (0)5 41/ Fax: +49 (0)5 41/ export@titgemeyer.com 23

24 The technical specifications contained in this brochure are approximate and no guarantee is given as to their accuracy! Designs are subject to change. Our design proposals are non-binding! TITGEMEYER and GETO are trademarks, registered trademarks or product names belonging to the respective title holder. Gebr. TITGEMEYER GmbH & Co. KG Hannoversche Straße 97 (Navigation: Hettlicher Masch 2) Osnabrück, Germany P.O. Box Osnabrück, Germany Phone: +49 (0)5 41/ Fax: +49 (0)5 41/