Attaching side portal with portal straightening set - AR60.20-P-1550-01G

Illustration: Celette straightening system 

Fig 1: Identifying Celette Straightening System

Illustration: Car-Bench straightening system 

Installation sequence for side portal 

Installation positions and designations for Car-Bench straightening system in brackets [...].

1. Position universal cross members U1, U2 in grid fields 56-58 and 63-65. (Car-Bench only)
2. Install side extensions (21, 22) on modular members [cross members ] grid fields 17, 33 [ 56-58, 63-65 ] hole pattern 2.- 4. [3.- 6 ].
3. Install multi-Z-elements MZ 601/602 (20) on side extensions (21, 22).

   Arrow must point toward front!

   Fig 2: Identifying Installation Sequence For Side Portal

   
4. Install cylindrical mount (19) in MZ 601/602 (20, upper hole).
5. Install cylindrical mount (18) (special mount from portal straightening set) in MZ 601/602 (20).

   Arrow must point toward front!

6. Align portal longitudinal member (23) on cylindrical mounts (18, 19) at front with 8 [5] and at rear with position number 9 [3] and fasten with M12 x35 bolts.

   In contrast to the usual installation schematic for portal frames it is necessary to install the portal longitudinal member with the flange surface pointing down (position numbers upside down).

Installation sequence for portal straightening set for A-pillar and cross member console 

Fig 3: Identifying Installation Sequence For Portal Straightening Set For A-Pillar And Cross Member Console

7. Position check and welding gauge for bottom A-pillar (1, 2) on no. 10 [8].

   When replacing A-pillar insert spacer plate (e).

8. Screw cross member console mount (3, 4) to check and welding gauge for A-pillar (1, 2).
9. Position check and welding gauge for upper A-pillar (5, 6) to no. 5 [3].

Installation sequence for portal straightening set for top and bottom A-pillar 

Fig 4: Identifying Installation Sequence For Portal Straightening Set For Top And Bottom A-Pillar

10. Position check and welding gauge for bottom A-pillar (7, 8) on no. 1 [3] (rear).

    When replacing wheelhouse insert spacer plate (d).

11. Screw top B-pillar mount onto check and welding gauge for main Vario roof mount (11/12).

    Use screw supplied for upper mounting point on B-pillar (upper belt guide console).

Installation sequence for portal straightening set for main Vario roof mount, rear fender and tubular console frame 

Fig 5: Identifying Installation Sequence For Portal Straightening Set For Main Vario Roof Mount And Frame

12. Position check and welding gauge for main Vario roof mount (11, 12) to no. 4 [6].
13. Screw rear fender mount (13, 14) onto check and welding gauge (11, 12).
14. Position check and welding gauge for tubular console frame (15, 16) on no. 8 [10].