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CHASSIS CAB 35C/E, 40C, 45C, 50C
026221 FITTING INSTRUCTIONS
1. Unpack the towing bracket and check its contents against the parts list. If necessary,
remove the underseal from around the fitting points of the luggage compartment/frame
members.
2. For mounting of the two side plates "1" and "2", a number of holes must be drilled. Proceed
as follows.
The holes "B", "D" and "E" are already present in the bottom flange of the chassis beam.
(If the chassis has been shortened for the superstructure, all fastening holes for the towbar
will have to be drilled.)
Mount plate "1", together with one of the counterplates "3", at the holes "B" and "D".
Mark the holes "A" and "C" on the underside of the chassis beam with a 12 mm drill. Remove
plate "1".
Drill the holes "A" and "C" through the bottom flange of the chassis beam.
Now mount the top counterplate "3", together with the spacer sleeve "4", at hole "A".
Ensure that counterplate "3" is in line with the chassis beam for the purpose of correct
alignment of the holes.
Now drill holes "C" and "E" through to the top flange of the chassis beam with a 12 mm drill
with a minimum length of 150 mm.
Repeat this procedure for the right-hand side.
3. Only in the case of models 45C and 50C need the rear beam (with lights) be raised 30 mm.
To this end, the bottom fastening hole "N" (see detail 1) must be drilled through (from inside
to outside) to 12 mm.
Mount the fastening bolts with the bolt head on the inside of the chassis beam so that the
spacer sleeves to be fitted can pass.
4. Mount the two side plates "1" and "2" (see detail 1).
Mount the side plate "1" together with counterplate "3" at holes "B" and "D" with the bolts
M12x40, incl. lock nuts (M12x1,75mm)..
5. Mount one of the spacer sleeves "4", the counterplate "3" and one of the counterplates at
hole "A" by means of the bolts M12x1,25x160, incl. lock nut (M12x1,25mm).
At the holes "C" and "E", mount the spacer sleeves "4" and two counter plates "5" by means of the bolts
M12x1,25x160, incl. lock nuts (M12x1,25mm).
Caution: the mounting set contains M12 nuts with a normal screw thread (1,75mm) and M12 nuts
with a fine screw thread (1,25mm). Use the correct nuts with the respective bolts.
If an auxiliary frame for the superstructure is fitted, this will serve as a counterplate.
In this case, the counterplates "5" are not required.
Repeat this procedure for the right-hand side.
6. Mount the cross beam, between the two side plates, at the desired position by means of the bolts
M12x40, incl. lock nuts (M12x1,75mm).
7. Mount the ball at the desired height, (see detail 5), in position "a" or "b".
First mount angle bracket "9" at hole "M" by means of the bolt M12x90, incl. washer 37x13x3 and lock nut
(M12x1,75mm). Then mount the coupling ball at the holes "K" together with the counterplate "8" with
bolts M10x100, incl. lock nuts M10.
Then at the holes "L" with bolts M10x40 (10.9) incl. lock nuts M10.
For ball 611.45.783: as given in detail 3a or 3b.
For ball 611.44.854: as given in detail 3a or 3b.
For Rockinger vario-bloc system: in accordance with the instructions for the system.
8. Secure the towbar using a torque-wrench. Torque the bolts as follows:
8.8
M6
9,5 Nm
M8
23 Nm
M10
46 Nm
M12
79 Nm
M12x100/110
M16
195Nm
280Nm
M10x1,25
49 Nm
M12x1,25
87 Nm
125Nm
M12x1,5
83 Nm
122Nm
After about 1000 km use, re-tighten the bolts and nuts to the specified torque.
9. Bosal cannot be held responsible for any defects in the product caused by fault or by any injudicious use
whatever of the user or a person he is liable for. (sect. 185, art. 2 N.B.W.)
10.9
8.8
10.9
14 Nm
34 Nm
68 Nm
117Nm
100Nm
72 Nm
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