Volkswagen Vas6131/19 User manual

Operating Manual

VAS6131/19 Mounting

Contents

Page

Denition of terms and basis 05

Denition of terms 05

Basis 05

Safety notices 06

Warnings and symbols 06

Operating company duty of care 06

Intended use 07

Foreseeable misuse 08

User qualications 08

Fundamental safety measures 09

Transportation and storage 10

Operation 11

Commissioning 12

Description 12

Application and limits 13

Operation 13

Maintenance and cleaning 13

Inspection 14

Maintaining proof of inspections 14

Inspection criteria 14

Template for proof of inspection 15

EC declaration of conformity 16

VAS6131/19 Mounting

Read this operating manual attentively

before using the load handling device for

the rst time. It provides you with

important information about safety, use,

and maintenance. This protects you and

prevents damage. Retain the operating

manual and pass it on to subsequent

owners if applicable.

(The original operating manual is in German.)

perfect products – best service

Maschinenbau

Kfz-Spezialwerkzeuge

Entwicklung & Fertigung

Werner Weitner GmbH

Sollnau 14

85072 Eichstätt

Deutschland

info@werner-weitner.com

VAS6131/19 Mounting

Perfection is our passion

This is guaranteed by our competent and

dedicated team on the one hand and, on the

other hand, by highly modern design systems

such as CATIA V5, SolidEdge, and Siemens NX.

These systems provide a linear development

process from CAD/CAM directly to 3D printing

and the CNC processing centers.

Our know-how ensures accurate results.

Wedevelop, design, and attend to your

product from the design concept to series

production readiness.

Qualied person:

A person who, based on technical training

and experience, has sucient knowledge to

evaluate the various sling gear and load

handling devices, and is suciently familiar

with the applicable state occupational

health and safety regulations, Employer’s

Liability Insurance Association regulations,

and the generally accepted state of the art

(for example, DGUV rules, DIN-EN standards,

DIN standards, ISO standards) to evaluate

the occupational health and safety state of

sling gear and load handling devices.

Load handling devices:

Components that are not permanently

connected to the hoisting equipment,

attached between the crane or hoisting

equipment hook and the load in order to

securely pick up the load. Examples:

Spreader bars, lifting clamps, C-hooks,

grippers, loading forks, etc.

In this operating manual, the assembly

xture is also called a load handling device.

Denition of terms

1 | Denition of terms and basis

Machinery Directive 2006/42/EC

DIN EN 13155:2009-08

Cranes – Safety – Non-xed load lifting

attachments

DIN EN ISO 12100:2011-03

Safety of Machinery

General principles for design –

Risk assessment and risk reduction

DIN 15003:1970-2

Lifting appliances; load suspending devices,

loads and forces; denitions

DIN EN ISO 20607

Safety of machinery – Instruction handbook

DGUV 100-500:2013-06

Operation of work equipment

DIN EN 1494:2009-05

Mobile or movable jacks and associated

lifting equipment

Basis

Skilled worker:

A user who, on the basis of training, has

specialized knowledge of the handling of

sling gear and load handling devices as well

as training certicates for specialized tasks.

Warnings and symbols

Operating company duty of care

Hazards and information are classied and

represented as follows in this operating

manual:

The load handling device was designed

andbuilt under consideration of a risk

assessment and after careful selection

ofthe applicable standards as well as

additional technical specications. It

therefore corresponds to the state of the art

and ensures the highest level of safety.

However, this level of safety can only be

reached in operational practice if all

required measures are implemented.

Planning these measures and verifying their

execution is part of the duty of care of the

operating company for the specialized tool.

The operating company has to supplement

this operating manual with instructions,

including supervision and reporting

obligations, to take into account operational

particularities, for example, regarding the

organization of work, operational procedures,

and the personnel that is deployed.

2 | Safety notices

Designates a hazard with a high risk level that can lead to death or serious injury

if it is not avoided.

Designates a hazard with a moderate risk level that can lead to death or serious injury

if it is not avoided.

Designates a hazard with a low risk level that can lead to minor or moderate injury

or damage to the product or in its environment if it is not avoided.

Designates user tips and other useful information.

DANGER

WARNING

NOTICE

CAUTION

In particular, the operating company has to

ensure that:

• The load handling device is only used

as intended.

• The load handling device is only used

in proper, functioning condition and,

inparticular, the functionality of the

safety devices is checked regularly.

• The required protective equipment for

the operating, maintenance, and repair

personnel is on hand and used.

• The operating manual, complete and in

legible condition, is always available at

the location where the load handling

device is used.

• The load handling device is only

operated, maintained, and repaired by

qualied and authorized personnel.

• This personnel is instructed regularly in

all relevant aspects of occupational

health and safety and environmental

protection, and is familiar with the

operating manual and in particular

thesafety instructions it contains.

• All safety notices and warnings on the

load handling device remain in legible

condition and are not removed.

2 | Safety notices

Making structural changes to the load handling device is prohibited.

DANGER

• In case of damage, the load handling

device may only be used again after it

has been repaired by a qualied

person. Only original replacement

parts may be used.

• Failing to comply with these provisions

voids all warranty claims.

• The manufacturer assumes no liability

in case of unauthorized conversion of

the components.

• The allowable ambient temperature

for storage and operation is -20°C

to+60°C.

• Using the device in potentially explosive

atmospheres is not permitted.

Proper use

• The load handling device is intended

for lifting and transporting loads.

• Complying with the manufacturer’s

instructions for operation,

maintenance, and upkeep as well as

repair guides is mandatory for

properuse.

• Exceeding the specied limit values is

not permitted.

Safe operation is not assured if the load handling device is not used as intended.

Allcases of personal injury and damage to property caused by improper use are

thesole responsibility of the operating company.

NOTICE

Foreseeable misuse

The following applications are not permitted:

• Breaking free of loads.

• Dragging loads along the oor.

• Use in potentially explosive

environments, unless the load

handling device has been modied for

this purpose and identied with

corresponding notices.

• Transporting persons and/or animals.

• Use while persons are present

underneath the load.

2 | Safety notices

User qualications

For safety reasons, only trained or

instructed skilled workers are permitted to

work with this load handling device. The

responsibilities of personnel have to be

clearly established. If apprentices are used,

then this may only take place with the

constant supervision of an experienced,

skilled worker. The operating company is

liable for all cases of personal injury or

damage to property if this provision is not

followed. The operating company is obligated

to clearly and unmistakably establish the

responsibilities of personnel for operation,

inspection, and maintenance.

In order to avoid severe injuries, the following must be observed when working with

theload handling device:

• Use personal protective equipment

• Tie back long hair

• No wearing of loose clothing or jewelery

• Persons are not permitted to be present underneath the load under any circumstances

DANGER

• Observe DGUV rule 100-500 for the

form-tting and friction-tting

attachment of loads.

• Observe the respective national

regulations for use outside of

Germany.

• Ensure adequate stability of the

building walls, ceilings, oor, or

structures on which the load handling

device is mounted or engaged. Consult

a structural engineer in case of doubt.

• After the load handling device has not

been used for a longer period of time,

conduct a visual inspection of all

components that are essential for

proper functioning. Replace damaged

components with original replacement

parts.

• Do not use a defective load handling

device.

• Stop the operation immediately and

eliminate the defect.

• Report damage and defects to the

responsible person immediately.

• Warn persons in the immediate vicinity

about work with the load handling

device.

• Ensure that the sling gear is securely

engaged in the load hook and lies

safely in the bed of the hook.

• Stop lowering the load when the sub-

block or load hits the ground or is

prevented from lowering further.

• Do not twist the load chain.

• Straighten twisted chains before

engaging the load. (The correct

alignment of the chain links is

identied by the weld seam.)

• Rows of chain links always have to run

in one direction.

• Be sure to prevent impacts of the load

or hook.

Fundamental safety measures

2 | Safety notices

• Observe the user information

(documentation).

• Observe the warnings on the device

and in the user information.

• Observe the safety distances.

• Ensure adequate lighting and good

visibility.

• Use the load handling device as

intended.

• Never exceed the specied load

bearing capacity of the load handling

device.

• Transporting persons is not permitted

under any circumstances. The load

handling device is intended solely for

moving the loads specied in the repair

guide.

• Observe the national accident

prevention regulations (UVV).

The following is not permitted:

• Exceeding the rated load.

• Manipulation of the devices in any form.

• Continuing to use stretched or damaged chains. These must be replaced immediately

with new original parts.

DANGER

• The load handling device is inspected

and properly packaged prior to delivery.

• When the load handling device is

received, the packaging has to be

inspected for damage.

• Only suitable means of transport may

be used for the transportation of the

load handling device.

• Under no circumstances may the load

handling device be dropped or thrown.

• The load handling device must be stored

in a clean and dry location.

• The load handling device must be

protected against dirt, moisture, and

corrosion.

• The load handling device should be

inspected for integrity prior to storage.

3 | Transportation and storage

Transportation may only be carried out by qualied personnel. No liability is assumed

for damage due to improper transportation and/or storage.

CAUTION

•When using the load handling device,

ensure that the load being lifted is

safely secured by the pins provided

(item 2). To do so, extend the pins by

hand until they are in full contact with

the load.

•All required screw connections on the

vehicle have to be unscrewed before

lowering the battery.

•Pushing the load while it is raised is

not permitted.

•Possible ne-tuning for positioning the

battery under the vehicle must be

carried out only with the VAS6131B

lifting table (item 4).

•The mountings may only be used and

moved together with the VAS6131B

table.

4 | Operation

•The VAS6131/19 mounting is a load

handling device for the installation and

removal of high-voltage motor vehicle

batteries.

•Four mountings have to be used for

removal.

•The maximum total permissible load

bearing capacity of one mounting is

300kg, and of four mountings

900kg.

•For use only in the congurations

dened in the repair guide for the

brands of the VW Group in

combination with the VAS6131B

liftingtable.

Applications and pulling directions other than those described in the repair guide are

not intended and therefore prohibited!

NOTICE

The maximum permissible movement speed is 2 km/h.

DANGER

•The top of the VAS6131B lifting table

has to be lowered before movement.

•The load must be protected against

unwanted impacts (e.g. tension belt).

•Tighten the M10x20 hexagon bolts

(item 3) to 25Nm.

•Using parts of this load handling

device individually is not permitted.

Commissioning

Verify the following prior to initial use:

• That inspection and test certicates

are on hand (acceptance record,

declaration of conformity etc.)

• That the identication and information

on the load handling device

corresponds to the information on

theinspection and test certicates.

• That all details of the load handling

device were transferred to an

inspection log.

Ensure that all packaging materials, tools,

implements, etc. have been removed from

the load handling device. All safety devices

must be installed and functioning.

Use the personal protective equipment

Check the following points:

• Visual inspection

• No other persons in the danger area

4 | Operation

Read this operating manual before putting

the load handling device into use for

therst time.

Observe the applicable national accident

insurance provisions, regulations, and

theinformation in this manual.

Description

Item Name Standard/comments Qty.

1 VAS6131/19 Mounting 4

2 Pin 42CrMo4+QT 4

3 Hexagon bolt DIN6921 – M10x40 – 8.8 16

4 VAS6131B Lifting table 1

Attaching to the load

To ensure safe handling, the attachment to

the load must be carried out diligently and in

compliance with the maximum limit values.

4 | Operation

Application and limits

Operation

Center of gravity

The following conditions have to be met in

order to lift the load without twisting or

upsetting it:

The prescribed and identied settings on

the load handling device for the respective

load have to be congured before attaching

the load.

Safety during lifting operations

To prevent injuries, the hands and other body

parts should be kept away from the device.

Once the load is ready for lifting, the device

should be lifted until it bears the full load.

Then check whether the load is securely

attached and remains in the intended

position. Only then can the operation

becompleted.

Preparation and inspection

The components must be inspected for

apparent damage and correct t before

attaching the load.

Weight of the load

The specied load bearing capacity of the

load handling device must not be exceeded.

Avoid swinging of the load.

Maintenance and cleaning

Regular maintenance considerably increases

the service life of the load handling device.

The load handling device has to be cleaned

if it gets dirty. All components must be

cleaned so they are free of oil, dirt and

corrosion. Any cleaning method that does

not attack the base material is permitted.

Methods that can cause hydrogen

embrittlement, overheating, material

removal or material deformation, or may

conceal cracks or other surface defects,

haveto be avoided.

5 | Inspection

Maintaining proof of inspections

Depending on the conditions under which

the load handling devices are used,

inspections may be required more

frequently than once per year. This applies,

for example, in case of very frequent use,

increased wear, corrosion, exposure to heat,

or when increased susceptibility to failure

can be expected. Load handling devices

should be inspected for the absence of cracks

every 3 years by qualied personnel using

appropriate inspection equipment. Records of

such inspections must be retained. If the user

has any doubts that the load handling device

is in safe condition, the load handling device

should be taken out of use and inspected by

qualied personnel.

The operating company has to ensure that

load handling devices are inspected by a

qualied person at least once a year.

The Employer's Liability Insurance

Association may demand that proof of

inspections be maintained for other

inspections on a case-by-case basis.

Proof of inspections must be submitted to

the supervisor on request. Therefore, they

must be stored so they are readily accessible

at all times.

The recurring inspections encompass a visual

inspection and functional tests. They

essentially extend to the integrity, suitability,

and eectiveness of the safety devices as well

as the condition of the load handling device

in regard to damage, wear, corrosion, or other

changes. Disassembly may be required for

the assessment of wear parts.

The operating company has to ensure that

proof of the inspections of load handling

devices is maintained. (See point 5.3. for a

template that can be copied)

Such proof has to include the following:

• Date and scope of the inspection with

information about any partial

inspections that are still pending.

• Result of the inspection including any

defects that were found.

• Assessment in case of concerns

regarding continued use.

• Information about required follow-up

inspections.

• Name and if applicable address of

theinspector.

Inspection criteria

If the following defects or disruptions occur,

the device must be taken out of use for

maintenance, repair, or entirely:

• Identication of the load bearing

capacity or proof of identity are illegible

• Permanent deformation of the

components

• Wear

• Incomplete device

• Damaged components: Cracks, notches,

grooves

• Surface damage: Corrosion, discoloration

due to heat

5 | Inspection

Template for proof of inspection

TYPE: Serial number:

Year of manufacture: Manufacturer: Werner Weitner GmbH

Load bearing capacity: Operating company:

Inspection prior to initial use Inspector: Date: Signature:

Inspection ndings: