Bosch Mounting Trestle VAS 6095A

1 General Information

Intended Use:

• To remove and install vehicle parts for repair work.
• To lift vehicle parts and to rotate them 360° about a horizontal axis.
• When using the universal support arm, to rotate vehicle parts about a vertical axis.

Terms of Use:

• To be used only by qualified personnel trained in accordance with Volkswagen Group standards.
• Use only for loads up to 600 kg.
• Use only for loads up to 350 kg on the universal support arm.
• Use all the clamping rails and spacer pins only together as a complete set.
• Use only for work expressly approved by the Volkswagen Group.
• Use only for loads expressly approved by the Volkswagen Group.
• Do not use for hot vehicle parts.
• Use only for one vehicle part at a time.
• Do not use the mounting trestle to lift persons.
• Do not climb on the mounting trestle.
• Use only with the accessories expressly approved by the manufacturer and the Volkswagen Group.
• Use the universal support arm and traverse VAS 6095/1 only with the mounting trestle VAS 6095 or VAS 6095A.
• For loads heavier than 20 kg, use the mounting trestle only with a suitable lifting device equipped with a sufficient load capacity.
• Use only on level ground.
• Use only the screws included in delivery or replacement screws the same size and quality grade.
• Use only at ambient air temperatures between -10°C and +60°C.
• Do not use in corrosive environments (e.g. acidic or caustic).
• To be used by only one person alone.

Manufacturer: Bosch Automotive Service Solutions GmbH, Am Dörrenhof 1, 85131 Pollenfeld-Preith, Germany

Included in Delivery:

Components and Accessories

Figure 1: Mounting Trestle Components

A: Flange Plate

B: Clamping Rail and Spacer Pin

C: Hydraulic Cylinder (Cylinder Lifting Height 200 mm)

D: Oil Drip Pan

E: Wheel Brake

F: Pedal

G: Safety Lock Lever

H: Crank Handle

Available Accessories:

Numerous accessories are also available to attach certain vehicle parts to the mounting trestle if they do not fit on the clamping rails.

Figure 2: Universal Support Arm and Traverse Components

A: Universal Support Arm

B: Traverse with Adapter

C: Pedal

D: Suspension Eye

Figure 3: Mounting Trestle with the Universal Support Arm and Traverse in Starting Position

2 General Safety Instructions

WARNING Improper use could cause serious personal injury or severe damage to materials!

The safety of the mounting device can no longer be ensured if it is misused or modified in ways not expressly approved by the manufacturer. These actions could result in serious personal injury or severe damage to materials.

• Read and follow these instructions carefully.
• Ensure that each person using the mounting device is familiar with these instructions and can access them at all times.
• Read and follow the vehicle manufacturer's service and repair manual carefully.
• Use the mounting device only for work expressly approved by the Volkswagen Group.
• Use the mounting device only with accessories expressly approved by the Volkswagen Group.

WARNING Disregarding the safety regulations could cause serious personal injury or severe damage to materials!

The load could fall or the mounting trestle could tip if the user does not follow the safety regulations. These actions could cause serious personal injury or severe damage to materials.

• Do not exceed the mounting trestle's maximum load capacity of 600 kg.
• Do not exceed the universal support arm's maximum load capacity of 350 kg.
• Move the mounting trestle when loads are on it only if the hydraulic cylinder has been lowered completely.
• Move and store the mounting trestle only on level ground. Do not move the mounting trestle over steps or slopes.
• Always lock the brakes on the castor wheels when working with or storing the mounting trestle.

CAUTION Crushing Hazard!

Handling special tools and vehicle parts carelessly could cause hands or feet to be crushed.

• Wear safety shoes that meet the ISO 20345, S2 standard.
• Position hands and feet so as to avoid potential crushing hazards.
• Always handle the load carefully.

3 Assembling the Universal Support Arm

1. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
2. Remove the six M14x50 8.8 hexagon head screws and their corresponding washers from the clamping rails. Remove the clamping rails from the mounting trestle and place them on a suitable surface.
3. Use a suitable lifting device to lift the universal support arm from the suspension eye.
4. Position the universal support arm on the mounting trestle.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

5. Tighten the four M14x95 8.8 screws included in delivery with a torque of 130 Nm.
6. Unhook the lifting device. Use the crank handle on the mounting trestle to rotate the universal support arm 180°.
7. Put the traverse on the universal support arm. Tighten the eight M12x30 8.8 screws and their corresponding washers included in delivery (80 Nm).

4 Removing the Universal Support Arm

1. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
2. Use the crank handle on the mounting trestle to rotate the universal support arm 180°.
3. Hang the universal support arm on a suitable lifting device from the suspension eye.
4. Remove the four M14x95 8.8 screws from the universal support arm.
5. Use the lifting device to lift the universal support arm carefully. Place the universal support arm in a suitable location and unhook it from the lifting device.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

5 Operating Instructions for a Seat on the Mounting Trestle

When attaching vehicle parts to the mounting trestle, follow the directions in the automobile manufacturer's service and repair manual exactly.

1. Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Falling parts could result in serious personal injury or severe damage to materials.

• Inspect the mounting trestle and its accessories for damage before each use.
• Take the mounting trestle or its accessories out of operation and secure them against unauthorised use if damaged or in poor condition.

2. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
3. Disengage the safety lock lever and fully depress the pedal on the mounting trestle until the hydraulic cylinder is in the lowest position.
4. If necessary, remove the clamping rails or universal support arm from the mounting trestle. To remove the clamping rails, perform step 2 in Chapter 3 of these instructions. To remove the universal support arm, perform steps 2 through 5 in Chapter 4 of these instructions.
5. Push the corresponding accessory through the flange plate's centre hole and into the hollow shaft until the end stop (see the automobile manufacturer's service and repair manual).

Figure 4: Flange Plate and Hollow Shaft

Use one of the ball lock pins included in delivery to secure the accessory to the hollow shaft and to ensure that the accessory can be rotated on the mounting trestle.

WARNING Loose accessories could cause loads to fall!

The load could fall if the accessory is not secured properly with the ball lock pin. This could cause serious personal injury or severe damage to materials.

• Use only accessories that have a shaft of Ø 60 mm (-0.5 mm) and a transverse hole of Ø 12 mm.
• For Volkswagen/Audi vehicle parts, use only accessories with a transverse hole that is located at least 78 mm from its shaft collar.
• For Porsche vehicle parts, use only accessories with a transverse hole that is located at least 73 mm from its shaft collar.
• Use the accessory only with the ball lock pin specified in these instructions.
• Insert the ball lock pin only into the hole in the hollow shaft that is specified in these instructions.

Figure 5: Black Ball Lock Pin in the Hollow Shaft for Volkswagen/Audi Vehicle Parts

Figure 6: Red Ball Lock Pin in the Hollow Shaft for Porsche Vehicle Parts

7. Store the unused ball lock pin in the ball lock pin support bracket.
8. Position the seat on the accessory.

If necessary, use a lifting device which has a suitable load capacity and which has been expressly approved by the vehicle manufacturer. Remove the lifting device only after the seat has been secured on the mounting trestle.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

9. Attach the seat to the accessory (see the service and repair manual of the vehicle manufacturer).

WARNING Danger of Falling Loads!

The load could fall if the accessories have not been attached to the mounting device correctly or if the load has not been secured onto the mounting device or the accessories correctly. This could result in serious personal injury or severe damage to materials.

• Ensure that the accessories have been attached to the mounting trestle correctly.
• Ensure that the vehicle part has been attached to the mounting trestle or the accessories correctly.
• Adhere to the torque specifications in the vehicle manufacturer's service and repair manual.

10. If necessary, remove the lifting device from the seat.
11. Move the seat to the desired working height by pressing the pedal on the mounting trestle several times.

i The maximum lifting height of the cylinder on the mounting trestle is 200 mm. If the load on the mounting trestle reaches its maximum load capacity of 600 kg, a force of up to 550 N is needed to raise the cylinder.

12. Turn the crank handle to rotate the load. Turning the handle slowly rotates the universal support arm over a worm gear. The rotation is unlimited in both clockwise and counter-clockwise directions.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• If the load starts swinging, stop turning the crank handle until the swinging stops.
• When rotating the load again, avoid swinging the load by turning the crank handle faster or more slowly.

CAUTION Danger of Leaking Oil, Loose Parts, and Loose Cables!

Rotation movements can cause oil to leak from the vehicle parts, creating oil puddles and resulting in slipping hazards. Parts and cables can also hang loosely from rotating vehicle parts. People could get caught in these cables and hurt themselves or damage the cables.

• Ensure that the oil drip pan can collect any leaked oil.
• Keep binding agents, rags, etc. ready to remove any leaked oil.
• Watch out for loose parts when rotating the load.
• Remove loose cables or secure them with cable ties, straps, or something similar.

13. Perform the service and maintenance work (see the vehicle manufacturer's service and repair manual).
14. Disengage the safety lock lever and fully depress the pedal on the mounting trestle to lower the seat.

i If the safety lock lever gets stuck while lowering the cylinder, raise the cylinder again. If the lever still does not release, bring the load to the starting position and remove it from the mounting trestle.

15. When not in use, store the mounting trestle in a suitable location and lock the brakes on the castor wheels.

6 Operating Instructions for Other Vehicle Parts on the Flange Plate

When attaching vehicle parts to the mounting trestle, follow the directions in the automobile manufacturer's service and repair manual exactly.

1. Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Falling parts could result in serious personal injury or severe damage to materials.

• Inspect the mounting trestle and its accessories for damage before each use.
• Take the mounting trestle or its accessories out of operation and secure them against unauthorised use if damaged or in poor condition.

2. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
3. Disengage the safety lock lever and fully depress the pedal on the mounting trestle until the hydraulic cylinder is in the lowest position.
4. If necessary, remove the clamping rails or universal support arm from the mounting trestle. To remove the clamping rails, perform step 2 in Chapter 3 of these instructions. To remove the universal support arm, perform steps 2 through 5 in Chapter 4 of these instructions.
5. Position the vehicle part on the mounting trestle. If necessary, use a lifting device which has a suitable load capacity and which has been expressly approved by the automobile manufacture. Remove the lifting device only after the vehicle part has been secured on the mounting trestle.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

6. Attach the corresponding accessory to the vehicle part (see the vehicle manufacturer's service and repair manual).
7. Secure the accessory to the flange plate with suitable M14 screws (130 Nm) (see the vehicle manufacturer's service and repair manual). Use only M14 screws that are longer than the combined width of the accessory and vehicle part.

WARNING Danger of Falling Loads!

The load could fall if the accessories have not been attached to the mounting device correctly or if the load has not been secured onto the mounting device or the accessories correctly. This could result in serious personal injury or severe damage to materials.

• Ensure that the accessories have been attached to the mounting trestle correctly.
• Ensure that the vehicle part has been attached to the mounting trestle or the accessories correctly.
• Adhere to the torque specifications in the vehicle manufacturer's service and repair manual.

8. If necessary, remove the lifting device from the vehicle part.
9. Move the vehicle part to the desired working height by pressing the pedal on the mounting trestle several times.

The maximum lifting height of the cylinder on the mounting trestle is 200 mm. If the load on the mounting trestle reaches its maximum load capacity of 600 kg, a force of up to 550 N is needed to raise the cylinder.

10. Turn the crank handle to rotate the load. Turning the handle slowly rotates the universal support arm over a worm gear. The rotation is unlimited in both clockwise and counter-clockwise directions.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• If the load starts swinging, stop turning the crank handle until the swinging stops.
• When rotating the load again, avoid swinging the load by turning the crank handle faster or more slowly.

CAUTION Danger of Leaking Oil, Loose Parts, and Loose Cables!

Rotation movements can cause oil to leak from the vehicle parts, creating oil puddles and resulting in slipping hazards. Parts and cables can also hang loosely from rotating vehicle parts. People could get caught in these cables and hurt themselves or damage the cables.

• Ensure that the oil drip pan can collect any leaked oil.
• Keep binding agents, rags, etc. ready to remove any leaked oil.
• Watch out for loose parts when rotating the load.
• Remove loose cables or secure them with cable ties, straps, or something similar.

11. Perform the service and maintenance work (see the vehicle manufacturer's service and repair manual).
12. Disengage the safety lock lever and fully depress the pedal on the mounting trestle to lower the vehicle part.

i If the safety lock lever gets stuck while lowering the cylinder, raise the cylinder again. If the lever still does not release, bring the load to the starting position and remove it from the mounting trestle.

13. When not in use, store the mounting trestle in a suitable location and lock the brakes on the castor wheels.

7 Operating Instructions for Other Vehicle Parts on the Hollow Shaft

When attaching vehicle parts to the mounting trestle, follow the directions in the automobile manufacturer's service and repair manual exactly.

1. Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Falling parts could result in serious personal injury or severe damage to materials.

• Inspect the mounting trestle and its accessories for damage before each use.
• Take the mounting trestle or its accessories out of operation and secure them against unauthorised use if damaged or in poor condition.

2. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
3. Disengage the safety lock lever and fully depress the pedal on the mounting trestle until the hydraulic cylinder is in the lowest position.
4. If necessary, remove the clamping rails or universal support arm from the mounting trestle. To remove the clamping rails, perform step 2 in Chapter 3 of these instructions. To remove the universal support arm, perform steps 2 through 5 in Chapter 4 of these instructions.
5. Position the vehicle part on the mounting trestle. If necessary, use a lifting device which has a suitable load capacity and which has been expressly approved by the automobile manufacture. Remove the lifting device only after the vehicle part has been secured on the mounting trestle.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

6. Attach the corresponding accessory to the vehicle part (see the vehicle manufacturer's service and repair manual).
7. Push the accessory through the flange plate's centre hole and into the hollow shaft until the end stop (see the automobile manufacturer's service and repair manual).

Figure 7: Flange Plate and Hollow Shaft

Use one of the ball lock pins included in delivery to secure the accessory to the hollow shaft and to ensure that the accessory can be rotated on the mounting trestle.

WARNING Loose accessories could cause loads to fall!

The load could fall if the accessory is not secured properly with the ball lock pin. This could cause serious personal injury or severe damage to materials.

• Use only accessories that have a shaft of Ø 60 mm (-0.5 mm) and a transverse hole of Ø 12 mm.
• For Volkswagen/Audi vehicle parts, use only accessories with a transverse hole that is located at least 78 mm from its shaft collar.
• For Porsche vehicle parts, use only accessories with a transverse hole that is located at least 73 mm from its shaft collar.
• Use the accessory only with the ball lock pin specified in these instructions.
• Insert the ball lock pin only into the hole in the hollow shaft that is specified in these instructions.

Figure 8: Black Ball Lock Pin in the Hollow Shaft for Volkswagen/Audi Vehicle Parts

Figure 9: Red Ball Lock Pin in the Hollow Shaft for Porsche Vehicle Parts

9. Store the unused ball lock pin in the ball lock pin support bracket.

i If necessary, secure the accessory to the flange plate with suitable M14 screws (130 Nm) (see the vehicle manufacturer's service and repair manual). Use only M14 screws that are longer than the combined width of the accessory and vehicle part.

WARNING Danger of Falling Loads!

The load could fall if the accessories have not been attached to the mounting device correctly or if the load has not been secured onto the mounting device or the accessories correctly. This could result in serious personal injury or severe damage to materials.

• Ensure that the accessories have been attached to the mounting trestle correctly.
• Ensure that the vehicle part has been attached to the mounting trestle or the accessories correctly.
• Adhere to the torque specifications in the vehicle manufacturer's service and repair manual.

11. If necessary, remove the lifting device from the vehicle part.
12. Move the vehicle part to the desired working height by pressing the pedal on the mounting trestle several times.

The maximum lifting height of the cylinder on the mounting trestle is 200 mm. If the load on the mounting trestle reaches its maximum load capacity of 600 kg, a force of up to 550 N is needed to raise the cylinder.

13. Turn the crank handle to rotate the load. Turning the handle slowly rotates the universal support arm over a worm gear. The rotation is unlimited in both clockwise and counter-clockwise directions.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• If the load starts swinging, stop turning the crank handle until the swinging stops.
• When rotating the load again, avoid swinging the load by turning the crank handle faster or more slowly.

CAUTION Danger of Leaking Oil, Loose Parts, and Loose Cables!

Rotation movements can cause oil to leak from the vehicle parts, creating oil puddles and resulting in slipping hazards. Parts and cables can also hang loosely from rotating vehicle parts. People could get caught in these cables and hurt themselves or damage the cables.

• Ensure that the oil drip pan can collect any leaked oil.
• Keep binding agents, rags, etc. ready to remove any leaked oil.
• Watch out for loose parts when rotating the load.
• Remove loose cables or secure them with cable ties, straps, or something similar.

14. Perform the service and maintenance work (see the vehicle manufacturer's service and repair manual).
15. Disengage the safety lock lever and fully depress the pedal on the mounting trestle to lower the vehicle part.

i If the safety lock lever gets stuck while lowering the cylinder, raise the cylinder again. If the lever still does not release, bring the load to the starting position and remove it from the mounting trestle.

16. When not in use, store the mounting trestle in a suitable location and lock the brakes on the castor wheels.

8 Operating Instructions for Other Vehicle Parts on the Universal Support Arm

When attaching vehicle parts to the mounting trestle, follow the directions in the automobile manufacturer's service and repair manual exactly.

1. Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Falling parts could result in serious personal injury or severe damage to materials.

• Inspect the mounting trestle and its accessories for damage before each use.
• Take the mounting trestle or its accessories out of operation and secure them against unauthorised use if damaged or in poor condition.

2. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
3. Disengage the safety lock lever and fully depress the pedal on the mounting trestle until the hydraulic cylinder is in the lowest position.
4. If necessary, perform the steps 2 through 6 in Chapter 3 to attach the universal support arm to the mounting trestle.
5. Bring the universal support arm to its starting position by turning the crank handle.
6. Test the brake force of the traverse before each use. Release the foot pedal of the universal support arm and pull on the arms of the traverse hard. Do not use the traverse or universal support arm if the brake on the traverse is damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Regular contact with oil could reduce the brake force of the traverse. This could result in serious personal injury or severe damage to materials.

• Test the brake force of the traverse before each use of the universal support arm.
• Take the universal support arm and traverse out of operation and secure them against unauthorised use if the brake on the traverse is damaged or in poor condition.

7. Position the vehicle part on the mounting trestle.

If necessary, use a lifting device which has a suitable load capacity and which has been expressly approved by the automobile manufacture. Remove the lifting device only after the vehicle part has been secured on the mounting trestle.

WARNING Suspended loads could cause serious personal injury!

Loads could swing out or drop while being lifted and result in serious personal injury.

• Stay out from under suspended loads and from the load's swinging range.

8. Attach the corresponding accessory or accessories to the vehicle part (see the vehicle manufacturer's service and repair manual).
9. The traverse has eight M12 threads for the support accessories. Tighten the M12x30 8.8 hexagon head screws included in delivery with a torque of 85 Nm to secure the support accessories to the traverse.

WARNING Danger of Falling Loads!

The load could fall if the accessories have not been attached to the mounting device correctly or if the load has not been secured onto the mounting device or the accessories correctly. This could result in serious personal injury or severe damage to materials.

• Ensure that the accessories have been attached to the mounting trestle correctly.
• Ensure that the vehicle part has been attached to the mounting trestle or the accessories correctly.
• Adhere to the torque specifications in the vehicle manufacturer's service and repair manual.

10. If necessary, remove the lifting device from the vehicle part.
11. Move the vehicle part to the desired working height by pressing the pedal on the mounting trestle several times.

The maximum lifting height of the cylinder on the mounting trestle is 200 mm. If the load on the mounting trestle reaches its maximum load capacity of 600 kg, a force of up to 550 N is needed to raise the cylinder.

12. Press the pedal on the universal support arm to rotate the traverse. Pressing the pedal releases the universal support arm's drum brake and allows the traverse to be rotated.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• Rotate the traverse only when the universal support arm is in its starting position and the traverse is level.
• Exercise extreme caution when pressing the pedal on the universal support arm.
• Remove the load if the drum brake is no longer working correctly. Take the universal support arm out of operation and secure it against unauthorised use.

13. Turn the crank handle to rotate the universal support arm. Turning the handle slowly rotates the universal support arm over a worm gear. The rotation is unlimited in clockwise and counter-clockwise directions.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• If the load starts swinging, stop turning the crank handle until the swinging stops.
• When rotating the load again, avoid swinging the load by turning the crank handle faster or more slowly.

CAUTION Danger of Leaking Oil, Loose Parts, and Loose Cables!

Rotation movements can cause oil to leak from the vehicle parts, creating oil puddles and resulting in slipping hazards. Parts and cables can also hang loosely from rotating vehicle parts. People could get caught in these cables and hurt themselves or damage the cables.

• Ensure that the oil drip pan can collect any leaked oil.
• Keep binding agents, rags, etc. ready to remove any leaked oil.
• Watch out for loose parts when rotating the load.
• Remove loose cables or secure them with cable ties, straps, or something similar.

14. Perform the service and maintenance work (see the vehicle manufacturer's service and repair manual).
15. Turn the crank handle to move the universal support arm back to its starting position.

9 Operating Instructions for Other Vehicle Parts on the Clamping Rails

When attaching vehicle parts to the mounting trestle, follow the directions in the automobile manufacturer's service and repair manual exactly.

1. Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

WARNING Damaged parts could cause loads to fall!

Falling parts could result in serious personal injury or severe damage to materials.

• Inspect the mounting trestle and its accessories for damage before each use.
• Take the mounting trestle or its accessories out of operation and secure them against unauthorised use if damaged or in poor condition.

2. Secure the mounting trestle from rolling by locking the brakes on the castor wheels.
3. Disengage the safety lock lever and fully depress the pedal on the mounting trestle until the hydraulic cylinder is in the lowest position.
4. If necessary, perform step 2 in Chapter 3 of these instructions to remove the clamping rails from the mounting trestle.
5. Prepare the clamping rails by loosening, but not removing, the M12x50 hexagon head screws that attach the spacer pins to the clamping rails.
6. Attach the clamping rails to the vehicle part. Screw the spacer pins into the vehicle part and tighten them with a 19 mm spanner (see the service and repair manual from the automobile manufacture).
7. Position the clamping rails to line up the elongated hole in each clamping rail to an outer hole in the flange plate.

Figure 10: Mounting Trestle with Clamping Rails

A: Side View

B: Front View

Use the M14x50 hexagon head screws included in delivery to secure the clamping rails to the flange plate (135 Nm). Tighten the loose M12x50 hexagon head screws to secure the spacer pins to the clamping rails (85 Nm).

WARNING Danger of Falling Loads!

The load could fall if the accessories have not been attached to the mounting device correctly or if the load has not been secured onto the mounting device or the accessories correctly. This could result in serious personal injury or severe damage to materials.

• Ensure that the accessories have been attached to the mounting trestle correctly.
• Ensure that the vehicle part has been attached to the mounting trestle or the accessories correctly.
• Adhere to the torque specifications in the vehicle manufacturer's service and repair manual.

9. Move the vehicle part to the desired working height by pressing the pedal on the mounting trestle several times.

The maximum lifting height of the cylinder on the mounting trestle is 200 mm. If the load on the mounting trestle reaches its maximum load capacity of 600 kg, a force of up to 550 N is needed to raise the cylinder.

10. Turn the crank handle to rotate the load. Turning the handle slowly rotates the universal support arm over a worm gear. The rotation is unlimited in both clockwise and counter-clockwise directions.

WARNING Danger of Uncontrolled Load Movements!

Uncontrolled load movements on the mounting trestle could cause serious personal injury or severe damage to materials.

• If the load starts swinging, stop turning the crank handle until the swinging stops.
• When rotating the load again, avoid swinging the load by turning the crank handle faster or more slowly.

CAUTION Danger of Leaking Oil, Loose Parts, and Loose Cables!

Rotation movements can cause oil to leak from the vehicle parts, creating oil puddles and resulting in slipping hazards. Parts and cables can also hang loosely from rotating vehicle parts. People could get caught in these cables and hurt themselves or damage the cables.

• Ensure that the oil drip pan can collect any leaked oil.
• Keep binding agents, rags, etc. ready to remove any leaked oil.
• Watch out for loose parts when rotating the load.
• Remove loose cables or secure them with cable ties, straps, or something similar.

11. Perform the service and maintenance work (see the vehicle manufacturer's service and repair manual).
12. Disengage the safety lock lever and fully depress the pedal on the mounting trestle to lower the vehicle part.

i If the safety lock lever gets stuck while lowering the cylinder, raise the cylinder again. If the lever still does not release, bring the load to the starting position and remove it from the mounting trestle.

13. When not in use, store the mounting trestle in a suitable location and lock the brakes on the castor wheels.

10 Inspection and Maintenance

Inspect the mounting trestle and accessories for visible damage before each use (e.g. leaks in the hydraulic cylinder, cracked parts or cracks on welded seams, defective wheels). Do not use the mounting trestle or accessories if damaged or in poor condition.

Inspect whether the drum brake on the universal support arm is works correctly.

The only maintenance required for the mounting trestle is an occasional cleaning. Only the manufacturer shall perform any necessary repair work on the mounting trestle.

NOTICE Modifications to this product which have not been expressly approved by the manufacturer shall void any warranty. The manufacturer assumes no liability for personal injuries or damages to materials which occur as the result of improper use of this product.

Before disposing of the mounting trestle, drain the oil from the oil drip pan completely.

Dispose of the used oil, oil-binding agents, and rags at a certified used oil collection centre.

Dispose of the mounting trestle and its accessories only at a certified scrap metal collection centre.

Contact the manufacturer or the Volkswagen Group for any questions.

Declaration of Conformity

Declaration of Conformity with the Machinery Directive 2006/42/EC, Annex II 1A

We hereby declare that each product described above complies with the relevant clauses of the 2006/42/EC Machinery Directive.

Any modification to a product not expressly approved by the manufacturer shall void the validity of this declaration.

The following harmonised standards have been applied:

• EN 1494:2000+A1:2008: Mobile or movable jacks and associated lifting equipment
• EN ISO 12100:2010: Safety of machinery - General principles for design - Risk assessment and risk reduction

Pollenfeld, 30 June 2014

Place, Date: Gary Palmer, Managing Director