BOSCH T40416/4 Adapters Instructions

BOSCH T40416/4 Adapters Instructions

1 General Information

Product Name: AdapterProduct Type: Load holding deviceProduct Number: T40416/4Weight: 2.1 kg per pieceMax. Load Capacity: 400 kg per piece in accordance with the table “Maximum load capacity per lifting method”Static Test Coefficient: 3.0

Intended use:

  • The adapters are used with the T40416 suspension devices to lift defined vehicles parts in cases where a greater distance to the suspension device as specified in the workshop manuals of the Volkswagen Group brands.

Terms of use:

  • For qualified workshop personnel only.
  • Use only for work approved by the Volkswagen Group.
  • For use on high-voltage components only by qualified personnel.
  • Use only for loads up to 400 kg per adapter.
  • Observe the maximum load capacities in the table “Maximum load capacity per lifting method”.
  • Use only with a suitable hoist with a sufficient load capacity and that has been approved by the Volkswagen Group.
  • Use only with the suspension devices T40416.
  • Use only with suitable chains, ropes, belts, or straps that have been approved by the Volkswagen Group and that have a sufficient load capacity.
  • Use only for vehicle parts that have been approved by the Volkswagen Group and that have suitable attachment points.
  • Do not hold or lift any persons or animals.
  • Do not hold or lift items other than those described in the workshop manuals of the Volkswagen Group brands.
  • Do not stand under suspended loads.
  • Use only on level, even and stable ground
  • Use only with the approved accessories (see the workshop manuals of the Volkswagen Group brands).
  • Do not work on suspended loads.
  • Use only at ambient air temperatures between -10 °C and +80 °C.

Included in Delivery

Product Name: AdapterQuantity: 4 pieces

  1. Adapter
  2. Hexagon head screw DIN 933 M12 x 80 10.9 with flange (2 pieces per adapter)
  3. Hexagon head screw DIN 933 M12 x 80 10.9 glued to a washer Ø 25 x 12 (2 pieces per suspension device)
  4. T40416/1: Top Bar
  5. Swivel lifting hook
  6. T40416/2: Bottom Bar

Maximum load capacity per lifting method1

1 ) This table applies only with suspension device T40416. Use the adapter T40416/4 only with the suspension device T40416.

2 General Safety Information

Read and follow all safety notes and instructions!

Failure to follow the safety instructions could result in serious injuries and severe damage to materials.

Observe and follow the safety notes below.

  • The load holding device has been specifically constructed for its intended use. The safety of the load holding device can no longer be ensured if it is misused or modified in ways not expressly approved by the manufacturer. Serious personal injuries or severe damage to materials could occur.
  • Ensure that each person using the load holding device is familiar with these instructions and can access them at all times.
  • Ensure that all users are also familiar with the instructions of the additional tools and workshop equipment that are necessary for the work.
  • Carefully read and adhere to the instructions in the technical safety information of the Volkswagen Group brands.
  • Observe and follow the basic information and safety notes for high-voltage vehicles in the corresponding Volkswagen Group information media when using on vehicles with high-voltage components.
  • Use only with sufficient light and good visibility.
  • Wear safety shoes that meet the ISO 20345, S2 standard.
  • Wear protective gloves in order to avoid cuts.
  • Position hands and feet so as to avoid potential crushing hazards.
  • Use the load holding device only for work approved by the Volkswagen Group.
  • Use the load holding device only with the accessories approved by the Volkswagen Group.
  • Do not exceed the maximum load capacity of 400 kg per adapter.
  • Observe the maximum load capacities in the table “Maximum load capacity per lifting method”.
  • Observe the tilt angles listed in the table “Maximum load capacity per lifting method”.
  • Use only the screws included in delivery or replacement screws the same size and quality grade.
  • Tighten the screws with the specified torque (see the workshop manuals of the Volkswagen Group brands).
  • Use the adapters only with suitable lifting equipment and approved chains, ropes, belts, or straps in accordance with the workshop manuals of the Volkswagen Group brands.
  • When using with hoist, ensure that the path is clear and easily visible.
  • Move the load slowly and carefully.
  • Observe the adapter and the load during all movements.
  • Persons may not be under the load or in the hazard area while the load is being moved.
  • Do not work on suspended loads.

3 Operating Instructions

Risk of electric shock

The HV battery is a high-voltage storage capacitor (HVSM). High voltage can cause serious personal injury or material damage.

  • Observe and follow the hazard classification of the high-voltage system in the workshop manuals.
  • Observe and follow the notes and work instructions in the workshop manuals.
  1. Ensure that the adapters and suspension devices are complete and inspect them for visible damages such as signs of wear, deformation, breaks, cracks, and corrosion before each use. Do not use the adapters and suspension devices if damaged or in poor condition, but discard them immediately.
  2. Perform the necessary preparatory work to use the adapters and suspension devices in accordance with the workshop manuals of the Volkswagen Group brands.
  3. To find out how many adapters and suspension devices are required for the relevant vehicle part, refer to the workshop manuals of the Volkswagen Group brands (see also Figure 2).
  4. Remove the hexagon head screws (2) from the adapters (1) and the hexagon head screws (3) from the top bar (4) and put them aside.
  5. Position the adapter (1), the top bar (4), and bottom bar (6) on the vehicle part in accordance with the workshop manuals of the Volkswagen Group brands.1 Adapter2 Hexagon head screw DIN 933 M12 x 80 10.9 with flange (2 pieces each per adapter)4 T40416/1: Top Bar5 Swivel lifting hook6 T40416/2: Bottom Bar
  6. Align the slotted holes in the top bar (4) and in the adapters (1) with the attachment holes in the vehicle part and the threaded holes in the bottom bar (6).
  7. Push the hexagon head screws (2) through the suspension devices and the adapters and screw them into the bottom bar (6) with the torque specified in the workshop manuals of the Volkswagen Group brands.
  8. Attach a chain, rope, belt, or strap to each suspension device. Attach the suspension devices to suitable lifting equipment (see the table “Maximum load capacity per lifting method” and the workshop manuals of the Volkswagen Group brands).Risk of a falling load!Attaching the suspension device incorrectly could cause the load to tip or fall. This could result in serious personal injury and severe damage to materials.
    • Attach the suspension device to the lifting equipment and vehicle part exactly as described in the workshop manuals.
    • Observe the maximum load capacities and angle of the chain, rope, belt, or strap in the table “Maximum load capacity per lifting method”.
    • Ensure that the suspension device is securely fastened before lifting the load.
  9. Carefully lift the vehicle part. Ensure that the load is secure when setting it down.
  10. Perform further work as described in the workshop manuals.
  11. Ensure that all parts of the special tool have been removed after completing the repair work.

4 Inspection and Maintenance

Ensure that the adapter and suspension devices are complete and inspect them for visible damages such as signs of wear, deformation, breaks, cracks, and corrosion before each use. Do not use the adapters and suspension devices if damaged or in poor condition, but discard them immediately.

Inspect the adapters and suspension devices in accordance with all applicable national regulations.

  • Inspect the adapters and suspension devices at least once a year.
  • Document the inspections in accordance with all applicable regulations and keep the documentation in a safe place.

Contact your first-level support representative with any queries.

NOTICE

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

Bosch Automotive Service Solutions GmbHAm Dörrenhof 185131 Pollenfeld-PreithGermanywww.bosch.com

2020-11-13

References

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