Volkswagen VAS 6321 A Usage Information Manual
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Volkswagen VAS 6321 A Usage Information Manual

Volkswagen VAS 6321 A Usage Information Manual

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Usage Information
VAS 6321 A

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  • Page 1 Usage Information VAS 6321 A...
  • Page 2 Usage information VAS 6321 A Version 2021/05 Read this usage information carefully before using the VAS 6321 A for the first time, keep the instructions for later use and pass this usage information on to other / further users. The dissemination or reproduction of these instructions or the re-use or communication of its contents are not permitted, unless expressly allowed.
  • Page 3 Dear Customer, Congratulations on your decision to purchase our VAS 6321 A. With this repair system, you have not only purchased a quality product from the company Carbon, but also made a future-oriented decision - we do hope that your work is successful with this equipment.

  • Page 4: Table Of Contents

    CBR-C1 PowerInverter | Power Source (VAS 6321 A/13) ....... . .
  • Page 5 CBR EasyTool adhesive system (VAS 6321 A/11)........

  • Page 6: Important Safety Instructions

    Persons The use of qualified personnel is recommended when carrying out work with the VAS 6321 A. The persons working with the system must in any case have been made aware of the possible risks and must have read and understood this usage information.
  • Page 7 Always work attentively and concentrate! Magnetic fields Please note that the VAS 6321 A/13 welding inverter included in the VAS 6321 A generates powerful magnetic fields that exert powerful attractive forces on magnetic metals. Watches, magnetic cards and data carriers can be damaged by this.

  • Page 8: Use / Guarantee

    - damaged tools must not be used any further! Guarantee Please refer to our General Terms and Conditions for the scope of guarantee for our VAS 6321 A. The guarantee does not cover damage caused by: Ordinary wear and tear „...

  • Page 9: Electrical Supply

    Important safety instruction regarding the electrical supply The VAS 6321 A trolley is supplied with a connection cable with a 16A plug type EN 60309-1. The connection cable must be connected to a three-phase, grounded 400V (50-60 Hz) socket (L1, L2, L3, N and PE) with neutral and protective conductor connected in accordance with the regulations and current standards for electrical installations.

  • Page 10: The Vas 6321 A In Use

    Th e VA S 6 3 2 1 A i n u s e 4. The VAS 6321 A in use The VAS 6321 A is a complete, innovatively designed repair system for the economical and high-quality repair of the car body outer skin.

  • Page 11: Typical Damage

    Ty p i c a l d a m a g e 5. Typical damage Attachment parts, as well as welded and bonded parts...

  • Page 12: The Vas 6321 A At A Glance

    Th e VA S 6 3 2 1 A a t a g l a n c e 6. The VAS 6321 A at a glance LineTool 160 Supports for EasyTool EasyTool Hand Puller Sliding Puller Dent removal hammers Supports for EasyTool...
  • Page 13 Th e VA S 6 3 2 1 A a t a g l a n c e LineTool 100 LeverTool Outriggers for LineTool StrongTool Outriggers for StrongTool Second pull-in unit for LineTool Enhancement / extension for StrongTool with L-support Steel scale 1 m LeverTool components Carbon electrode...
  • Page 14 Th e VA S 6 3 2 1 A a t a g l a n c e The VAS 6321 A essentially consists of the components listed below, whose use and application is described in more detail in this usage information:...
  • Page 15 CBR LineTool 100 with pull-in unit and double pull hook VAS 6321 A / 3 Second pull-in unit with double hooks for VAS 6321 A / 1 and VAS 6321 A / 7 VAS 6321 A / 2 Enhancement / extension for CBR StrongTool CBR-ST-00...

  • Page 16: Cbr Pulling Tools At A Glance

    C B R p u l l i n g t o o l s a t a g l a n c e 7. CBR pulling tools at a glance Second pull-in unit with double hooks for LineTool CBR LeverTool CBR EasyTool...
  • Page 17 C B R p u l l i n g t o o l s a t a g l a n c e CBR LineTool 160 CBR LineTool 100 CBR StrongTool Enhancement / extension for CBR StrongTool with L-support...

  • Page 18: Cbr-C1 Powerinverter | Power Source (Vas 6321 A/13)

    The CBR-C1 PowerInverter The VAS 6321 A/13 PowerInverter is the multifunctional power source (hereinafter referred to as SQ) at the heart of the VAS 6321 A. It enables a wide range of applications in the repair of damage to the body outer skin.

  • Page 19: The Operation Of The Sq

    C B R - C 1 P o w e r I n v e r t e r | P o w e r S o u r c e ( VA S 6 3 2 1 A / 1 3 ) The operation of the SQ After switching on the SQ via the main switch (1), the MANUAL (2) and GROUND (5) LEDs light up.

  • Page 20: Attaching The Ground Clamp With Program 1

    Important For all work with the VAS 6321 A, make sure that the zinc coating is removed from the sheet metal without leaving any residue. This should be done with nylon discs or similar at low speed to introduce as little heat as possible into the sheet metal being machined.

  • Page 21: Clamping The Ground Clamp

    Important: If the edge is ground off on one side, the fixed and not the moving part of the ground clamp should have contact with the body part - otherwise faulty welding or even hole burn-through may occur! For your consideration: The VAS 6321 A/13 requires a secure ground connection to the vehicle body to achieve a good result.

  • Page 22: Attaching The Flexible Ground

    Note: The welded-on ground connections are only suitable for work where little current flows - if possible, always use the clamped ground connection. For your consideration: The VAS 6321 A/13 requires a secure ground connection to the vehicle body to achieve a good result. 1. Place the ground clamp in the specified recess of the extension.

  • Page 23: Working With The Cbr Bits

    W o r k i n g w i t h t h e C B R B i t s 9. Working with the CBR Bits The CBR Bits The CBR Bits serve as a force-transmitting medium between the CBR StrongTool, the CBR LineTool, the CBR LeverTool, as well as the CBR PressSystem and the surfaces and edges of the body outer skin to be repaired.

  • Page 24: Welding On The Bits With Program 2

    Plug the MultiTool with connection cable into the corresponding socket (AUTO or MANUAL) on the VAS 6321 A/13. Insert the bit holding electrode into the selected MultiTool. When using the C1-06, plug the control cable into the VAS 6321 A/13.

  • Page 25: Useful And Interesting Facts About Bits

    Insufficient contact pressure during welding. „ Unsafe, hesitant handling. „ Poor ground connection. „ Insufficient power supply (VAS 6321 A/13 is operated with extension cable). „ Power is set too low. „ Shunt (adjacent bit is touched during welding). „...

  • Page 26: Important Notes On Welding On The Bits

    W o r k i n g w i t h t h e C B R B i t s Important notes on welding on the bits: Start welding on the bits at the deepest spot of the damage. „...

  • Page 27: The Cbr Pull Rods

    W o r k i n g w i t h t h e C B R B i t s The CBR pull rods According to the number of bits welded on, select the appropriate pull rod, which is inserted through the slotted holes of the bits. If the damage to the body part is slightly deeper than the height of the slotted holes, it is possible to advance to greater depths of damage by tilting the outer bits.

  • Page 28: Bitcutter & Recutting Bits

    B i t C u t t e r & r e c u t t i n g b i t s 10. BitCutter & recutting bits 10.1 The BitCutter and how it is used The BitCutter is used to cut bits that have already been welded on several times in order to obtain a defined geometry of the bit tip and the same length of the bits used.

  • Page 29: Important Notes On Use And Care Of The Bits

    Only use original CBR Bits - these bits are made of a special alloy and are matched to the performance characteristics of the VAS 6321 A/13. This ensures a high level of process reliability. Remove the bits after use by twisting them off the body panel –...

  • Page 30: Cbr Strongtool (Vas 6321 A/4)

    C B R S t r o n g To o l ( VA S 6 3 2 1 A /4 ) 11. CBR StrongTool (VAS 6321 A/4) As the name suggests, the CBR StrongTool is the pulling tool in the VAS 6321 A that can be used to build up the highest pulling forces.

  • Page 31: Components Of The Cbr Strongtool

    11.1 Components of the CBR StrongTool Important: If the support points on the body are far apart or at very different levels, the optionally available VAS 6321 A/2 enhancement / extension is a powerful help when using the StrongTool. Here, too, make sure that the support point is exactly in the center of the outriggers.

  • Page 32: Enhancement Set Cbr Strongtool (Vas 6321 A/2)

    C B R S t r o n g To o l ( VA S 6 3 2 1 A /4 ) 11.2 Enhancement set CBR StrongTool (VAS 6321 A/2) Extension blade, as well as small and large L-supports With the many possible combinations of the various individual parts, a...

  • Page 33: Working With The Cbr Strongtool

    C B R S t r o n g To o l ( VA S 6 3 2 1 A /4 ) 11.3 Working with the CBR StrongTool Incorrect Correct Foot must be placed centrally to the edge. Incorrect Correct Foot must be placed centrally to the edge.

  • Page 34: Cbr Linetool (Vas 6321 A/6 And Vas 6321 A/7)

    The CBR LineTool is available in two lengths (1600 mm in the basic version of the VAS 6321 A and 1000 mm as an option) and is a very universally applicable tool due to its sliding pull-in unit.
  • Page 35 C B R L i n e To o l ( VA S 6 3 2 1 A / 6 a n d VA S 6 3 2 1 A / 7 ) The LineTool can be supplemented with additional pull-in units that can be positioned independently on the LineTool. Thus, you can create the possibility of pulling at several points at the same time.

  • Page 36: Working With The Cbr Linetool

    C B R L i n e To o l ( VA S 6 3 2 1 A / 6 a n d VA S 6 3 2 1 A / 7 ) 11.4 Working with the CBR LineTool When working with the LineTool, the same procedure, process and instructions apply as when working with the StrongTool. With any extensive damage to doors and side panels, it is important to start at the bottom or strongest line (bead, edge).
  • Page 37 C B R L i n e To o l ( VA S 6 3 2 1 A / 6 a n d VA S 6 3 2 1 A / 7 ) Place the suction cups of the LineTool in the desired position and press them onto the cleaned surface with light pressure. The length is fixed with the blue line.
  • Page 38 C B R L i n e To o l ( VA S 6 3 2 1 A / 6 a n d VA S 6 3 2 1 A / 7 ) The LineTool 160 with the pull-in unit in conjunction with the adhesive system. The LineTool 100 with two additional pull-in units in the hard sill area.

  • Page 39: Cbr Easytool (Vas 6321 A/5)

    C B R E a s y To o l ( VA S 6 3 2 1 A / 5 ) 13. CBR EasyTool (VAS 6321 A/5) The CBR StrongTool, LineTool and LeverTool are mainly used on large-area damage. After repair with these tools, minor damage often remains, which is then removed with subsequent finishing work.

  • Page 40: Components Of The Cbr Easytool

    Important: To avoid damage to the vehicle electronics, the vehicle’s electrical system must be switched off according to the vehicle manufacturer‘s specifications before using the VAS 6321 A/13! In the first step, assess the damage site and select the appropriate support and attach it to the CBR EasyTool. Then make the basic setting of the CBR EasyTool.
  • Page 41 C B R E a s y To o l ( VA S 6 3 2 1 A / 5 ) Also in this application, the VAS 6321 A/13 requires a secure ground connection to the vehicle body to achieve a good result.

  • Page 42: Program Setting With The Cbr Easytool

    C B R E a s y To o l ( VA S 6 3 2 1 A / 5 ) Use only original CBR welding tips - these are made of a special alloy. The dimensions and geometry of the tips have been adjusted for best heat dissipation and low wear.
  • Page 43 C B R E a s y To o l ( VA S 6 3 2 1 A / 5 ) Place the EasyTool on the damaged spot with the handles pulled together and slowly loosen the handles. When the welding tip makes contact, the welding process is triggered automatically.
  • Page 44 C B R E a s y To o l ( VA S 6 3 2 1 A / 5 ) In the edge and border area, it is recommended to work with the half feet. For grazing damage, the EasyTool is a very effective tool. It is recommended to fix one foot at a distance of 2-3 cm in the direction to be worked.

  • Page 45: Cbr Levertool (Vas 6321 A/8)

    C B R L e v e r To o l ( VA S 6 3 2 1 A / 8 ) 14. CBR LeverTool (VAS 6321 A/8) The CBR LeverTool is used when the situation around the damage does not allow the use of the StrongTool or LineTool.

  • Page 46: Working With The Cbr Levertool

    C B R L e v e r To o l ( VA S 6 3 2 1 A / 8 ) 14.1 Working with the CBR LeverTool The LeverTool is mostly used where there is only one possibility of support. The LeverTool can be converted from pushing to pull-in in just a few steps by exchanging the outrigger and pull carriage.

  • Page 47: Cbr Hand Pullers & Impact Hammer

    15.1 The hand puller & the sliding puller The CBR hand puller and the CBR sliding puller prove to be useful supplements to the VAS 6321 A. These tools are mostly used where the use of the EasyTool is not possible.

  • Page 48: Working With The Cbr Handtool

    C B R h a n d p u l l e r s & i m p a c t h a m m e r 15.2 Working with the CBR HandTool Use of the CBR hand pullers Pulling large, soft dents in the sheet metal while simultaneously relaxing them with the aluminum hammer. Pull-in of small dents and peaks in the sheet metal.

  • Page 49: Pull-In With The Cbr

    P u l l - i n w i t h t h e C B R 16. Pull-in with the CBR 16.1 The pull-in of steel sheets The benefit of this method is that dent removal and pull-in work can be performed with the same tool, saving time while keeping the heat impact on the sheet metal very low.

  • Page 50: Thermal Pull-In - Copper Electrode - Ball

    VAS 6321 A/13 offers you various tools and options for this purpose. For your consideration: Make sure that during pull-in the VAS 6321 A/13 has a secure ground connection to the vehicle body in order to achieve a good result.

  • Page 51: Thermal Pull-In - Copper Electrode - Flat

    Th e r m a l p u l l - i n – c o p p e r e l e c t r o d e - f l a t 18. Thermal pull-in – copper electrode - flat 18.1 Pull-in with the copper electrode –- flat In both modes, you can also use the copper electrode - flat (CBR-U-B22) instead of the copper electrode - ball (CBR-U-B12) - however, this is not unrolled, but pressed onto the excess material with the flat head at specific points.

  • Page 52: Thermal Pull-In - Carbon Electrode

    Th e r m a l p u l l - i n - c a r b o n e l e c t r o d e 19. Thermal pull-in - carbon electrode 19.1 Pull-in and stabilizing with the carbon electrode This method should only be used for pull-in, or stabilizing, soft, thin deep-drawing metal sheets of older vehicles.

  • Page 53: Thermal Pull-In Aluminum Sheets

    Important: To avoid damage to the vehicle electronics, the vehicle’s electrical system must be switched off according to the vehicle manufacturer‘s specifications before using the VAS 6321 A/13! Select program 5 for “Aluminum”. With or without pulse, depending on the application.

  • Page 54: Cbr Aluminum Hammers

    21.1 The CBR aluminum hammers and plastic wedges The scope of delivery of the VAS 6321 A includes three different aluminum hammers, a wide as well as a narrow plastic wedge. The hammers differ not only in size, but also in the different position of their fins - these are arranged vertically or horizon- tally to the hammer handle.
  • Page 55 C B R a l u m i n u m h a m m e r s A very important step in dent removal work with the VAS 6321 A is to remove the tension from the sheet metal under tension at the right time.

  • Page 56: Creative Approaches To Different Repair Methods

    C r e a t i v e a p p r o a c h e s t o d i f f e r e n t r e p a i r m e t h o d s 22.
  • Page 57 C r e a t i v e a p p r o a c h e s t o d i f f e r e n t r e p a i r m e t h o d s...

  • Page 58: Cbr Easytool Adhesive System (Vas 6321 A/11)

    C B R E a s y To o l a d h e s i v e s y s t e m ( VA S 6 3 2 1 A / 1 1 ) 23. CBR EasyTool adhesive system (VAS 6321 A/11) 23.1 Paintless dent removal with the CBR adhesive system...

  • Page 59: Equipping The Easytool With The Adhesive System

    23.3 Equipping the EasyTool with the adhesive system On the left side of the VAS 6321 A trolley there is a punched out hexagon on the upper cable holder. Plug in the welding pull tip into the punched hole and loosen the nut behind it using a 17 mm open-end wrench. Twist off the welding tip and turn...

  • Page 60: Cbr Adhesive System (Vas 6321 A/9)

    C B R a d h e s i v e s y s t e m ( VA S 6 3 2 1 A / 9 ) 24. CBR adhesive system (VAS 6321 A/9) 24.1 Adhesive system with the StrongTool / LineTool / LeverTool For larger areas of damage, the Strong- or LineTool is used analogously to the repair with welded-on bits.
  • Page 61 C B R a d h e s i v e s y s t e m ( VA S 6 3 2 1 A / 9 ) Apply special cleaner to soft cloth and clean For optimum adhesive effect, the damaged the surface of the adhesive pad.

  • Page 62: Adhesive System With The Linetool

    C B R a d h e s i v e s y s t e m ( VA S 6 3 2 1 A / 9 ) 24.2 Adhesive system with the LineTool 24.3 Adhesive system with the StrongTool 24.4 Adhesive system with the LeverTool...

  • Page 63: Cbr Gluetech

    The procedure for applying the adhesive and setting the pull tab is identical to the CBR adhesive system (VAS 6321 A/9). MGT-200 GlueTech Plus adhesive pad MGT-11 GlueTech Plus pull tab blue MGT-10 GlueTech Plus pull plate...

  • Page 64: Decommissioning The Vas 6321 A

    D e c o m m i s s i o n i n g t h e VA S 6 3 2 1 A 26. Decommissioning the VAS 6321 A Temporary decommissioning Switch off the SQ. „ Disconnect the cables from the SQ and store the cables on the cable holders provided.

  • Page 65: Declaration Of Conformity

    D e c l a r a t i o n o f C o n f o r m i t y Carbon GmbH Haldenhoefe 3 DE - 78253 Eigeltingen - Heudorf Tel.: +49 (0) 7465 – 466 27. Declaration of Conformity Fax: +49 (0) 7465 –...

  • Page 66: Notes

    N o t e s 28. Notes...
  • Page 67 N o t e s...
  • Page 68 In collaboration with: CARBON GmbH © Volkswagen Aktiengesellschaft Haldenhöfe 3 Konzern Abteilung D-78253 Eigeltingen-Heudorf Brieffach 1848 - 2 Phone +49 7465 466 +49 7465 2217 38436 Wolfsburg Mail info@carbon.ag Deutschland ©2021 CARBON | VAS-004 EN | 5/2021...

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