Gedore KL-1000-20 A User manual

GEDORE WELTWEIT / GEDORE WORLDWIDE
Weltweite GEDORE Servicestellen / Niederlassungen finden Sie im Internet unter: www.gedore.com
Worldwide GEDORE service centers / offices are listed on the Internet at: www.gedore.com
GEDORE Automotive GmbH
Breslauer Straße 41
78166 - Donaueschingen
Postfach 1329
78154 Donaueschingen - GERMANY
T +49 (0) 771 / 8 32 23-0
F +49 (0) 771 / 8 32 23-90
[email protected]
www.gedore-automotive.com
GEDORE TOOLS, INC.
Only for USA, Canada & Mexico
Sólo para EE.UU., Canadá y México
Seulement pour les USA, le Canada et le Mexique
7187 Bryhawke Circle, Suite 700
North Charleston, SC 29418, USA
Phone +1-843 / 225 50 15
Fax +1-843 / 225 50 20
[e-mail]
04/2019
www.gedore-automotive.com
1000-20Ae190211.docx
K
L
-
1000-20 A
King Pin Press (65t)

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Instruction Manual EN
English 3 - 18
Impressum
Im Zuge der Verbesserung und Anpassung an den Stand der Technik behalten wir uns Änderungen im Hinblick auf Aussehen, Abmessungen, Gewichte und Eigenschaften sowie
Leistungen vor.
Damit ist kein Anspruch auf Korrektur oder Nachlieferung bereits gelieferter Produkte verbunden. Streichungen können jederzeit vorgenommen werden, ohne dass ein rechtlicher
Anspruch entsteht.
Alle Hinweise zur Benutzung und Sicherheit sind unverbindlich. Sie ersetzen keinesfalls irgendwelche gesetzlichen oder berufsgenossenschaftlichen Vorschriften.
Für Druckfehler übernehmen wir keine Haftung.
Ein Nachdruck, auch auszugsweise, bedarf der vorherigen schriftlichen Zustimmung durch GEDORE Automotive GmbH.
Alle Rechte weltweit vorbehalten.
Wir verweisen auf unsere Allgemeinen Geschäftsbedingungen, ersichtlich im Impressum unter www.gedore-automotive.com.
© Copyright by GEDORE Automotive GmbH Donaueschingen (GERMANY)
Impressum/Legal Notice
As part of our commitment to continuous product improvement and adaptation to state-of-the art technology, we reserve the right to make modifications to our products with
regard to design, dimension, weight, features and performances at any time and without prior notice.
Thus, the right to adjustments or replacement deliveries of goods already delivered is excluded. Cuts and cancellations can be made by us at any time without notice and no legal
claims against us may arise or be derived from this.
All indications regarding use and safety are given for information only and without any commitment. In no case do they substitute for legal provisions or the regulations of the
Employer’s Liability Insurance Association.
Errors and omissions excepted.
Any reproduction, also in extracts, is subject to the prior written consent of GEDORE Automotive GmbH.
All rights reserved.
We refer to our General Terms and Conditions of Sale under ‘Imprint’ at www.gedore-automotive.com.
© Copyright by GEDORE Automotive GmbH Donaueschingen (GERMANY)
Impressum / Mentions légales
En raison des améliorations continues que nous apportons à nos produits et pour assurer leur adaptation constante à l'évolution des techniques, nous nous réservons le droit de
procéder à des modifications de nos produits quant à l’apparence, aux dimensions, aux poids, aux caractéristiques et aux performances à tout moment sanspréavis et sans obligation
de modifier ou de remplacer des produits précédemment livrés.
Des suppressions peuvent être effectuées à tout moment et sans préavis sans qu’elles puissent donner lieu à réclamation.
Toutes les instructions d’utilisation et conseils de sécurité sont donnés sans engagement de notre part. Ils ne se substituent en aucun cas aux réglementations légales en vigueur
ou à celles émises par les associations professionnelles.
Le plus grand soin possible a été apporté à la rédaction de ce document. Toutefois, nous n’assumons aucune responsabilité pour des erreurs, omissions ou défauts d’impression
éventuels.
Une reproduction, même en partie, ne peut être effectuée qu’après autorisation écrite préalable de GEDORE Automotive GmbH.
Tous droits réservés.
Vous trouverez nos conditions générales de vente, sous Impressum/Mentions légales sur www.gedore-automotive.com.
© Copyright by GEDORE Automotive GmbH Donaueschingen (GERMANY)

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Instruction Manual EN
Table of Contents
Page
1. Essential Safety Notices .....................................................................................................4
1.1 Safety Notices and Warnings ....................................................................................................................................... 4
1.2 Personal Protective Equipment.................................................................................................................................... 7
1.3 Intended Use .................................................................................................................................................................. 7
1.4 Safe and Proper Use...................................................................................................................................................... 7
1.5 Work Environment......................................................................................................................................................... 7
1.6 Appropriate Users ......................................................................................................................................................... 7
2. Product Description.............................................................................................................8
2.1 KL-1000-20 A King Pin Press ........................................................................................................................................ 8
2.2 Technical Data ............................................................................................................................................................... 8
3. Preparatory Work.................................................................................................................8
3.1 Lifting the King Pin Press off the Pallet....................................................................................................................... 8
3.2 Checking the Delivery.................................................................................................................................................... 8
3.3 Preparing the Vehicle. ................................................................................................................................................... 8
3.4 Checking the Components of the King Pin Press. ..................................................................................................... 8
3.5 Turning the Bridge ‘A11’ Upside Down if necessary................................................................................................... 9
3.6 Manoeuvring the King Pin Press.................................................................................................................................. 9
3.7 Checking the Hydraulic Oil Level and Topping Up if necessary................................................................................ 9
3.8 Bleeding the Hydraulic Cylinder ’A13’. ........................................................................................................................ 9
4. King Pin Removal/Installation...........................................................................................10
4.1 Removing the King Pin. .............................................................................................................................................. 10
4.2 Installing the King Pin ................................................................................................................................................. 14
5. Care and Storage ...............................................................................................................17
6. Maintenance and Repair by the GEDORE Automotive Service Centre.............................17
7. Spare Parts List..................................................................................................................17
8. Accessories........................................................................................................................17
9. Environmentally Safe Disposal.........................................................................................17
10. EC Declaration of Conformity.........................................................................................18

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Instruction Manual EN
1. Essential Safety Notices
Before using the king pin press, it is imperative that you read and understand the Instruction Manual. Misuse can lead to
SERIOUS INJURIES and even DEATH.
This Instruction Manual is part of the king pin press. Keep the Instruction Manual in a safe place for future reference and pass
it on to subsequent users of the king pin press. All vehicle-specific data stated herein are supplied under reserve and without
commitment.
1.1 Safety Notices and Warnings
For better differentiation, the warning notices in this Instruction Manual are classified as follows:
Warning
sign Sign reads Signification
DANGER
Indicates a hazardous situation which, if not avoided, may result in serious or fatal injuries.
CAUTION
Indicates a hazardous situation which, if not avoided, may result in moderate or minor injuries.
ATTENTION
Indicates a situation which, if not avoided, may result in possible damage to the king pin press or
its functioning, or to objects in its vicinity.
DANGER
When removing king pins with the aid of the king pin press, there is a risk that the mandrel and/or support ring may break or slip out of
position. This will lead to parts becoming projectiles which could cause severe injuries and even death.
Before inserting the mandrel and support ring, the respective retaining bore in the hydraulic cylinder and in the bridge must be
checked for foreign bodies and dirt, and cleaned if necessary.
The mandrel and support ring must be fully inserted and accurately seated in their respective retaining bore in the hydraulic cylinder
and bridge.
When removing king pins with the aid of the king pin press, there is a risk that the press frame and mandrel may break and fall to pieces.
This will lead to parts becoming projectiles which could cause severe injuries and even death.
When removing the king pin, the operator must ensure no other person is present in and around the working area of the king pin press.
Never use the king pin press without the appropriate mandrel and support ring.
Observe and do not exceed the maximum load capacity of the king pin press.
Observe the recommended direction for the removal of the king pin.
Never stack several mandrels, pressure pieces or support rings on top of each other during removal/installation.
Start removing the king pin using the shortest mandrel possible. Then, withdraw and replace the mandrel with the next longer one.
Continue in this way until king pin is extracted.
Make sure that the mandrel and support ring are fully inserted and accurately seated in their respective retaining bore in the hydraulic
cylinder and bridge.
Before each use, visually check the components of the king pin press to make sure they are in good condition. In particular, check that
all bolted connections are properly tightened and that the hydraulic hose, the mandrels, support rings, spacer ring and thrust piece are
in good order and condition.
Always keep all parts of your body away from the axial extension of the press frame.
Only use the original spare parts and accessories from GEDORE Automotive.
When installing a king pin with the aid of the king pin press, there is a risk that the king pin may slip out of position and/or the press
frame may break. This will lead to parts becoming projectiles which could cause severe injuries and even death.
When installing the king pin, the operator must ensure no other person is present in and around the working area of the king pin press.
Never use the king pin press without the appropriate support ring/thrust piece.
Observe and do not exceed the maximum load capacity of the king pin press.
Never stack several mandrels, pressure pieces or support rings on top of each other during removal/installation.
Make sure that thrust piece and support ring are fully inserted and accurately seated in their respective retaining bore in the hydraulic
cylinder and bridge.
Before each use, visually check the components of the king pin press to make sure they are in good condition. In particular, check that
all bolted connections are properly tightened and that the hydraulic hose, the mandrels, support rings, spacer ring and thrust piece are
in good order and condition.
Always keep all parts of your body away from the axial extension of the press frame.
Only use the original spare parts and accessories from GEDORE Automotive.

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When installing a king pin with the aid of the king pin press, there is a risk that the thrust piece and/or support ring may break or slip out
of position. This will lead to parts becoming projectiles which could cause severe injuries and even death.
Before inserting the thrust piece and support ring, the respective retaining bore in the hydraulic cylinder and in the bridge must be
checked for foreign bodies and dirt, and cleaned if necessary.
The thrust piece and support ring must be fully inserted and accurately seated in their respective retaining bore in the hydraulic cylinder
and bridge.
Make sure that the bridge is properly aligned with the hydraulic cylinder, otherwise there is a risk that these could shift. As a result, there
is a danger of the king pin slipping out of position and of the press frame breaking. This will lead to parts becoming projectiles which
could cause severe injuries and even death.
The bridge and hydraulic cylinder must be aligned so that they are parallel to each other. For this, measure the distance between the
bridge and the hydraulic cylinder at the right and left threaded rod. The distance must be equal on either side.
The press frame must be perfectly aligned (rectilinear) with the king pin retaining bore.
Once the alignment completed, tighten all the hex nuts on the press frame to approx. 60 Nm.
CAUTION
There is a risk of the hydraulic hose bursting which could lead to an uncontrolled whipping of the hose as well as hydraulic fluid
escaping at high pressure.
In accordance with DIN 20 066 recommendations, hydraulic hoses should be replaced after a period of use of 6 years. The date
of manufacture of the hydraulic hose can be found on the press sleeves of the hose for verification.
The bridge can cause injuries to feet if dropped.
Always wear safety shoes/boots.
The king pin press can cause injuries to feet if dropped.
Always wear safety shoes/boots.
Lift king pin press off the pallet by means of a suitable hoist.
When lifting the king pin press off the pallet, always pay attention to the centre of gravity of the press.
Place hydraulic cylinder into its lowest possible position.
When manoeuvring the king pin press, there is a risk of the press tipping over and causing injuries to feet.
Always wear safety shoes/boots.
Place hydraulic cylinder into its lowest possible position.
Risk of hydraulic fluid escaping under pressure from the king pin press potentially causing eye injuries and skin irritations.
Always wear safety gloves and safety goggles.
Always make sure that system is depressurised before attempting to check the hydraulic fluid level.
After checking/topping up, completely re-insert oil dipstick into pump unit.
When removing and installing king pins with the aid of the king pin press, there is a danger of hydraulic fluid escaping under high
pressure potentially causing serious eye injuries and skin irritations.
Never attempt to turn the pressure gauge on the king pin press if the gauge is still under pressure/displaying pressure.
When removing and installing king pins with the aid of the king pin press, there is a risk of injuries to hands and fingers.
During removal/installation of the king pin, always keep your hands clear of the press frame.
When bleeding the king pin press, there is a risk of hydraulic fluid escaping under pressure potentially causing eye injuries and skin
irritations.
Always wear safety gloves and safety goggles.
Extend hydraulic cylinder 1-2cm at the most.
Once the bleeding of the king pin press completed, re-insert/fully tighten grub screw on hydraulic cylinder.
When inserting the support ring and mandrel/thrust piece, there is a risk that these may fall and cause injuries to your feet.
Always wear safety shoes/boots.
When inserting the
mandrel and support piece, there is a risk of injuries to hands and fingers.
Always make sure that the system is depressurised before attempting to insert the mandrel and support ring.
When turning the press frame upside down, there is a risk of injuries to hands and fingers.
Always wear safety gloves.
Align crank relative to pump unit.
While turning the press frame upside down, always keep your hands clear of the press frame and moving parts.
Turn press frame upside down with the help of a second person.
Once the press frame in upside-down position, tighten tapered handle.

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When removing the support ring and mandrel/thrust piece, there is a risk that these could get stuck or fall and cause injuries to
your hands and feet.
Always wear safety gloves and safety shoes/boots.
When positioning the press frame, there is a risk of injuries to hands and fingers.
Always wear safety gloves.
Turn crank in a controlled way in order to avoid any slippage.
When positioning the press on the steering knuckle, always keep your hands clear of the press frame.
The crank must only be operated when the press frame is in vertical position.
When operating the pump lever, there is a risk that it could slip out of position and cause injuries to your hands and fingers.
The pump lever must be fully inserted in the pump sleeve.
When using the quick-stroke 'Extend/Retract ' valve, there is a risk of injuries to hands and fingers.
When using the quick-stroke valve, always keep your hands clear of the press frame of the king pin press.
The quick-stroke valve is only intended to quickly extend and retract the piston rod on the hydraulic cylinder when positioning the
king pin press.
When operating the pump lever, there is a risk that it could slip out of position and cause injuries to your hands and fingers.
The pump lever must be fully inserted into the pump sleeve.
ATTENTION
Risk of damage to steering knuckle.
Observe the mounting direction for the king pin specified by the vehicle manufacturer.
Risk of damage to king pin press and vehicle.
Connect the king pin press only to air systems that are dry and oiled.
Observe and do not exceed the maximum approved air pressure of 13 bar.
Never use the king pin press without the appropriate support ring and mandrel/thrust piece.
Regularly clean crank spindle and lubricate with molybdenum disulphide paste such as KL-0014-0030 (accessory).
Any work on vehicles should only be performed by qualified specialist personnel observing and complying with the directions,
provisions, and safety regulations specified by the vehicle manufacturer!
Risk of damage to hydraulic cylinder piston rod.
When using mandrels that are shorter than 120mm, make sure that the piston rod is not pressing against the steering knuckle while
removing the king pin.
Risk of damage to support ring and king pin press.
When choosing the appropriate support ring, bear in mind that its internal diameter must not be too small, otherwise there is a risk
that the king pin, while being pressed out, could get stuck in the support sleeve.
Misalignment between the bridge and hydraulic cylinder can lead to damage to the hydraulic cylinder resulting in leakage.
The press frame must be aligned so as to allow the mandrel/thrust piece to press precisely centrally against the king pin.
The press frame must be aligned so as to allow the king pin to be pressed into the support ring (inner Ø) without any risk of collision.
The bridge and hydraulic cylinder must be aligned so that they are parallel to each other. For this, measure the distance between
the bridge and the hydraulic cylinder at the right and left threaded rod. The distance must be equal on either side.
The contact surface of the support ring must rest level on the supporting surface of the steering knuckle.
Risk of damage to mandrel and steering knuckle.
When choosing the appropriate mandrel, bear in mind that its outer diameter must not be too large, otherwise there is a risk that
the mandrel could be pressed into the bore on the steering knuckle.
Risk of damage to mandrel, thrust piece, support ring and steering knuckle.
The press frame must be aligned so as to allow the thrust piece to press precisely centrally against the king pin.
The press frame must be aligned so as to allow the king pin to be pressed into the support ring (inner Ø) without any risk of collision
in case the pin, in its final position, protrudes from of the bearing bore.
The bridge and hydraulic cylinder must be aligned so that they are parallel to each other and at right angles to the threaded rods.
The contact surface of the support ring must rest level on the supporting surface of the steering knuckle.

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1.2 Personal Protective Equipment
ALWAYS wear personal protective equipment when using the king pin press. The king pin press can cause mechanical hazards
leading to injuries such as contusions, cuts or concussions.
EYE PROTECTION (see OSHA 29 CFR 1910.133 and ANSI Z87) designed to protect you from flying debris/parts must
be worn when using the king pin press.
Particles may be ejected at very high speed while working with the king pin press and could cause serious injuries to
your eyes.
SAFETY GLOVES must be worn when using the king pin press.
Working with the king pin press can cause skin abrasions and contusions.
SAFETY SHOES/BOOTS with slip resistant soles and steel-toe caps (see OSHA 29 CFR 1910.136 and ANSI 241) must
be worn when using the king pin press.
Falling parts can cause serious injuries to feet and toes.
1.3 Intended Use
The king pin press is only designed for the pressing in/pressing out of king pins in situ on the vehicle.
The king pin press may only be used for the purpose and in the manner as described in this Instruction Manual.
Any other use can result in severe injuries or even death.
In addition to the instructions in this manual, the general and specific statutory regulations on accident prevention and
environmental protection must be observed and complied with.
1.4 Safe and Proper Use
Take the following safety precautions to prevent injuries and damage that could be caused by improper handling or unsafe use
of the king pin press:
Misuse can result in extremely severe injuries or even death.
Prior to the first commissioning, the king pin press must be checked for technical defects by an expert; and thereafter, this
inspection is to be carried out once a year.
NEVER overload the king pin press.
Before EACH use, visually check the components of the king pin press to make sure they are in good condition. In particular,
check that all bolted connections are properly tightened and that the hydraulic hose, the mandrels, support rings, spacer ring
and thrust piece are in good order and condition.
ALWAYS replace all damaged and worn parts prior to using the king pin press.
Only qualified specialist personnel should be allowed to perform repairs on the king pin press. Repair work must only be
performed with the king pin press switched off and in depressurised condition. (compressed air switched off, pressure in
hydraulic system relieved)
Technical modifications on the king pin press are not allowed.
ONLY use the original spare parts and accessories from GEDORE Automotive on the king pin press.
1.5 Work Environment
Work with the king pin press should only be carried out in a safe and secure work environment.
The workplace should be adequately illuminated.
The workplace should be clean and tidy.
The workplace should be sufficiently large and must be secured.
The workplace should have a solid, level surface.
1.6 Appropriate Users
This Instruction Manual is designed for technicians/mechanics in workshops.
DO NOT allow children to use the king pin press.
Purchasers/employers purchasing the king pin press MUST ensure that any person using the king pin press has read and
understood this Instruction Manual prior to using the king pin press. This Instruction Manual MUST be made available to the
users of the king pin press for reference at all times.

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Instruction Manual EN
2. Product Description
2.1 KL-1000-20 A King Pin Press
Universal application
Designed to press out/press in king pins on lorries.
A King Pin Press (65t)
A1 - Pump Rod
A2 - Pump Sleeve
A3 - Pressure Gauge
A4 - Relief Valve
A5 - Air System Connection
A6 - Quick-Stroke Valve
A7 - Crank
A8 - Tapered Handle
A9 - Threaded Rods
A10 - Hex Nuts
A11 - Bridge (long)
A12 - Tapered Handle
A13 - Hydraulic Cylinder
A14 - Press Frame
B KL-1000-2621-1 Mandrel, Ø 21.5mm, length 95mm
C KL-1000-2630-1 Mandrel, Ø 30mm, length 95mm
D KL-1000-2634-1 Mandrel, Ø 34mm, length 95mm
E KL-1000-2621-2 Mandrel, Ø 21.5mm, length 185mm
F KL-1000-2630-2 Mandrel, Ø 30mm, length 185mm
G KL-1000-2634-2 Mandrel, Ø 34mm, length 185mm
H KL-1000-2621-3 Mandrel, Ø 21.5mm, length 275mm
J KL-1000-2630-3 Mandrel, Ø 30mm, length 275mm
K KL-1000-2890 Support Ring, Ø 90mm
L KL-1000-2863 Support Ring, Ø 63mm
M KL-1000-2290 Spacer Ring for Bridge, Ø 70.5mm
N KL-1000-2758 Thrust Piece, Ø 58mm
O KL-1000-2690 Open-End Spanner, Size (waf) 50mm
3. Preparatory Work
Before the first commissioning of the king pin press, check and confirm
you have all the parts listed in the scope of delivery. Then, read and
follow the mounting instructions.
3.1 Lifting the King Pin Press off the Pallet
CAUTION
The king pin press can cause injuries to feet if dropped.
Always wear safety shoes/boots.
Lift king pin press off the pallet by means of a suitable hoist.
When lifting the king pin press off the pallet, always pay attention
to the centre of gravity of the press.
Place hydraulic cylinder ’A13’ into its lowest possible position.
Lift king pin press off the pallet. (Fig. 1)
3.2 Checking the Delivery.
3.3 Preparing the Vehicle.
Loosen and/or remove parts as necessary in accordance with the
manufacturer's instructions.
3.4 Checking the Components of the King Pin Press.
CAUTION
There is a risk of the hydraulic hose bursting which could lead to an
uncontrolled whipping of the hose as well as hydraulic fluid escaping
at high pressure.
In accordance with DIN 20 066 recommendations, hydraulic
hoses should be replaced after a period of use of 6 years. The
date of manufacture of the hydraulic hose can be found on the
press sleeves of the hose for verification.
Before each use, visually check the components of the king pin
press to make sure they are in good condition. In particular, check
that all bolted connections are properly tightened and that the
hydraulic hose, the mandrels, support rings, spacer ring and thrust
piece are in good order and condition.
KL-1000-20 A
2.2 Technical Data:
•Press capacity:............................................................................ 65t
• Clear width between threaded bolts:.................................... 290mm
• Clear height (max.):.............................................................. 480mm
• Stroke: .................................................................................. 120mm
• Nominal pressure: .................................................................420 bar
• Compressed air connection: ...........................................max.13 bar
• Weight: ....................................................................... approx. 130kg
• Oil fill volume:.......................................................... approx. 3.5 litre
• Noise level:....................................................................... >60 dB(A)
• Support ring ‘K’ for king pin Ø (max.): .................................. 88mm
• Support ring ‘L’ for king pin Ø (max.): ................................... 61mm
Fig. 1: Adjustment features of the king pin press
A13
A3
A
A2
A4
A1
A7
A9
A10
A13
A6
C
B D E FG H J
K L
M
N
Short / 95mm
Medium / 185mm
Lon
g
/ 275mm
A10
A11
A5
A12
A8
A14
O

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3.5 Turning the Bridge ‘A11’ Upside Down
if necessary.
CAUTION
The bridge ’A11’ can cause injuries to feet if dropped.
Always wear safety shoes/boots.
In certain cases, for example due to space constraints, it may be
necessary to turn the bridge ’A11’ on the threaded rods
‘A9’ upside
down.
For this, loosen the two upper hex nuts ’A10’ by means of open-
end spanner ’O’, remove bridge ’A11’ from threaded rods ‘A9’, turn
it upside down and place it back on threaded rods. Next, screw on
again hex nuts ‘A10’ and tighten to 60
Nm. (Fig. 2)
3.6 Manoeuvring the King Pin Press.
CAUTION
When manoeuvring the king pin press, there is a risk of the press
tipping over and causing injuries to your feet.
Always wear safety shoes/boots.
Place hydraulic cylinder ’A13’ into its lowest possible position.
Insert pump rod ’A1’ into retaining bore on the chassis of the press,
secure via tapered handle. You can now manoeuver/move the king
pin press. (Fig. 2)
3.7 Checking the Hydraulic Oil Level and
Topping Up if necessary.
1. To check the level of the hydraulic oil, open relief valve ’A4’ and
completely retract piston rod of hydraulic cylinder ’A13’ (Pressure
on hydraulic cylinder ’A13’ relieved).
2. CAUTION
Risk of hydraulic fluid escaping under pressure from the king pin
press potentially causing eye injuries and skin irritations.
Always wear safety gloves and safety goggles.
Always make sure that system is depressurised before attempting
to check the hydraulic fluid level.
After checking/topping up, completely re-insert oil dipstick into
pump unit.
Unscrew oil dipstick from pump unit and check oil level.
After checking/topping up, completely re-insert oil dipstick into pump
unit.
Note: The oil level should be between the upper and lower mark on
the oil dipstick. (Fig. 3). Top up with hydraulic oil HLP 22 if
necessary.
3.8 Bleeding the Hydraulic Cylinder ’A13’.
1. Close relief valve ’A4’. Insert pump lever ’A1’ into pump
sleeve ’A2’, next operate pump lever ‘A1’ and extend piston rod of
hydraulic cylinder ’A13’ approximately 1
- 2cm.
2. CAUTION
When bleeding the king pin press, there is a risk of hydraulic fluid
escaping under pressure potentially causing eye injuries and skin
irritations.
Always wear safety gloves and safety goggles.
Extend hydraulic cylinder ’A13’ 1-2cm at the most.
Once the bleeding of the king pin press completed, re-insert/fully
tighten grub screw on hydraulic cylinder ‘A13’.
To bleed hydraulic cylinder ’A13’, slightly loosen grub screw in the
centre of retaining bore (piston rod) by means of a 5mm (waf) hex
socket key.(Fig. 4)
Once all air has been eliminated and bubble-free hydraulic fluid
flows from the bore, re-tighten grub screw securely. Next, open relief
valve ’A4’ to relieve pressure on hydraulic cylinder ’A13’.
Fig. 2: Manoeuvring the king pin press.
Fig. 3: Checking the oil level.
Fig. 4: Bleeding the hydraulic cylinder ’A13’.
Grub screw
Upper mark
Lower mark
A4
A13
A10
A11
A9
A
1
Tapered Handle

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Instruction Manual EN
4. King Pin Removal/Installation
The following instructions describe the procedure of removing and
installing a king pin on a Mercedes ACTROS
®
with the specified direction
of removal from bottom to top.
When the direction of removal from top to bottom is required,
procedure follows the same principle with the press frame turned 180°.
4.1 Removing the King Pin.
1. CAUTION
When turning the press frame ‘A14’ upside down, there is a risk of
injuries to hands and fingers.
Always wear safety gloves.
While turning the press frame ‘A14’ upside down, always keep
your hands clear of the press frame and moving parts.
Align crank ‘A7’ relative to pump unit. (Fig. 5 A)
Turn press frame ‘A14’ upside down with the help of a second
person.
Once the press frame in upside-down position, tighten tapered
handle ‘A12’.
ATTENTION
Risk of damage to steering knuckle.
Observe the direction of removal for the king pin specified by the
vehicle manufacturer.
Turn press frame ’A14’ into direction of removal as required by the
vehicle manufacturer. For this, loosen tapered handle ’A12, turn
press frame ’A14’ upside down, re-tighten tapered handle ’A12’.
(Fig. 5 A + B)
2. CAUTION
When positioning the press frame ’A14’, there is a risk of injuries to
hands and fingers.
Always wear safety gloves.
Turn crank ’A7’ in a controlled way to prevent any slippage.
When positioning the press on the steering knuckle, always keep
your hands clear of the press frame ‘A14’.
Crank ’A7’ must only be operated when press frame ’A14’ is in
vertical position.
ATTENTION
Risk of damage to king pin press.
Regularly clean spindle of crank ‘A7’ and lubricate with
molybdenum disulphide paste such as KL-0014-0030
(accessory).
Mount king pin press on steering knuckle as shown in Fig. 6. Adjust
press frame ‘A14’ to the required height by turning crank ‘A7’.
3. ATTENTION
Risk of damage to mandrel ’B’-’J’ and steering knuckle.

When choosing the mandrel, bear in mind that its outer diameter
must not be too large, otherwise there is a risk that mandrel ‘B’-
’J’ could be pressed into the bore on steering knuckle.
To identify suitable mandrel, measure the retaining bore inner Ø.
(Fig. 7 A).
Note: Always use the mandrel with the largest possible diameter.
Remember that the Ø of the mandrel must be approximately 2-3mm
less than the retaining bore inner Ø.
Start removing the king pin using the shortest mandrel possible.
Then, withdraw and replace the mandrel with the next longer one.
Continue in this way until king pin is extracted.
4. ATTENTION
Risk of damage to support ring ’K’ or ‘L + M’ and king pin press.

When choosing the support ring, bear in mind that its internal
diameter must not be too small, otherwise there is a risk that the
king pin, while being pressed out, could get stuck in support
ring ’K’ or ‘L + M’.
To identify suitable support ring, measure the king pin outer Ø.
(Fig. 7 B)
Note: The support ring inner Ø should be approximately 2-3mm
greater than the king pin outer Ø.
Fig. 5: Turning the press frame ‘A14’ upside down
if necessary.
Fig. 6: Positioning the king pin press on vehicle axle.
Fig. 7: Identifying the correct mandrel and support ring.
“A“ “B“
A12
A14
“A“ “B“
A7
A14
A7