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)

1000-20Ae190211.docx ©Copyright by GEDORE Automotive GmbH, Germany
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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

1000-20Ae190211.docx ©Copyright by GEDORE Automotive GmbH, Germany
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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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Instruction Manual EN
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.