Gedore KL-0014-46D User manual

GEDORE Automotive GmbH
Breslauer Straße 41 Postfach 1329 Tel.: +49 (0) 771 / 8 32 23-0 E-Mail: [email protected]
78166 Donaueschingen 78154 Donaueschingen - GERMANY Fax: +49 (0) 771 / 8 32 23-90 Internet: gedore-automotive.com
0041-46De121211_g.docx
KL-0041-46 D
KL-0041-460
KL-0041-461
Wheel Bearing Tool, Ø78 mm and Ø82 mm,
with hydraulic cylinder

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© Copyright by GEDORE Automotive GmbH, Germany
Product Information
English 11 - 17
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 KLANN-Spezial-Werkzeugbau GmbH.
Alle Rechte weltweit vorbehalten.
Wir verweisen auf unsere Allgemeinen Geschäftsbedingungen, ersichtlich im Impressum unter www.klann-online.de.
© Copyright by KLANN-Spezial-Werkzeugbau GmbH Donaueschingen
Legal Notice
Due to continuous improvements 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 the right to legal claim.
All indications regarding use and safety are given for information only and without any commitment. In no case do they substitute legal provisions or the regulations
of the Employer’s Liability Insurance Association.
Errors and omissions excepted.
All information and technical data in this document were compiled with the utmost care. However, KLANN assumes no responsibility for possible errors and omissions.
Any reproduction, also in extracts, is subject to the prior and written consent of KLANN Spezial-Werkzeugbau-GmbH.
All rights reserved.
We refer to our General Terms and Conditions of Sale under ‘Legal Notice’ at www.klann-online.de.
© Copyright by KLANN Spezial-Werkzeugbau-GmbH Donaueschingen
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 sans préavis 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 KLANN Spezial-Werkzeugbau GmbH.
Tous droits réservés.
Vous trouverez nos conditions générales de vente, sous Impressum/ Mentions légales sur www.klann-online.de.
© Copyright by KLANN-Spezial-Werkzeugbau GmbH Donaueschingen

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© Copyright by GEDORE Automotive GmbH, Germany
Product Information
Contents
1. Essential Safety Notices ...................................................................................................12
1.1 Safety Notices and Warnings...................................................................................................................................... 12
1.2 Personal Protective Equipment .................................................................................................................................. 12
1.3 Intended Use................................................................................................................................................................. 13
1.4 Safe and Proper Use .................................................................................................................................................... 13
1.5 Work Environment........................................................................................................................................................ 13
1.6 Appropriate Users........................................................................................................................................................ 13
2. Product Description...........................................................................................................14
2.1 KL-0041-46 D - Wheel bearing tool Ø78 mm and Ø82 mm, with hydraulic cylinder ............................................... 14
2.2 Technical Data .............................................................................................................................................................. 14
3. Preparatory Work...............................................................................................................14
3.1 Checking the Delivery (Fig.1) ...................................................................................................................................... 14
3.2 Preparing the Vehicle................................................................................................................................................... 14
4. Wheel Hub Bearing Unit Installation ................................................................................15
5. Care and Storage...............................................................................................................16
6. Accessories........................................................................................................................17
7. Maintenance and Repair by the GEDORE Automotive Service Centre........................17
8. Spare Parts List..................................................................................................................17
9. Environmentally Safe Disposal.........................................................................................17

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© Copyright by GEDORE Automotive GmbH, Germany
Product Information
1. Essential Safety Notices
Before using the wheel bearing tool, it is imperative to read and understand the instruction manual. Misuse can lead to SERIOUS
or FATAL INJURIES.
This instruction manual is part of the wheel bearing tool. Store the instruction manual in a safe place for any further use and
give it to the subsequent users of the wheel bearing tool.
All specific vehicle 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 Meaning
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 wheel bearing
tool or its functioning, or to objects in its vicinity.
DANGER
When removing and installing wheel bearings, there is the risk that the tool could break and fall to pieces. This will lead to parts
becoming projectiles.
Observe and do not exceed the maximum load capacity of the tool.
Use hydraulic pump with pressure gauge KL-0040-2529.
Only use Original GEDORE AUTOMOTIVE spare parts.
Always keep all parts of your body away from the axial extension of the tool.
CAUTION
A falling tool can cause injuries.
Always wear safety shoes / boots.
ATTENTION
Risk of damage to the vehicle and tool.
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.
Only the vehicle manufacturer’s data apply to any work on the vehicle.
1.2 Personal Protective Equipment
ALWAYS wear personal protective equipment when using the wheel bearing tool. The wheel bearing tool 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 objects must be
worn when using the wheel bearing tool.
Particles may be ejected at high speed while working with the wheel bearing tool and could cause serious injuries to
your eyes.
SAFETY GLOVES must be worn when using the wheel bearing tool.
Working with the wheel bearing tool 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 wheel bearing tool.
Falling parts can cause serious injuries to feet and toes.

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Product Information
1.3 Intended Use
The wheel bearing tool should only be used for installing wheel hub bearing units on vehicles with bearing-Ø78 mm, e.g. Ford
Focus II, C-Max (from 10/03 onwards); Mazda 3 (from 10/03 until 06/09) Volvo C30, C70 II, S40 II, V50, and vehicles with
bearing-Ø82 mm, e.g. Ford S-Max (from 2006 onwards), Galaxy (from 2006 onwards), Mondeo IV (from 2006 onwards); Volvo
S60 II, S80 II, V60, V70 III (from 10/2007 onwards), XC60, XC70 II.
The wheel bearing tool may only be used in accordance with the instructions specified in this manual.
Any other use can result in severe injuries or even death.
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 wheel bearing tool:
Misuse can result in extremely severe injuries or even death.
NEVER overload the wheel bearing tool.
Always check the wheel bearing tool prior to EACH use to ensure that it is in good order and condition.
Damaged or worn parts MUST be replaced prior to use.
ONLY use Original GEDORE AUTOMOTIVE spare parts and accessories on the wheel bearing tool.
1.5 Work Environment
Work with the wheel bearing tool should only be carried out in a safe work environment.
The workplace must always be clean and tidy.
The workplace must be sufficiently large and secured.
1.6 Appropriate Users
This instruction manual is designed for technicians in workshops.
DO NOT allow children to use the wheel bearing tool.
Purchasers / employers purchasing the wheel bearing tool MUST ensure that any person / employee using the wheel bearing
tool have read and understood this instruction manual prior to using the tool. This instruction manual MUST be made available
to the users of the wheel bearing tool for reference at all times.

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Product Information
2. Product Description
2.1 KL-0041-46 D -Wheel bearing tool
Ø78 mm and Ø82 mm,
with hydraulic cylinder
Suitable for vehicles with bearing-Ø78 mm, e.g. Ford Focus
II, C-Max (from 10/03 onwards); Mazda 3 (from 10/03 until
06/09) Volvo C30, C70 II, S40 II, V50
and vehicles with bearing-Ø82 mm, e.g. Ford S-Max (from
2006 onwards), Galaxy (from 2006 onwards), Mondeo IV
(from 2006 onwards); Volvo S60 II, S80 II, V60, V70 III (from
10/2007 onwards), XC60, XC70 II.
Designed for the professional installation of wheel hub bearing
units in-situ on the vehicle. Due to its special design, this tool
ensures that during the installation process the applied pressing
force will only be distributed on the outer bearing race and not
on the wheel hub. This prevents damage to the bearing.
Note: A hydraulic pump is needed to drive the hydraulic cylinder
KL-0040-2500.
Pos. Part No. Description Make and Model
Focus,
C30,
C70
S40,
V50
Mazda
3 S-Max, Galaxy
Mondeo
S60,
S80,
V60,
V70,
XC60,
XC70
Wheel nuts Wheel
bolts
1 KL-0040-2500 Hydraulic cylinder X X X X
2 KL-0039-1002 Retainer adaptor for
clamping nut X X X X
3 KL-0039-1003 Retainer adaptor for
hydraulic cylinder X X X X
4 KL-0040-3009 Clamping nut X X X X
5 KL-0039-1920-1 Pull spindle X X X X
6 KL-0041-4601 Guide sleeve
Ø29.5 mm X X
7 KL-0041-4602 Guide sleeve
Ø26.3 mm X X
8 KL-0041-4608 D Cover X X X
9 KL-0041-4607 Housing X X X
10 KL-0041-4600 D Clamping jaws
(pair) Ø78 mm X X X X
11 KL-0041-3931 Pressure screw
M14x1.5 (5 pcs.) X
12 KL-0039-1272 Pressure ring
Ø72 mm X
13 KL-0039-1288 Pressure ring
Ø88 mm X X X
14 KL-0039-1682 Support sleeve
Ø82 mm X
2.2Technical Data
Maximum load capacity of the pull spindle: ........................20 t
Maximum load capacity of the hydraulic cylinder:...............17 t
3. Preparatory Work
Before the first commissioning of the wheel bearing tool, check
and confirm you have all the parts listed in the scope of delivery.
Then, read and follow the mounting instructions.
3.1 Checking the Delivery (Fig. 1)
3.2 Preparing the Vehicle
Loosen and/or remove all necessary components.
Use wheel hub puller KL-0041-38 (accessory) to remove
the wheel hub bearing unit. (Fig. 2)
Note: Use safety belt KL-0040-2590 (accessory) to
prevent tool from falling.
Fig. 1: KL-0041-46 D
Fig. 2: Wheel Hub Bearing Unit Removal.
Fig. 3: Wheel Hub Bearing Units
Wheel nut system Wheel bolt system
(Technique 1) (Technique 2)
KL-0041-38 (Accessory)
KL-0040-2590 (Accessory)
KL-0041-461 D
KL-0041-460 D 1
2 3
4 5
6 7 8 910
11 12 13 14
11
11 11 11

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Product Information
4. Wheel Hub Bearing Unit Installation
These instructions describe the procedure of installing a wheel
hub bearing unit.
Technique 1 (Wheel Nuts)
1. ATTENTION
Risk of damage to pair of clamping jaws “10“ and wheel hub
bearing unit.
Make sure that clamping jaws "10" are correctly positioned
on the wheel hub bearing unit.
Mount clamping jaws “10“ to wheel hub bearing unit as
shown in Fig. 4.
2. Mount tool to wheel bearing housing and secure with wheel
nuts as shown in Fig. 5 and 6.
Note: Do not tighten the wheel nuts.
3. Connect hydraulic cylinder “1“ to hydraulic pump
(accessory).
4.
DANGER
When installing wheel hub bearing units with the aid of the
hydraulic cylinder KL-0040-2500 (accessory), there is the
risk that the pull spindle could break and fall to pieces. This
will lead to parts becoming projectiles.
Observe and do not exceed the maximum load capacity of
the pull spindle and hydraulic cylinder.
Use hydraulic pump with pressure gauge KL-0040-2529.
Only use Original GEDORE AUTOMOTIVE spare parts.
Always keep all parts of your body away from the axial
extension of the pull spindle.
Operate hydraulic pump and install wheel hub bearing unit.
(Fig. 6)
During the installation process, read the required force on
the pressure gauge of the hydraulic pump.
5. Stop the installation process as soon as the wheel hub
bearing unit has reached its correct position.
6. Remove tool from wheel bearing housing. Check position of
wheel hub bearing unit and reassemble vehicle according to
the manufacturer's directions and instructions.
Technique 1 (wheel nuts)
Fig. 4: Mount clamping jaws.
Fig. 5: Mount tool.
Fig. 6: Install Wheel Hub Bearing Unit.
10
10
1
35
5x wheel nut
4214 1
3
98
5
17 t
10
4 2 14
Guide sleeve:
See table on page 6
542
1
3
8
9
10
17 t
13
4 2 13
Guide sleeve:
See table on page 6
8
9
10
“A“ Ford, Volvo
“B“ Mazda 3

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© Copyright by GEDORE Automotive GmbH, Germany
Product Information
Technique 2 (Wheel Bolts)
7. ATTENTION
Risk of damage to pair of clamping jaws “10“ and wheel hub
bearing unit.
Make sure that clamping jaws "10" are correctly positioned
on the wheel hub bearing unit.
Mount clamping jaws “10“ to wheel hub bearing unit as
shown in Fig. 7.
8. Uniformly screw in pressure screws “11” into wheel hub until
the pressure heads of the screws engage and fit the groove
of the clamping jaws (Fig. 8 A). By hand, uniformly tighten
pressure screws in a crosswise sequence. (Fig. 8 B).
Note: If necessary, check to make sure that screws are level
with each other using a vernier calliper.
9. Mount tool to wheel bearing housing as shown in Fig. 9.
10.Connect hydraulic cylinder “1“ to hydraulic pump
(accessory).
11. DANGER
When installing wheel hub bearing units with the aid of the
hydraulic cylinder KL-0040-2500 (accessory), there is the
risk that the pull spindle could break and fall to pieces. This
will lead to parts becoming projectiles.
Observe and do not exceed the maximum load capacity of
the pull spindle and hydraulic cylinder.
Use hydraulic pump with pressure gauge KL-0040-2529.
Only use Original GEDORE AUTOMOTIVE spare parts.
Always keep all parts of your body away from the axial
extension of the pull spindle.
Operate hydraulic pump and install wheel hub bearing unit.
(Fig. 9)
During the installation process, read the required force on
the pressure gauge of the hydraulic pump.
12.Stop the installation process as soon as the wheel hub
bearing unit has reached its correct position.
13.Remove tool from wheel bearing housing. Check position of
wheel hub bearing unit and reassemble vehicle according to
the manufacturer's directions and instructions.
5. Care and Storage
ATTENTION: Petroleum ether and chemical solvents can
damage plastic parts. Always clean all parts after their use with
a clean cloth only.
In order to protect against corrosion, lightly lubricate all metal
parts after their use and store them in a clean and dry place.
Technique 2 (wheel bolts)
Fig. 7: Mount clamping jaws.
Fig. 8: Mount pressure screws.
Fig. 9: Mount tool.
Install wheel hub bearing unit
“B“
“A“
“A“ Uniformly screw pressure screws into wheel hub.
“B“ Uniformly tighten pressure screws by hand.
10
10
4 2 13
Guide sleeve:
See table on page 6
425
1
12 3
10
13
17 t
Pressure
head
Groove
11
11
11
11 11

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Product Information
6. Accessories
KL-0215-35 M25 Hydraulic Hand Pump
The hydraulic hand pump KL-0215-35 M25 is used to drive the hydraulic
cylinder KL-0040-2500.
KL-0041-380 Wheel Hub Puller with Adjusting
Spindle,
without Hydraulic Cylinder (German Utility Model)
The wheel hub puller: KL-0041-380 enables the quick, safe, and
accurate extraction of wheel hub bearing units or wheel hubs. For this,
the hydraulic cylinder KL-0040-2500 and pull spindle M20 x 550 mm
KL-0039-1920-1 are necessary. Even bonded, seized or corroded
wheel hub bearing units or wheel hubs are no longer an issue thanks to
this tool.
Due to its special design, the wheel hub puller allows the extraction of a
wide range of different wheel hubs equipped with diameters of up to 250
mm.
Note: The plates KL-0041-3821 and KL-0041-3822 are used as
distance adjustment plates. They are needed if during the removal of a
wheel hub it is necessary to support on the rear side of the hooks and if
the supporting surface is not even.
KL-0040-2590 Safety Belt
By fastening the safety belt KL-0040-2590 to the vehicle and to the
hydraulic cylinder KL-0040-2500, the latter is prevented from falling.
7. Maintenance and Repair by the
GEDORE AUTOMOTIVE Service Centre
For safety reasons, as soon as damage is noticed on the wheel bearing
tool, immediate steps must be taken to prevent it from being used. For
professional checking and repair of the tool, please contact the
GEDORE AUTOMOTIVE Service Centre.
Address:
GEDORE AUTOMOTIVE GmbH
Breslauerstr. 41
DE-78166 Donaueschingen
Phone: [phone]
Email: [email protected]
For additional information concerning the use of our wheel bearing tool,
please contact the GEDORE AUTOMOTIVE Service Centre.
8. Spare Parts List
Pos. Part No. Description Qty.
KL-0041-46 D Wheel bearing tool with hydr. cyl. 1
bestehend aus:
KL-0041-460 D Wheel bearing tool without hydr. cyl. 1
1 KL-0040-2500 Hydraulic cylinder 17 t 1
Pos. Part No. Description Qty.
KL-0041-460 D Wheel bearing tool without hydr. cyl. 1
bestehend aus:
KL-0041-461 D Upgrade Kit Volvo, Ford, Mazda 1
2 KL-0039-1003 Retainer adaptor for hydraulic cylinder 1
3 KL-0039-1002 Retainer adaptor for clamping nut 1
4 KL-0040-3009 Clamping nut, M20 1
5 KL-0039-1920-1 Pull spindle M20 1
Pos. Part No. Description Qty.
KL-0041-461 D Upgrade Kit Volvo 1
bestehend aus:
6 KL-0041-4602 Guide sleeve Ø26.3 mm 1
7 KL-0041-4601 Guide sleeve Ø29.5 mm 1
8 KL-0041-4608 D Cover 1
9 KL-0041-4607 Housing 1
10 KL-0041-4600 D Clamping jaws (pair) Ø78 mm 1
11 KL-0041-3931 Pressure screw M14x1.5 5
12 KL-0039-1272 Pressure ring Ø72 mm 1
13 KL-0039-1288 Pressure ring Ø88 mm 1
14 KL-0039-1682 Pressure-/support sleeve (short) Ø82 mm 1
9. Environmentally Safe Disposal
Dispose of the wheel bearing tool and its packaging material in
compliance with the legal rules and regulations in force.
Fig. 10: Accessory: KL-0215-35 M25
Fig. 11: Accessory: KL-0041-380
Fig. 12: Accessory: KL-0040-2590
Fig. 13: Spare parts: KL-0041-46 D
KL-0041-461 D
KL-0041-460 D 1
2 3
4 5
6 7 8 9 10
11 12 13 14
11
11 11 11

GEDORE Automotive GmbH
Breslauer Strasse 41
78166 Donaueschingen
Postfach 1329
78154 Donaueschingen - GERMANY
Tel.: +49 (0) 771 / 8 32 23-0
Fax: +49 (0) 771 / 8 32 23-90
E-Mail: [email protected]
Internet: www.gedore.com