KLANN KL-0039 Series User manual

Wheel Bearing Tool
Spezial-Werkzeugbau GmbH
0039-Radlagere110609.doc
KL-0039-..Series
KLANN-Spezial-Werkzeugbau-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.klann-online.de
KLANN France
GEDORE-KLANN FRANCE SARL
10, rue du Bois du Pont – Bâtiment 6
Parc d'activités des Béthunes
BP 79144 - Saint-Ouen-L'Aumône
95074 CERGY PONTOISE CEDEX
FRANCE
Tél: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.gedore.fr
KLANN UK
KLANN Tools Ltd.
Marton Street
BD23 1TF
Skipton, North Yorkshire
UNITED KINGDOM
Phone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.klanntools.co.uk

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Chapter 3
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Instruction Manual
English
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Instruction Manual
Contents
1. Essential Safety Notices .............................................................................................4
1.1 Safety Notices and Warnings .......................................................................................................................... 4
1.2 Personal Protective Equipment ...................................................................................................................... 5
1.3 Intended Use..................................................................................................................................................... 5
1.4 Safe and Proper Use ........................................................................................................................................ 5
1.5 Work Environment ........................................................................................................................................... 5
1.6 Appropriate Users............................................................................................................................................ 5
2. Product Description KL-0039-..Series Wheel Bearing Tool ...................................6
2.1 Mechanical Drive.............................................................................................................................................. 6
2.2 Hydraulic Drive................................................................................................................................................. 6
2.3 Supporting-, Pressure-, and Centring Parts .................................................................................................. 7
3. Preparatory Work.........................................................................................................8
3.1 Checking the Delivery...................................................................................................................................... 8
3.2 Securing the Tool against Falling ................................................................................................................... 8
3.3 Preparing the Vehicle....................................................................................................................................... 8
3.4 Lift vehicle and loosen and/or remove all necessary components.............................................................. 8
3.5 Wheel Hub Removal......................................................................................................................................... 8
4. Wheel Bearing Removal..............................................................................................8
4.1 Determination of Tool Components................................................................................................................ 8
4.2 Removing a Wheel Bearing by means of the Mechanical Drive................................................................... 9
4.3 Removing a Wheel Bearing by means of the Hydraulic Drive.................................................................... 10
5. Wheel Bearing Installation........................................................................................11
5.1 Determination of Tool Components...............................................................................................................11
5.2 Installing a wheel bearing by means of the mechanical drive.....................................................................11
5.3 Installing a wheel bearing by means of the Hydraulic Drive ......................................................................12
6. Wheel Hub Installation ..............................................................................................13
6.1 Determination of Tool Components.............................................................................................................. 13
6.2 Installing a Wheel Hub by means of the Mechanical Drive.........................................................................13
6.3 Installing a Wheel Hub by means of the Hydraulic Drive............................................................................ 14
7. Care and Storage.......................................................................................................15
8. Accessories ...............................................................................................................15
9. Maintenance and Repair by the KLANN Service Centre .......................................15
10. Components List .......................................................................................................16

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Instruction Manual
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 subsequent users of the Wheel Bearing Tool.
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, as well as when installing wheel hubs by means of a hydraulic drive, there is
the risk that the pull spindle could break and fall to pieces. This will lead to parts or the pull spindle becoming projectiles.
• Observe and do not exceed the maximum load capacity of the pull spindle.
• Use hydraulic pump with pressure gauge KL-0040-2529.
• Only use Original KLANN spare parts.
• Always keep all parts of your body away from the axial extension of the pull spindle.
DANGER
When removing and installing wheel bearings, as well as when installing wheel hubs by means of a mechanical drive, there is
the risk that the pull spindle could break and fall to pieces. This will lead to parts or the pull spindle becoming projectiles.
• Observe and do not exceed the maximum load capacity of the pull spindle.
• Only use Original KLANN spare parts.
• Always keep all parts of your body away from the axial extension of the pull spindle.
CAUTION
A falling tool can cause injuries.
• Always wear safety shoes / boots.
• Mechanical drive: Secure the tool by means of safety belt KL-0040-2590 and adaptor KL-0040-2591 (accessories) against
falling.
• Hydraulic drive: Secure the tool by means of safety belt KL-0040-2590 (accessories) against falling.
ATTENTION
Risk of damage to the pull spindle.
• Lubricate pull spindle with molybdenum disulphide paste KL-0014-0030.

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1.2 Personal Protective Equipment
ALWAYS wear personal protective equipment when using the wheel bearing tool. The wheel bearing tool can cause
mechanical hazards which could result in serious injuries such as contusions, cuts and 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.
1.3 Intended Use
The wheel bearing tool must only be used for removing and installing wheel bearings, and for installing wheel hubs.
The wheel bearing tool may only be used according to the directions and provisions specified in the instruction 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 exceed the load capacity of the wheel bearing tool.
• NEVER attempt to drive both clamping nut and spindle at the same time. (Risk of pull spindle overload)
• Do not use an impact wrench or any extensions!
• Damaged or worn parts MUST be replaced prior to use.
• ONLY use KLANN Original replacement and accessory parts for 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.

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2. Product Description:
KL-0039-..Series Wheel Bearing Tool
2.1 Mechanical Drive
KL-0040-3008 Pull Spindle M20
Overall length: .......................................................................... 290 mm
Drive:................................................................................. (waf) 19 mm
Max. load:........................................................................................ 20 t
KL-0039-2030 Pull Spindle M20
Overall length: .......................................................................... 420 mm
Drive:................................................................................. (waf) 19 mm
Max. load:........................................................................................ 20 t
KL-0040-3009 Clamping Nut M20
Overall length: ............................................................................ 50 mm
Drive:................................................................................. (waf) 30 mm
KL-0039-1011 Retainer Adaptor
for Mechanical Spindle
This tool is necessary to retain the various KL-0039-.. or KL-0043-..
press/support sleeves if these are to be inserted by using the
mechanical drive.
The built-in ball bearing allows for accurate and professional working,
even under intensive load.
KL-0039-1002 Retainer Adaptor
for Clamping Nut and Pressure Spindle
This adaptor is designed to retain the various pressure-/support
sleeves of the KL-0039-.. or KL-0043-..Series.
Locating-Ø for clamping nut or pressure spindle: ....................... 20 mm
2.2 Hydraulic Drive
KL-0040-2500 Hydraulic Cylinder
Due to its special design as a tubular piston cylinder and the possibility
to be used in conjunction with various spindles, the hydraulic cylinder
KL-0040-2500 is suitable for pulling and pushing operations.
Note: Hydraulic pump KL-0215-35 M25 (accessory) is required to
drive the hydraulic cylinder.
KL-0039-1920 Pull Spindle M20 with Clamping Nut
Overall length: .......................................................................... 590 mm
Working travel: ......................................................................... 390 mm
Max. load:........................................................................................ 20 t
KL-0039-1003 Retainer Adaptor
for Hydraulic cylinder
This tool is necessary to retain the various KL-0039-.. or KL-0043-..
pressure-/support sleeves if these are to be inserted by using the
hydraulic cylinder KL-0040-2500.
(Connecting thread: M42 x 2)
KL-0039-1002 Retainer Adaptor
for Clamping Nut and Pressure Spindle
This adaptor is designed to retain the various pressure-/support
sleeves of the KL-0039-.. or KL-0043-..Series.
Locating-Ø for clamping nut or pressure spindle: ....................... 20 mm
Fig. 1: KL-0040-3008 Pull Spindle M20
Fig. 2: KL-0039-2030 Pull Spindle M20
Fig. 3: KL-0040-3009 Clamping Nut M20
Fig. 4: KL-0039-1011 Retainer Adaptor
for mechanical spindle
Fig. 5: KL-0039-1002 Retainer Adaptor
for clamping nut and pressure spindle
Fig. 6: KL-0040-2500 Hydraulic Cylinder
Fig. 7: KL-0039-1920 Pull Spindle with clamping nut M20
Fig. 8: KL-0039-1003 Retainer Adaptor
for hydraulic cylinder
Fig. 9: KL-0039-1002 Retainer Adaptor
for clamping nut and pressure spindle
Connection 3/8"
Thread M42 × 2
Thread
2¼"-14UNS
Pulling side
Pushing side

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2.3 Supporting-, Pressure-, and Centring
Parts
Support
KL-0039-14.. Centring Rings for Housing
Designed to support the housing of the wheel bearing tool on
the wheel bearing housing.
Part No. Inner-∅
∅∅
∅
KL-0039-1413............................................................... Ø70 mm
KL-0039-1414............................................................... Ø75 mm
KL-0039-1415............................................................... Ø80 mm
KL-0039-1402 Housing
Suitable for bearing Ø of up to 90 mm.
KL-0039-1401 Bearing Cover
This tool enables centred power transmission from drive to
housing.
Pressure Rings
KL-0039-12.. Pressure Rings
These rings allow for the accurate pressure force transmission
to the outer bearing race or inner bearing race.
The pressure ring set KL-0039-120 includes the dimensions
from Ø54 mm up to Ø90 mm in 32 gradations.
Centring Rings
KL-0039-13.. Centring Rings
The centring rings ensure the accurate guiding of the wheel
bearing throughout the removal and installation process.
The centring ring set KL-0039-130 includes the dimensions
from Ø25 mm up to Ø60 mm in 36 gradations.
Fig. 10: KL-0039-14.. Centring Rings for Housing
Fig. 11: KL-0039-1402 Housing
Fig. 12: KL-0039-1401 Bearing Cover
Fig. 13: KL-0039-12.. Pressure Rings
Fig. 14: KL-0039-13.. Centring Rings

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Instruction Manual
3. Preparatory Work
Before using the wheel bearing tool for the first time, check and
confirm you have all parts listed in the scope of delivery. Then,
follow the mounting instructions.
3.1 Checking the Delivery (see pages 16 - 23)
3.2 Securing the Tool against Falling.
Mechanical drive: Fasten safety belt KL-0040-2590
(accessory) with adaptor KL-00400-2591 (accessory) to
retainer adaptor KL-0039-1011. (Fig. 15 A)
Hydraulic drive: Fasten safety belt KL-0040-2590
(accessories) to hydraulic cylinder KL-0040-2500.
(Fig. 15 B)
3.3 Preparing the Vehicle.
3.4 Lift vehicle and loosen and/or remove all
necessary components.
3.5 Wheel Hub Removal
1. Remove the wheel hub either by means of wheel hub
puller KL-0041-380 (accessory) or by means of puller set
KL-0174-110 (accessory) in conjunction with slide
hammer KL-0049-31 (accessory).
2. Remove retaining rings.
4. Wheel Bearing Removal
These instructions describe how to identify the correct tool
components, and how to remove a wheel bearing from the
wheel bearing housing (by means of the mechanical or
hydraulic drive).
4.1 Determination of Tool Components
1. Centring ring for wheel bearing housing
ATTENTION
Risk of damage to the centring ring for housing.
• The inner diameter of the centring ring should not be
chosen too small as there is the risk that the dismounted
wheel bearing could get stuck in the centring ring.
Identifying the correct centring ring.
⇒For this, measure the outer-Ø of the wheel bearing.
(Fig. 16 A)
The correct centring ring inner-Ø results from the wheel
bearing outer-Ø +approx. 2 to 3 mm.
2. Pressure ring for wheel bearing
ATTENTION
Risk of damage to the pressure ring and wheel bearing
housing.
• The pressure ring outer-Ø has to be smaller than the
smallest inner-Ø of the wheel bearing locating bore,
otherwise the pressure ring will be pressed into the wheel
bearing housing.
When removing a wheel bearing, be sure to use the flat
side of the pressure ring.
Identifying the correct pressure ring.
⇒Identify the correct pressure ring by trying. (Fig. 16 B)
Fig. 15: Securing the tool against falling.
Fig. 16: Identifying the dimensions: Wheel bearing removal
“A“
Wheel
bearing-
outer-∅
∅∅
∅
Wheel
bearing
Centring
ring
Centring ring-
inner-∅
∅∅
∅
Identifying the centring ring for wheel bearing housing
Identifying the pressure ring for wheel bearing
“B“
Pressure ring outer-Ø smaller than
wheel bearing housing inner-Ø
KL-0040-2591
(Accessory)
Hydraulic cylinder
“B“ hydraulic drive
KL-0040-2590
(Accessory)
KL-0040-2591
(Accessory)
“A“ mechanical drive
Retainer Adaptor
f. mech. spindle

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4.2 Removing a Wheel Bearing by means of the
Mechanical Drive
1. ATTENTION
Risk of damage to the centring ring for housing.
• Align the centring ring with the housing so that the
dismounted wheel bearing can be inserted into the
centring ring inner-Ø without risk of collision.
• The contact surface of the centring ring must be even and
parallel to the wheel bearing.
Please note that the minimum contact surface consists of
two points which are level with each other and displaced
by 180°.
Mount the tool using the tool components as determined
under point 4.1 on the wheel bearing housing as shown in
Fig. 17 A.
2.
DANGER
When removing wheel bearings by means of the
mechanical drive, there is the risk that the pull spindle
could break and fall to pieces. This will lead to parts or the
pull spindle becoming projectiles.
• Observe and do not exceed the maximum load capacity
of the pull spindle.
• Only use Original KLANN spare parts.
• Always keep all parts of your body away from the axial
extension of the pull spindle.
Remove the wheel bearing by turning the spindle by means
of a spanner (size waf) 19 mm. (Fig. 17 B)
Note: Lock the opposite clamping nut by means of a
spanner (size waf) 30 mm.
3. Remove tool with the dismounted wheel bearing from the
wheel bearing housing.
Fig. 17: Wheel bearing removal (mechanical drive)
Pressure
ring
Centring ring
for
housing
Pull spindle
Bearing cover
“A“
Retainer adapto
r
for mech. spindle
Housing Retainer adapto
r
for clamping nut
Clamping
nut
Wheel bearing
housing
“B“
KL-0040-2590
(Accessory)
KL-0040-2591
(Accessory)

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4.3 Removing a Wheel Bearing by means of the
Hydraulic Drive
Note:
The hydraulic drive without hydraulic cylinder KL-0039-802,
hydraulic cylinder KL-0040-2500 and hydraulic hand pump
KL-0215-35 M25 will be required.
1.
ATTENTION
Risk of damage to the centring ring for housing.
• Align the centring ring with housing so that the extracted
wheel bearing can be inserted into the centring ring
inner-Ø without risk of collision.
• The contact surface of the centring ring must be even and
parallel to the wheel bearing.
Please note that the minimum contact surface consists of
two points which are level with each other and displaced
by 180°.
Mount the tool using the tool components as determined
under point 4.1 on the wheel bearing housing as shown in
Fig. 18 A.
2. Connect hydraulic cylinder to hydraulic pump (accessory).
3.
DANGER
When removing wheel bearings by means of 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 or the pull spindle 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 KLANN spare parts.
• Always keep all parts of your body away from the axial
extension of the pull spindle.
Operate hydraulic pump and remove wheel bearing.
(Fig. 18 B) During the removal process, read the required
force on the pressure gauge of the hydraulic pump.
4. Remove tool with the dismounted wheel bearing from the
wheel bearing housing.
Fig. 18: Wheel bearing removal (hydraulic drive)
“B“
17 t
KL-0040-2590
(Accessory)
“A“
KL-0040-2500
Housing
Clamping
nut
Pressure
ring
Pull spindle
Bearing
cover
Retainer adapto
r
for hydr. cyl. Retainer adapto
r
for clamping nut
Centring ring
for
housing