KUKKO BA-20-30-120 User manual

BEDIENUNGSANLEITUNG
OPERATING INSTRUCTIONS
Abzieher mit gleitenden, immer parallelen Abzughaken
Pullers with sliding, parallel jaws
20er, 20-1+, 20-10+, 20-2+, 20-20+, 20-3+, 20-30+, 20-1+S, 20-10+S, 20-
2+S, 20-20+S, 20-3+S, 20-30+S, 20-1+S-T, 20-10+S-T, 20-10-V, 20-2+B,
20-20+B, 20-3+B, 20-30+B, 20-3-H, 20-30-H, 20-4-AV, 20-40-AV, 20-5,
20-4-H, 20-40-H, 20-5-H, 20-ST+, 20-ST-S, 219-1, 30er, 30-1+, 30-10+,
30-2+, 30-20+, 30-3+, 30-30+, 30-1+S, 30-10+S, 30-2+S, 30-20+S,
30-3+S, 30-2+B, 30-20+B, 30-3+B, 30-30+B, K-2030-10, K-2030-10+S,
K-2030-10-S, K-2030-10-S-T, K-2030-20, K-2030-20-B, K-2030-20-S, 30-
20+T, 120er, 120-1, 120-10, 120-2, 120-20, 120-3, 120-30, 120-ST,
GÜLTIG FÜR / VALID FOR
A world in motion
since 1919!
AVOID INJURY.
You MUST read and understand these Operating instructions before using the pullers.
VERLETZUNGEN VERMEIDEN.
Sie müssen diese Bedienungsanleitung lesen und verstehen, bevor Sie die Abzieher benutzen.
Version
BA-20-30-120-2017-02-28
BA-20-30-120
KUKKO Werkzeugfabrik
Kleinbongartz & Kaiser oHG
Heinrich-Hertz-Str. 5
40721 Hilden (Germany)
www.KUKKO.com
EN
ES
DE
FR

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Table of content
1. Important Safety Information .............................................................................................................4
1.1. Safety Warnings ..................................................................................................................................4
1.2. Personal Protective Equipment............................................................................................................5
1.3. Intended Use .......................................................................................................................................5
1.4. Handling..............................................................................................................................................5
1.5. Work Environment...............................................................................................................................5
2. Product Description.............................................................................................................................6
3. Preparing the Puller for Use ................................................................................................................6
3.1. Assembling the forcing screw..............................................................................................................6
3.2. Assembling the Jaws on the Crossarm ................................................................................................6
3.3. Clamping the Jaws on the Crossarm ....................................................................................................7
4. Safety Use............................................................................................................................................8
4.1. Setting for Pulling ...............................................................................................................................8
4.2. The Pulling Process..............................................................................................................................9
5. Removing the Puller............................................................................................................................9
6. Care and Storage ...............................................................................................................................10
7. Optional Accessories .........................................................................................................................10
8. Maintenance Repair...........................................................................................................................10
9. Environmentally Friendly Disposal ....................................................................................................10
10. Technical Data ...................................................................................................................................10
11. Customer Service...............................................................................................................................10

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1. Important Safety Information
Read and understand these Operating instructions before using the puller. SERIOUS
INJURIES or DEATH can result from incorrect use. The Operating Instructions are part
of the puller. They must be kept in a safe place for later use and be passed along with
the puller it it is sold, loaned, or otherwise transferred.
The puller should be used only by TRAINED PERSONNEL who have been taught how
to safely use and handle the puller. Using the puller without proper training may
result in SERIOUS INJURIES or DEATH. If you are unsure of which puller or attachment
to select, or the proper use of the slected puller, contact KUKKO.
1.1. Safety Warnings
Throughout this manual WANING, CAUTION, NOTICE and the SAFETY ALERT SYMBOL
will be used.
Indicated a hazardous situation which, if not avoided, could result in death or serious
injury.
Indicated a hazardous situation which, if not avoided, could result in minor or mod-
erates injury.
Addresses practices not related to personal injury. Relates to property damage or
damage to the puller.
This is the safety alter symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
NOTICE
WARNING
CAUTION
WARNING
OVERLOAD HAZARD
INCORRECT usage and not to OBEY the TECHNICAL DATA (see section 10) can
lead to break during use and cause SERIOUS INJURY or DEATH.
NEVER use electric or pneumatic torque multipliers, impact wrenches or impact
drivers. NEVER lengthen the driver tool for the puller. NEVER hit the drive tool
with a hammer.
WARNING
ELECTRICAL HAZARD
Contact with live electrical parts or circuits could result in SERIOUS INJURY or
DEATH.
ALWAYS DISCONNECT electricity before using puller on or near electrical parts or
circuits.
WARNING
HYDRAULIC HAZARD
Niels, Kevin, Schultes?????????????????????WEITERE????????????????????unten Halle
Was muss bei Hydraulikprodukten beachtet werden?
Welche anderen Gefahrenquellen gibt es bei den Produkten aus dem USA-Sorti-
ment?
TEXT

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1.2. Personal Protective Equipment
Always wear personal protective equipment as listed when using the puller. The
puller can slip or break causing SERIOUS INURIES.
EYE PROTECTION (see ANSI Z87.1) designed to protect you from FLYING OBJECTS
INJURY to your eyes.
• Particles may y upward during work with the puller and cause SERIOUS INJURY
to your eyes.
SAFETY GLOVES must be worn when using the puller.
• The puller can slip or break during use causing SERIOUS INJURY to your ngers
and hands.
SAFETY SHOES with slip-resistant soles and steel toe caps (see ASTM F2413.05) must
be worn when using the puller.
• Falling parts can cause SERIOUS INJURY to your feet and toes.
PROTECTIVE SAFETY COVERS should be utilized when using the puller (see Section 8,
Optional Accessories)
• For added safety, KUKKO highly recommends the use of a Protective Safety Cover
when using the puller.
• High forces exerted on the part being pulled can cause breakage and ying
debris, resulting in SERIOUS INJURIES.
• Safety covers provide maximum active-safety protection from suddenly detach-
ing ball bearings, driving pinions, or other small parts.
1.3. Intended Use
? The puller is designed to remove pulleys, ball bearings, gear wheels, and
other components from shafts and axles.
• DONOTusethepullerforanyotherpurpose.
• MISSUSEcanleadtoSERIOUSINJURYorDEATH.
• DONOTallowchildrentousethepuller.
1.4. Handling
Improper handling can result in SERIOUS INJURY or DEATH.
• ALWAYS check the puller for damage before use.
• ALWAYS replace damaged or worn parts before use.
• ALWAYS use only KUKKO original spare party and accessories.
• NEVER use electric or pneumatic torque multipliers or impact wrenches.
• NEVER use electric, pneumatic, percussion drivers.
• NEVER heat the puller.
• NEVER modify any parts of the puller, especially the jaws.
• NEVER bend over the part being pulled during the pulling process.
• DO NOT allow children to use the puller.
1.5. Work Environment
ALWAYS use the puller in a safe work environment.
• Keeptheworkareacleanandtidy.
• Usethepullerinalargeandsecuredarea.
LOGO
LOGO
?
?
?
?
WARNING
ELECTRICAL SHOCK HAZARD
Always DISCONNECT electricity before using the puller on or near electrical parts
or circuits.
Take the following safety precautions to prevent injuries and damage caused by
improper handling and unsafe use of the puller.

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2. Product Description
PARTS TYPE/SERIES/MODEL
A: Crossarm
B: Forcing Screw
C: Jaws
D: Clamps
E: KUKKO Quick Adjust
F: Drive Hex
G: Forcing Screw point
20-1+, 20-10+, 20-2+, 20-20+,
20-3+, 20-30+, 20-4+, 20-40+, 20-
5+, 20-1+S-T, 20-10+S-T, 20-1+S,
20-10+S, 20-2+S, 20-20+S, 20-3+S,
20-30+S, 20-1+S-T, 20-10+S-T
A: Hydraulic forcing screw point
B: Crossarm
C: KUKKO Quick Adjust
D: Jaws
E: H: Hydraulic Forcing Screw Point
20-2-B, 20-20-B, 20-3-B, 20-30-B,
20-4-B, 20-40-B, 20-4-H, 20-40-H,
20-5-H
A: Forcing Screw
B: Clamps
C: Jaws
D: Forcing Screw point
20-4-AV, 20-40-AV, 20-5
3. Preparing the Puller for Use
ALWAYS assemble the pullers on a work bench. During the assembly of the puller,
parts can fall o and cause INJURIES.
3.1. Assembling the forcing screw
All Types
• REMOVE the net of the forcing screw before each use
• Screw the forcing screw (B) into the crossarm (A)
3.2. Assembling the Jaws on the Crossarm
PINCH HARZARD. Take the following precautions to prevent pinch injuries to your
ngers when sliding the jaws on the crossarm:
• ALWAYS perform the assembly on a work bench.
• DO NOT grasp in between the jaws when sliding the jaws on the crossarm with
your ngers.
• Hold the crossarm horizontally so that the jaws cannot slip down.
The jaws can subseuqently slip back o the crossarm and fall on feet or legs causing
INJURIES.
CAUTION
CAUTION

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Type 0-P (for Puller 20-1) Pulling legs with screw clamp
Loosen the screw connection (E, H) until you can push the pulling legs onto the trav-
erse easily.
Push the pulling legs (C) onto the traverse (A)
Type 2-P (for the 20 Series) Pulling legs wih KUKKO Quick Adjust
Loosen the clamp (D) on the pulling leg (C) by turning the Quick Adjust (E) clockwise.
Push the pulling legs (C) onto the traverse (A
3.3. Clamping the Jaws on the Crossarm
ALWAYS seat the Jaws securely. Loose Jaws can slip o the crossarm and cause INJU-
RIES
Type 20-1
Pulling legs with screw clamp
Tighten the screw connection (H) slightly. The pulling legs(C) can still be adjusted
using manual pressure.
Type 2-P
Pulling legs with Quick Adjust
To adjust the clamp properly:
1. Turn Quick Adjust (E) clockwise until pressure release on clamps (D)
2. Turn Quick Adjust (E) counterclockwise to put pressure on clamps (D)
NOTE: There are dierent jaws with various clamping methods. Each clamping method is explained in the
following instructions. Follow the instructions for the model you have purchased.
CAUTION
SIEHE BILD OBEN,
NUR MIT QUICK
ADJUST

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4. Safety Use
WARNING
OVERLOAD HAZARD.
The puller may break if it is overloaded causing damage,
SERIOUS INJURY, or DEATH
ALWAYS take the following precautions to avoid damage, serious injury, or death:
• NEVER use electric or pneumatic torque multipliers or impact wrenches
• NEVER use electric, pneumatic or precussion drivers.
• NEVER lengthen the drive tool for the puller.
• NEVER hit the drive tool with a hammer.
• If maximum force has been applied, and the part has not moved, us a puller
with a larger capacity.
• DO NOT hit the part with a hammer in an attempt to jar it loose.
• ALWAYS use a Protective Safety Cover when using the puller.
For added safety, KUKKO highly recommends the use of a Protective Safety Cover
(shown in photo) when using the puller.
Cover the puller setup and part to be pulled with the Protective Safety Cover* before
applying force. High forces exerted on the part being pulled can cause breakage and
ying debris. Safety covers provide maximum active-safety protection from sudden-
ly detaching ball bearingsm driving pinionsm or other small parts.
*See Section 7, Optional Accessories. Protective Safety Cover available at www.xxxxx.com, part number XXX
4.1. Setting for Pulling
ALWAYS slide the jaws COMPLETELY onto the crossarm
If the clamps are not positioned completely onto the crossarm, the jaws can slip
under pressure, causing damage and SERIOUS INJURY
For all puller types, there must be minimum distance of 0.12 inches (3mm) form the
clamps (D) to the end of the crossarm (A)
BEFORE pulling, take the following safety precautions:
• Position the jaws (C) so that they are in contact with the part to be pulled
• Firmly tighten the jaws (C) so that the forcing screw operates centrally along the
axis of the puller
• Position the forcing screw (D) with the forcing screw point (G) at a 90° angle
directly on the part to be pulled.
• Correctly position the puller so that it is vertical to the part to be pulled.

9
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ALWAYS position both jaws (C) so that they are the same distance away (X) from the
ends of the crossarm (A)
4.2. The Pulling Process
During the pulling process, puller parts and component parts can fall or suddenly
detach causing INJURIES
ALWAYS take the following precautions to prevent INJURY:
• Wearpersonalprotectiveequipment(seeSafetysection1.2)
• Securecomponentpartsandpullersfromfalling
• Cover the puller set up with Protective Safety Cover
•Only apply maximal force load as indicated in technicle data sheet
Types 20-1 and Types 20-P
Screw the forcing screw (B) on hand-tight and then use a suitable drive tool, such as a
wrench, to build up slight pressure on the component part
Continue pulling until the part to be pulled is completely loose.
5. Removing the Puller
WARNING
Component party may suddenly become loose and shatter causing particles to y
upward when you remove the pullers from the component part. This may cause
DEATH or SERIOUS INJURY. ALWAYS take the following precautions:
• ALWAYS wear personal preotective equipment when using the puller (see
Section 1.2)
• If maximum force has been applied, and the part has not moved, use a puller
with a larger capacity. (ggf. Verweis)
• Cover the puller setup and part with a protective safety cover* before aplly-
ing force. High forces exerted on the part being pulled can cause breakage
and ying debris.
*Protective Safety Cover available at www.XXX.com , part number XXX
If the part to be pulled does not come loose, unscrew the forcing screw (B) with ex-
treme caution until you can remove the puller from the component part. Then select
a larger puller designed for the load.
CAUTION

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6. Care and Storage
DO NOT use cleaning solvents or chemicle solvents to clean the puller. Hey can
degrade the mechanism’s permanent lubrication.
Use ONLY a clean cloth to clean all party of the puller after every use.
Alternatively use K69….
Store the puller in a dry, clean location.
7. Optional Accessories
There is a wide range of KUKKO accessories for the puller. The most essential acces-
sory parts are displayed below. Accessories are available at www.KUKKO.com and in
the KUKKO General Catalogs.
Protective Safety Cover
Part No. XXX
Hydraulic Pressure forcing screw
Part No. XXXX
jaws for various applications and extensions
KUKKO Fett
Additional hazards and risks may be associated with using accessory parts with your
puller. To AVOID INJURY you must read and understand the Operationg Instructions
or Safety Information provided with the accessory party before using it with your
puller.
8. Maintenance Repair
Damaged parts can be exchanged through KUKKO customer service (see last page
of this manual for telephone number).
9. Environmentally Friendly Disposal
Dispose of the puller and packaging material in accordance with applicable provi-
sions of law.
10. Technical Data
11. Customer Service
KUKKO Quality Tool INC. C/O
Rödl Langford de Kock LLP
Certied Public Accountants, Wirtschaftsprüfer, Steuerberater
55 West Monroe Street Suite
2900 Chicago, IL 60603, USA
Tel.:
NOTICE

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