SEALEY PS982 25pc Hydraulic Puller Set User Manual

HYDRAULIC PULLER SET
MODEL NO: PS982.V2

Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these instructions, and properly maintained, give you years of trouble-free performance.

IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

 SAFETY

• WARNING! Ensure all Health and Safety, local authority, and general workshop practice regulations are strictly adhered to when using tools.

x  DO NOT use tools if damaged or worn.
Maintain the tools in good and clean condition for best and safest performance.
Ensure all threads are clean and well lubricated.
Always check that the puller is correctly assembled and is square with the workpiece.
If the vehicle is raised, ensure it is adequately supported with axle stands, ramps, etc. as appropriate.
Wear suitable clothing to avoid snagging. Do not wear jewelry. Tie back long hair.
Wear approved eye protection. A full range of personal safety equipment is available from your Sealey dealer.
Where possible shield workpiece with canvas or similar to provide protection against failed parts.
x  DO NOT heat puller jaws when heating a gear or bearing as this will affect the temper and, therefore, the strength of the material.
x  DO NOT use any tool or lever to turn the ram tommy bar, use hand effort only.
x  DO NOT hit workpiece, or ram, with a hammer if the workpiece has not moved with maximum puller force applied. Use a larger capacity puller.
Account for all tools and parts being used and do not leave them in or on the vehicle.
IMPORTANT: Always refer to the vehicle manufacturer’s service instructions, or proprietary manual, to establish the correct procedure and data. These instructions for use are provided as a guide only.

INTRODUCTION

PS982 consists of a set of gear pullers and a forged steel bearing separator, all operated by a 10-tonne hydraulic ram. The ram is also compatible with sets PS981 and PS983.

CONTENTS

PS982.V2 Issue: 5 (W) 12/11/18

OPERATION

• WARNING! Ensure that you read, understand and apply the safety instructions in Section 1.
4.1. Confirm that the workpiece is retained by interference fit (parallel or taper) only.
4.2. Assemble the appropriate puller, see (fig.1) and adjust T-handle (fig. 2.) so that the tommy bar (fig.2.B) is approximately 80mm (3”)  above the top of the ram, see (fig.2).
4.3. Fit the puller claws behind the workpiece and then screw ram body down, with centre adaptor (item 9) over piston end, until centre adaptor point locates at the end of the shaft from which workpiece is to be pulled. If necessary use ram extension(s) (items 7 & 8) to achieve this.
4.4. Turn the T-handle clockwise, by hand only, to pull the workpiece from the shaft, draw the workpiece up the shaft. Do not screw T-handle in further than 25mm (1”) from the end of the ram (see fig.2). If the workpiece requires additional movement then unscrew T-handle to 80mm from the end of the ram, screw ram body down so that the centre adaptor again contacts the shaft and then continue to draw the workpiece up the shaft.
4.5. IMPORTANT: The maximum safe load for the puller can be achieved by hand effort alone.
4.6. The use of tools or levers on the tommy bar to increase the load will damage the puller and may result in injury.
Such misuse will also invalidate the warranty. If the workpiece does not move, with maximum puller force applied, DO NOT hit it, or the puller, in an attempt to free it. Damage to puller/workpiece and personal injury may result: use a larger capacity puller.

MAINTENANCE

5.1. GENERAL
5.1.1. Keep all items clean and lightly oiled. Keep all threads free from grit and lubricate the ram regularly.
5.1.2. Store the ram in a closed position to prevent piston surface corrosion.
5.2. TO CHANGE OIL IN RAM 
IMPORTANT: The hydraulic system operates on a specially formulated oil which must be replaced from time to time. Use Sealey Hydraulic Jack Oil, available from your authorised Sealey dealer. Quote model number: HJO500MLS for 1 x 500ml  bottle or PS982/OIL for 15gm of oil for a single refill.
• WARNING! Use of any other oil in the ram may cause the ram to fail and will invalidate your warranty. Wear appropriate eye, face and hand protection.
5.2.1. Dismantle by removing the ram cover (fig.3.2) with soft jaw grips (fig.3.A) (body may have to be held in a soft jaw vice, ensure body thread is not damaged).
▲CAUTION! The cover is spring-loaded, take care when removing it. Remove components 2, 3, and 4 from the cylinder carefully.
5.2.2. Screw T-handle (fig.4.5) down as far as it will go, then unscrew and remove it from the body (fig.4.5).
5.2.3. Push a narrow screwdriver (fig.4.9), or a rod of appropriate diameter, down the small opening in the head of a ram (fig.4.B), in order to push components (fig.4.6, 7, and 8) plus the oil, out of the main cylinder.
NOTE: A medium force may be required.
5.2.4. Remove remaining oil from the main cylinder, clean all components and replace any showing signs of damage or wear.
5.2.5. Take a small seal and piston (fig.5.7 & 8) and gently push them down the narrow bore of the cylinder ensuring the metal piston (fig.5.8)  is first, with the concave face pointing in the direction of the T-handle, and the seal (fig.5.7) second, with the widest part of the seal facing upwards towards the main cylinder (fig.5.7). Push into the bore as far as possible.

5.2.6. Pour 15gm of oil into the bore (fig.6). Insert a larger seal (fig.7.6) as shown, with the widest part of the seal facing downwards into the bore. Push down into the main cylinder as far as ‘X’ (fig.7) followed by the piston (fig.7.4) and spring (fig.7.3).
5.2.7. Refit (do not overtighten) ram cover (fig.7.2) and replace T-handle (fig.7.5).
• WARNING! The correct orientation of pistons and seals in the ram is critical.
5.2.8. Screw T-handle into ram until it contacts small piston and then turns a further two or three times.
5.2.9. Remove the T-handle and firmly bounce the ram piston (fig.8) on a hard, but non-damaging, surface 6 to 10 times to consolidate the oil.
5.2.10. Replace the T-handle, wipe clean and the ram is ready for use.
5.3. MAINTENANCE OF EARLY MODELS
NOTE: Earlier models of the PS990 were filled with hydraulic grease.
• WARNING! DO NOT put oil into units previously filled with grease as the seals will be configured for grease only and will leak if used with oil.
5.4. CONVERTING EARLY MODELS TO OIL
5.4.1. The old type grease-filled PS990 can be converted for use with oil by replacing the internal components with those supplied in the repair kit Part No PS982/8002. DO NOT mix old and new components. A single 15gm refill of oil may be obtained by quoting Part no. PS982/OIL.

ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to a recycling centre and disposed of in a manner that is compatible with the environment. When the product becomes completely unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids according to local regulations.

Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.

Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR

© Jack Sealey Limited
Original Language Version
PS982.V2 Issue: 5 (W) 12/11/18