SEALEY PS980.V2 HYDRAULIC BEARING SEPARATOR PULLER SET User Manual

: June 5, 2024
: SEALEY

Table of Contents

SEALEY PS980.V2 HYDRAULIC BEARING SEPARATOR PULLER SET
SAFETY
INTRODUCTION
CONTENTS
OPERATION
MAINTENANCE
- TO CHANGE OIL IN RAM
MAINTENANCE OF EARLY MODELS
Warranty
Sealey Group
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SEALEY PS980.V2 HYDRAULIC BEARING SEPARATOR PULLER SET

SEALEY-PS980-V2-HYDRAULIC-BEARING-SEPARATOR-PULLER-SET-
product

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 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.

Refer to instructions
Wear eye protection
Wear protective gloves
Wear safety footwear
Wear protective clothing

SAFETY

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

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 the workpiece with canvas or similar to provide protection against failed parts.
DO NOT heat puller jaws when heating a gear or bearing as this will affect the temper and, therefore, the strength of the material.
DO NOT use any tool or lever to turn the ram tommy bar, use hand effort only.
DO NOT hit the 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 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

Cast puller yoke with forged separator. 10tonne Hydraulic ram interchangeable with other units in the series. Supplied with Ø75-105mm (PS980) or Ø105-200mm (PS985) bearing separator. Maximum puller depth 420mm. Supplied in a steel case.

Model PS980.V2 (fig.1)

Model PS985.V2 (fig.2)

Item| Part No.| Description
1| PS989| Bearing Separator Ø105 to 200mm
2| PS990| Hydraulic Ram 10tonne
3| PS985/03| Beam
4| PS985/04| Main rod with nut (male thread on both ends).
5| PS982/8013| Centre Adaptor
6| PS985/05| Plug
7| PS982/8014| Rod, extension (1x50mm)
8| PS982/8015| Rod, extension (1x100mm)

OPERATION

WARNING! Ensure that you read, understand, and apply the safety instructions in Section 1.

Confirm that the bearing is retained by interference fit (parallel or taper).
Assemble splitter around the rear of bearing and clamp together using the studs and nuts fitted.
Screw the fully threaded ends of the two puller rods (fig.1.4) into the splitter.
Remove nuts from free ends of rods and place yoke (fig.1.3) over thread shanks.
Retain yoke with flat washers provided and nuts but DO NOT tighten at this stage.
Adjust ram T-handle (fig.3.A) so that tommy bar (fig.3.B) is approximately 80mm above ram end cap (see fig.2) and screw ram body into yoke until ram piston (fig.1.G) contacts the end of the shaft.
If the shaft has a ‘center’ machining fit the center adaptor to the piston before screwing the ram down. If the ram will not reach the shaft use extension piece(s).

NOTE: Only use centre adaptor where the end of the shaft has a matching ‘center’ machining. PS985 contains a plug that provides a thrust pad for the piston in applications where the shaft is hollow.

Adjust the position of the yoke to get the ram piston on the shaft center and then tighten yoke retaining nuts.
Turn the T-handle clockwise, by hand only, to pull the workpiece from the shaft.
DO NOT screw T-handle in further than 25mm (1”) from the end of the ram (see fig.3). If the workpiece requires additional movement then unscrew T-handle to 80mm from the end of the ram, screw the ram body down so that center adaptor again contacts shaft and then continue to draw workpiece up the shaft.

IMPORTANT: The maximum safe load for the puller can be achieved by hand effort alone. The use of tools or levers on the tommy bar to increase the load will damage the splitter and may result in injury. Such misuse will also invalidate the warranty.

WARNING! If the workpiece does not move when maximum puller force is applied, DO NOT hit it, or the puller, in an attempt to jar it free. Damage to puller/workpiece and personal injury may result. Use a larger capacity puller.

MAINTENANCE

GENERAL

Keep all items clean and lightly oiled. Keep all threads free from grit and lubricate the ram regularly.
Store the ram in the closed position to prevent piston surface corrosion.

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 authorized Sealey dealer. Quote model number: HJO500MLS for 1 x 500ml bottle or PS982/OIL for 15grms 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.

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. Carefully remove components 2, 3, and 4 from the cylinder.
Screw T-handle (fig.4.5) down as far as it will go, then unscrew and remove it from the body (fig.4.5).
Push a narrow screwdriver (fig.5.9), or a rod of appropriate diameter, down the small opening in the head of a ram (B), in order to push components 6, 7, and 8, plus the oil, out of the main cylinder. NOTE: A medium force may be required.
Remove remaining oil from the main cylinder, clean all components and replace any showing signs of damage or wear.
Take a small seal and piston (fig.6.7 & 8) and gently push them down the narrow bore of the cylinder ensuring the metal piston is first, with the concave face pointing in the direction of the T-handle, and the seal (fig.6.7) second, with the widest part of the seal facing upwards towards the main cylinder (fig.6). Push into the bore as far as possible.
Pour 15grms of oil into the bore (fig.7). Insert a larger seal (fig.8.6) 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.8) followed by the piston (fig.8.4) and spring (fig.8.3).
Refit (do not overtighten) cover (fig.8.2) and replace T-handle (fig.8.5.)
WARNING! The correct orientation of pistons and seals in the ram is critical.
Screw T-handle into ram until it contacts small piston and then turns a further two or three times.
Remove the T-handle and firmly bounce the ram piston (fig.9) on a hard, but non-damaging, surface 6 to 10 times to consolidate oil. Replace the T-handle, wipe clean and the ram is ready for use.

MAINTENANCE OF EARLY MODELS

Please note that earlier models of the PS990 were filled with hydraulic grease.

WARNING! DO NOT put oil into units previously filled with grease as seals will be configured for grease only and will leak if used with oil. ****

CONVERTING OLD UNITS TO OIL

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 shown in fig.9 PS982/8002. DO NOT mix old and new components. A single 15grm refill of oil may be obtained by quoting Part No.PS982/OIL.

Parts support is available for this product. Please email sales@sealey.co.uk or telephone 01284 757500

ENVIRONMENT PROTECTION

Recycle unwanted materials instead of disposing of them as waste. All tools, accessories, and packaging should be sorted, taken to a recycling center, 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. Please note that other versions of this product are available. If you require documentation for alternative versions, please email or call our technical team at technical@sealey.co.uk or 01284 757505.

Important: No Liability is accepted for incorrect use of this product.