Enerpac L1697 User manual

L1697 Rev. C 07/16
IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. If any shipping damage is found, notify carrier at
once. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or replace-
ment cost resulting from damage in shipment.
DESCRIPTION
The Enerpac Posi Lock Puller System is manually or hydraulically operated. The puller consists of a
control cage (item 1), jaw (item 2), jaw-head assembly (item 3), ball lock pins (item 4), T-handle (item
5), center bolt (item 6), and a snap ring (item 7). The control cage holds the puller jaws securely in any
position. Operating, closing, locking, and aligning the jaws is done by turning the T-Handle. In hydraulic
pullers, the center bolt is replaced by a hydraulic cylinder.
The 100 ton puller comes with an electrically powered lift cart, enabling the puller to be raised up to 5
feet above ground.
CONTENTS
English ............................................................. 1
Deutsch............................................................. 8
Français............................................................. 15
Español ............................................................. 22
Italiano ............................................................. 29
Nederlands .......................................................... 36
Русский ............................................................ 43
Polski. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Instruction Sheet
Posi Lock Puller System
POWERFUL SOLUTIONS. GLOBAL FORCE.
Figure 1, Components of Posi Lock Puller
(see page 58 for parts list)

SAFETY INFORMATION
WARNING
Do not overload cylinder. Do not exceed clamping forces. Overloading causes
equipment failure and possible personal injury. Use hydraulic gauges to ensure proper
operating pressure in each hydraulic system. Do NOT exceed maximum pressure
limits of lowest rated component in your system. Always use high pressure hoses and
fittings.
WARNING
Do not over-extend the cylinder. Do not operate beyond limits of its rated stroke. It will
cause unnecessary strain to the cylinder.
WARNING
AVOID SHARP BENDS AND KINKS IN HOSES. The oil flow will be restricted
causing severe back-pressure. Sharp bends and kinks will internally damage
hoses leading to premature failure.
WARNING
WEAR SAFETY GLASSES to protect your eyes against injury.
WARNING
KEEP FINGERS AWAY. During operation, keep hands and fingers away from the
operation area to avoid personal injury.
INSTALLATION
Selection guide
When determining which puller to use, follow these guidelines:
• Themechanicalpuller’scenterboltdiametermustbeatleastonehalfas
large as the diameter of the shaft from which the object will be removed.
(See figure 2.)
(2)
Figure 2, Relative Size of Center Bolt versus Diameter of Shaft

• Themaximumforceexertedintonsshouldbe7to10timesthediameteroftheshaftininches
or0.3to0.4timesthediameterinmillimeters.(Example:A1½”(40mm)diametershaftwould
generally require a 15 ton puller.)
• LongJawsareavailableforlargercapacitypullers.Tochangejaws,removetheballlockpinsand
slidethestandardjawsoutofthecage.Insertthe“T”ofthelongjawsintothe
T-slot of the cage and secure the jaws by inserting ball lock pins.
CAUTION
The rating of the puller remains the same when using the long jaws but the gripping
force is reduced by 75%. Never attempt to pry the puller by inserting anything
between the jaws. This may cause center bolt damage.
• Distortionofthejawheadassemblywilloccuriftheboltnutiscontinuallyforcedagainstthe
jawheadassembly.Toreducethisrisk,usetheoptionalshaftprotectors/extendersthatfitoverthe
puller’sendfortipprotectionandadditionalreach.
Note
Itisimpossibletopredicttheexactforceneededforeverypullingsituation.Theamountofpressfitand
force of removal can vary greatly between jobs. The set-up requirements along with the size, shape, and
condition of the parts being pulled are variables which must be considered.
Study each pulling application before you select your puller. Notice that a significant amount of force can
beexertedwithapuller.Respecttheseforcesandalwaysobserveallsafetyprecautionsandwarnings.
OPERATION
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Figure 3 Figure 4 Figure 5

Mechanical Pullers
1. Make sure that all items being pulled are supported by a means other than the puller. Do not use the
puller for lifting or supporting objects.
2. Before each use, lubricate the center bolt threads with a graphite-based lubricant.
3. To operate puller, grasp the puller with one hand and turn the T-handle counter-clockwise with the
other hand until the jaw opening is big enough to fit over the component to be pulled.
CAUTION
Do not pinch your fingers during this process.
4. Place puller over component to be pulled. When only the inner bearing race is remaining on the
shaft, clean the shaft first with emery cloth and then attach the jaws in the ball groove.
If the jaws appear to be coming out of the ball groove, loosen the center bolt and re-tighten the
T-Handle by hand. This may be necessary when the puller is new to get the jaws to properly seat in
the cage.
5. Turn the T-Handle clockwise to tighten the jaws firmly onto the component. (See Figure 3.)
6. Make sure that the center of the puller is aligned with the center of the shaft of the component to
be pulled. Using hand tools only, tighten the center bolt to pull the component off of its shaft. (See
Figure 4.)
To remove the component from the puller, turn the T-Handle counter-clockwise to open the jaws.
(See Figure 5.)
Maintenance
Alwayscleanthepullerafteruseandstoreinaclean,dryplace.
Hydraulic Pullers
1. Make sure that all items being pulled are supported by a means other than the puller. Do not use the
puller for lifting or supporting objects.
2. Install cylinder into puller by threading collar threads clock-wise into the jawhead assembly. Make
surethatthecylindercollarthreadsarefullyengagedinthepuller.Attachliftplatetothebootom-
endofthecylinder.Removethesaddlefromthecylinderandinserttherampointintotheplunger.
Selecttherampointthatwillprovidemaximumcontactwiththeshaftend.
3. To operate puller, grasp the puller with one hand and turn the T-handle counter-clockwise with the
other hand until the jaw opening is big enough to fit over the component to be pulled.
CAUTION
Do not pinch your fingers during this process.
4. Place the puller over the component to be pulled. (See Figure 3.) When only the inner bearing race
is remaining on the shaft, clean the shaft first with emery cloth and then attach the jaws in the ball
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groove.
If the jaws appear to be coming out of the ball groove, release hydraulic pressure and re-tighten the
T-Handle by hand. This may be necessary when the puller is new to get the jaws to properly seat in
the cage.
5. Turn the T-handle clockwise to tighten the jaws firmly onto the component.
6. Makesurethatthepullerissquarewiththecomponenttobepulled.Advancetheplungeruntil
therampointcontactstheshafttoensurecorrectalignment.(Ifnecessary,refertothepump’s
instruction sheet.) The center of the ram point should be aligned with the center of the shaft.
Continue to advance the plunger slowly to pull the component off of the shaft. Do not re-tighten the
T-handleduringthepullingoperation.Neverexceedthemaximumtorqueratingofthepullers.
Maintenance
Alwayscleanthepullerafteruseandstoreinaclean,dryplace.
100-Ton Hydraulic Puller
WARNING
Do NOT stand on, under, or near puller while in use. Keep hands, feet and clothing
away from moving parts.
WARNING
When transporting puller, always place the puller in its lowest position and
remove ram extenders.
1. Make sure that all items being pulled are supported by a means other than the puller. Do not use the
puller for lifting or supporting objects.
2. Alignthepullertotheshafttoensureastraightpull.(Thepuller’sliftcartcanraisethepullerupto5
feet. For distances beyond 5 feet, the puller can be removed from the cart. See Removing Puller
from Lift Cart.)
 Toraisethepuller,placethecylindercontrolvalveinthe“HoistOilSupply”position,openthepuller
hoistverticalcontrolvalve,andraisethepullerbyplacingtheremotejogswitchinthe“On”position.
When puller has reached the desired height, release the remote jog switch and close the vertical
control valve.
Tolowerthepuller,placethecylindercontrolvalveinthe“HoistLower”position,turnthehoist
vertical control valve counterclockwise, and close the hoist vertical control valve after the puller has
reached its desired height.
Note
The restrictor valve, located at the top of the hoist cylinder, is used to control the rate of puller
descent. This valve should be set at the desired rate and locked in place using the nut on the valve
shaft.(AnappropriatestartingpointisonefullturnfromtheclosedpositionThisrestrictorvalveis
only a one-way restrictor valve; it does not affect the rate at which the puller is raised.)
WARNING
Always keep the puller hoist vertical control valve closed when not adjusting the
vertical position.
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3. Open the jaws to the desired spread.
Placethecylindercontrolvalveleverinthe“OilSupply”position,placethecagecontrolvalvelever
inthe“JawOpen”position,andactivatethepumpbyplacingtheremotejogswitchinthe“On”
position.Releasetheremotejogswitchwhenthejawshavereachedthecorrectspread.
To close jaws, place the cylinder control valve in the oil supply position, place the cage control valve
leverinthe“JawControl”position,andactivatethepumpbyplacingtheremotejogswitchinthe
“On”position.
4. Adjustjawtipssothejawswillpullonaflatsurface.
Alwaysusethemaximumpullingsurfaceofthejaw.Adjustthejawtipsbyturningthe11/4" cap
screw. To angle tip inward, turn the cap screw clockwise. To angle the tip outward, turn the cap
screw counterclockwise. Before pulling, always ensure that the machined caps are properly fitted to
the curved surface.
5. Extendthe100-toncylinder.
Placethe100-toncylindercontrolvalveinthe“Extend”positionandactivatethepumpbyplacing
theremotejogswitchinthe“On”position.
Toretractcylinder,placethe100-toncylindercontrolvalveinthe“Retract”position.Thecylinderwill
retract automatically without activating the pump.
Removing Puller from Lift Cart
1. Support puller weight using the lifting brackets provided.
2. Close the puller hoist vertical control valve.
3. Disconnect the puller hoist hose coupler at the control panel.
4. Removethe(2)1/2" bolts that fasten the locking plate to the puller lift bracket.
5. Removethepullerfromthecartbyrotatingthecartwhilekeepingthepullerstationary.
Maintenance
Keep slide rollers and mast clean and lubricated with light machine oil. Note that a small
amount of oil seepage from the breather vent on the hoist cylinder is normal.
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Troubleshooting
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Problem
1. Cylinder will not advance
2. Cylinder advances partly
3. Cylinder advances in spurts
4. Cylinder advances slower than
normal
5. Cylinder advances but will not hold pressure
6. Cylinder leaks oil
7. Cylinder will not retract or retracts slower than
normal
Possible Cause
A. Pumpreleasevalveopen
B. No oil in pump
C. Airinhydraulicsystem
D. Couplers are not fully tightened
E. Blocked hydraulic line
A. Oillevelinpumptoolow
B. Cylinder’splungerbinding
A. Airinhydraulicsystem
B. Cylinder’splungerbinding
A. Leakingconnection
B. Restrictedhydraulicline
C. Loose coupler or fitting
A. Sealsleaking
B. Leaking connection
C. Pump malfunction
A. Wornordamagedplunger
B. Leaking or loose connection
C. Internal leakage
A. Pumpreleaseclosed
B. Coupler not fully closed
C. Blocked hydraulic line
D. Pump reservoir over-filled
E. Cylinder damaged

L1697 Rev. C 10/14
WICHTIGE ANWEISUNGEN FÜR DIE EINGANGSKONTROLLE
Unterziehen Sie alle Teile einer Sichtkontrolle auf eventuelle Transportschäden. Wird ein solcher
Transportschaden festgestellt, benachrichtigen Sie unverzüglich den Spediteur. Transportschäden sind von
derGewährleistungNICHTabgedeckt.DerSpediteurhaftetfüralleReparatur-undAustauschkosten,die
sich aus einer Beschädigung beim Transport ergeben.
BESCHREIBUNG
DasEnerpacPosiLockAbziehsystemwirdmanuelloderhydraulischbetrieben.DieAbziehvorrichtung
besteht aus einem Steuergerippe (Element 1), den Klemmbacken (Element 2), dem Backenkopf (Element
3), den Kugelsperrstiften (Element 4), dem Knebelgriff (Element 5), dem Mittelbolzen (Element 6) und
einem Sprengring (Element 7). Das Steuergerippe hält die Zugbacken in beliebigen Stellungen sicher
fest.DerBetrieb,dasSchließen,VerriegelnundAusrichtenderKlemmbackenerfolgtdurchDrehendes
Knebelgriffs.BeihydraulischenAbziehvorrichtungenwirdderMittelbolzendurcheinenhydraulischen
Zylinder ersetzt.
DieAbziehvorrichtungfür100US-Tonnen(90,7Tonnen)wirdmiteinemelektrischangetriebenen
Hebewagengeliefert,wodurchesmöglichist,dieAbziehvorrichtungbiszu1,5MeterüberdemBoden
anzuheben.
(8)
POWERFUL SOLUTIONS. GLOBAL FORCE.
Abbildung 1, Komponenten der Posi Lock Abziehvorrichtung
(Teileliste siehe Seite 58)
Bedienungsanleitung
Posi Lock Abziehsystem

SICHERHEITSINFORMATIONEN
ACHTUNG
Den Zylinder nicht überlasten. Die Spannkräfte nicht überschreiten. Durch
Überlastung können Sachschäden und Körperverletzungen hervorgerufen
werden. Hydraulikmanometer verwenden, um den richtigen Betriebsdruck in
jedem Hydrauliksystem sicherzustellen. Den maximalen Druck der Komponente
mit dem niedrigsten Nenndruck in ihrem System NICHT überschreiten. Stets
Hochdruckschläuche und -fittings verwenden.
ACHTUNG
Den Zylinder nicht zu weit ausfahren. Nicht über den Nennhub hinaus betreiben. Dies
würde den Zylinder unnötigerweise belasten.
ACHTUNG
SCHARFE BIEGUNGEN UND KNICKE IN SCHLÄUCHEN VERMEIDEN. Dadurch würde
der Ölfluß eingeschränkt, wodurch beträchtlicher Staudruck verursacht wird. Scharfe
Biegungen und Knicke führen zu inneren Schäden in Schläuchen, was vorzeitigen
Ausfall zur Folge hat.
ACHTUNG
EINE SCHUTZBRILLE TRAGEN, um Augen vor Verletzungen zu schützen.
ACHTUNG
DIE FINGER FERNHALTEN. Während des Betriebs Hände und Finger vom
Arbeitsbereich fernhalten, um Verletzungen zu verhüten.
INSTALLATION
Leitfaden zur Auswahl
BeiderAuswahlderzweckmäßigenAbziehvorrichtungsinddiefolgendenRichtlinienzubefolgen:
• DerDurchmesserdesMittelbolzensdermechanischenAbziehvorrichtungmußmindestenshalbso
großseinwiederDurchmesserderWelle,vonderdasObjektabgezogenwird.(SieheAbbildung2.)
• DieinUS-TonnenausgedrücktemaximaleKraftsollte7-bis10-malsogroßwieder
Wellendurchmesser in Inch oder 0,3- bis 0,4-mal so groß wie der Durchmesser in mm sein. Beispiel:
(9)
Abbildung 2, Relative Größe des Mittelbolzens im Verhältnis zum Wellendurchmesser

EineWellemit40mm(1½Inch)DurchmesserwürdeimallgemeineneineAbziehvorrichtungmit15
US-Tonnen (13,6 Tonnen) Zugkraft erfordern.
• LangeKlemmbackensindfürAbziehvorrichtungenmithöhererKapazitätlieferbar.ZumAustauschen
der Klemmbacken die Kugelsperrstifte entnehmen und die Standardklemmbacken aus dem Gerippe
schieben. Das „T“ der langen Klemmbacken in den T-Schlitz des Gerippes einlegen und die
Klemmbacken sichern, indem die Kugelsperrstifte eingeführt werden.
VORSICHT
Die Nennwerte der Abziehvorrichtung bleiben gleich, wenn die langen Klemmbacken
verwendet werden, doch die Greifkraft wird um 75 % verringert. Niemals versuchen,
die Abziehvorrichtung aufzupressen, indem etwas zwischen die Klemmbacken
eingeführt wird. Dadurch kann es zur Beschädigung des Mittelbolzens kommen.
• EineVerwindungdesBackenkopfestrittauf,wenndieBolzenmutterständiggegendenBackenkopf
gedrücktwird.ZurVerringerungdiesesRisikosdiealsSonderausstattunglieferbarenWellenschutz-/
verlängerungsvorrichtungenverwenden,dieüberdasEndederAbziehvorrichtungpassen,umdie
SpitzezuschützenundzusätzlicheReichweitezuerzielen.
Hinweis
Esistunmöglich,diefürdiejeweiligeAbziehsituationerforderlicheKraftgenauvorauszuberechnen.Das
AusmaßderPreßpassungundderAbziehkraftkannvonFallzuFallsehrverschiedensein.Zudenin
Betracht zu ziehenden Variablen zählen die Einrichtungserfordernisse sowie Größe, Form und Zustand der
abzuziehenden Werkstücke.
JedeAbziehsituationsolltevorderAuswahlderAbziehvorrichtunggenauuntersuchtwerden.Esistzu
beachten,daßmiteinerAbziehvorrichtungeineerheblicheKraftausgeübtwerdenkann.DieseKräftedür-
fen nicht unterschätzt werden; stets alle Sicherheitsvorkehrungen und Warnhinweise beachten.
BETRIEB
Mechanische Abziehvorrichtungen
1. Sicherstellen, daß alle Werkstücke, an denen gezogen wird, durch andere Vorrichtungen außer der
Abziehvorrichtungunterstütztwerden.DieAbziehvorrichtungnichtzumHebenoderStützenvon
Werkstücken verwenden.
(10)
Abbildung 3 Abbildung 4 Abbildung 5