Sealey PS982.V2 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.
1. SAFETY
 WARNING! Ensure all Health and Safety, local authority, and general workshop practice regulations are strictly adhered to when using tools.
8DO NOT use tools if damaged or worn.
9Maintain the tools in good and clean condition for best and safest performance.
9Ensure all threads are clean and well lubricated.
9Always check that puller is correctly assembled and is square with the workpiece.
9If vehicle is raised, ensure it is adequately supported with axle stands, ramps, etc. as appropriate.
9Wear suitable clothing to avoid snagging. Do not wear jewellery. Tie back long hair.
9Wear approved eye protection. A full range of personal safety equipment is available from your Sealey dealer.
9Where possible shield workpiece with canvas or similar to provide protection against failed parts.
8DO NOT heat puller jaws when heating a gear or bearing as this will affect the temper and, therefore, the strength of the material.
8DO NOT use any tool or lever to turn the ram tommy bar, use hand effort only.
8DO NOT hit workpiece, or ram, with a hammer if workpiece has not moved with maximum puller force applied. Use a larger capacity puller.
9Account 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.
2. 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.
3. CONTENTS
PS982.V2 Issue: 5 (W) 12/11/18
Original Language Version
© Jack Sealey Limited
Refer to
Instructions
Wear Eye
Protection
Item Part No. Description
1 PS982/8004 Leg, 100mm x 3
2 PS982/8006 Leg, 150mm x 3
3 PS982/8008 Leg, 200mm x 3
4 PS982/9016 Rod, Main x 2
5 PS982/9017 Rod, Extension x 2
6 PS982/8011 Ring, Ram Adaptor
7 PS982/8014 Rod, Ram Extension, 50mm
8 PS982/8015 Rod, Ram Extension, 100mm
9 PS982/8013 Centre Adaptor, 1¼”
10 PS990 Ram, Hydraulic, 10 tonne
11 PS982/9013 Head, Triple
12 PS982/8012 Head, Twin
13 PS982.V2-B Bearing Separator, 75-105mm
14 PS982/9014 Beam
 PS982/OIL 15gmofoilforasinglerell
(not supplied)
PS982/8002 Repair Kit for PS990 Ram
(not supplied)

4. OPERATION
WARNING! Ensure that you read, understand and apply the safety instructions in Section 1.
4.1. Conrmthattheworkpieceisretainedbyinterferencet(parallelortaper)only.
4.2. Assembletheappropriatepuller,see(g.1)andadjustT-handle(g.2.A)sothattommybar(g.2.B)isapproximately80mm(3”) 
 abovetopofram,see(g.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 in end of shaft from which workpiece is to be pulled. If necessary use ram extension(s) (items 7 & 8) to achieve this.
4.4. Turn T-handle clockwise, by hand only, to pull workpiece from shaft, draw workpiece up shaft. Do not screw T-handle in further than
 25mm(1”)fromendoftheram(seeg.2).IfworkpiecerequiresadditionalmovementthenunscrewT-handleto80mmfromend
of ram, screw ram body down so that centre adaptor again contacts shaft and then continue to draw workpiece up 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.
5. 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 the 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rell.
WARNING! Use of any other oil in ram may cause ram to fail and will invalidate your warranty. Wear appropriate eye, face
and hand protection.
5.2.1. Dismantlebyremovingtheramcover(g.3.2)withsoftjawgrips(g.3.A)(bodymayhavetobeheldinasoftjawvice,ensure 
bodythread is not damaged).
▲CAUTION! The cover is spring loaded, take care when removing. Remove components 2, 3, and 4 from the cylinder carefully.
5.2.2. ScrewT-handle(g.4.5)downasfarasitwillgo,thenunscrewandremoveitfromthebody(g.4.5).
5.2.3. Pushanarrowscrewdriver(g.4.9),orarodofappropriatediameter,downthesmallopeninginheadofram(g.4.B),inordertopush
 components(g.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 main cylinder, clean all components and replace any showing signs of damage or wear.
5.2.5. Takesmallsealandpiston(g.5.7&8)andgentlypushthemdownthenarrowboreofthecylinderensuringthemetalpiston(g.5.8)
 isrst,withtheconcavefacepointinginthedirectionoftheT-handle,andtheseal(g.5.7)second,withthewidestpartoftheseal
 facingupwardstowardsthemaincylinder(g.5.7).Pushintoboreasfaraspossible.
g.1
PS982.V2 Issue: 5 (W) 12/11/18
Original Language Version
© Jack Sealey Limited
g.2
g.3 g.4 g.5 g.6 g.7 g.8

PS982.V2 Issue: 5 (W) 12/11/18
Original Language Version
© Jack Sealey Limited
5.2.6. Pour15gmofoilintothebore(g.6).Insertlargerseal(g.7.6)asshown,withthewidestpartofthesealfacingdownwardsintothe
 bore.Pushdownintomaincylinderasfaras‘X’(g.7)followedbypiston(g.7.4)andspring(g.7.3).
5.2.7. Ret(donotovertighten)ramcover(g.7.2)andreplaceT-handle(g.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 turn a further two or three times.
5.2.9. RemoveT-handleandrmlybouncetherampiston(g.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lledwithahydraulicgrease.
 WARNING! DO NOTputoilintounitspreviouslylledwithgreaseasthesealswillbeconguredforgreaseonlyandwillleakifused
with oil.
5.4. CONVERTING EARLY MODELS TO OIL
5.4.1. Theoldtypegreaselled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rellofoilmaybeobtainedbyquotingPartno.
PS982/OIL.
SealeyGroup,KempsonWay,SuffolkBusinessPark,BuryStEdmunds,Suffolk.IP327AR
01284757500 01284703534 [e-mail] www.sealey.co.uk
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 which 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.