Sealey AUTO SERVICE PS990.V2 User manual

 WARNING! Ensure all Health and Safety, local authority, and general
workshop practice regulations are strictly adhered to when using tools.
DO NOT use ram or associated tools if damaged or worn.
Maintain the ram and associated tools in good and clean condition
for best and safest performance.
Check the specification of the puller tool you will be using to ensure
that it is rated to match the force that the ram can apply.
Ensure all threads are clean and well lubricated.
Always check that the ram is correctly assembled into the puller
being used and is square with the workpiece.
If working on a raised vehicle, ensure that it is adequately supported
with axle stands, ramps, etc. as appropriate.
Wear suitable clothing to avoid snagging. Do not wear jewellery.
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.
DO NOT use any tool or lever to turn the ram Tommy bar, use
hand effort only.
DO NOT hit workpiece, or ram, with a hammer if 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.
INSTRUCTIONS FOR:
HYDRAULIC RAM UNIT
MODEL NO: PS990.V2
1. INTRODUCTION
Part No. Description
PS982.V2-RK Repair Kit (Items 1,2,3,4,5,7,8)
PS982/OIL 15grms of oil for a single refill.
Issue No.:-1 Issue Date:-12/12/08
3. SAFETY INSTRUCTIONS
2. CONTENTS & PARTS
1.1. INTRODUCTION
The PS990.V2Hydraulic Ram Piston will fit all Sealey hydraulic puller
sets and is also suitable for use with other popular makes of hydraulic
gear pullers. Screw mechanism converts power to 10 Ton ram head with
enough force to remove most stubborn bearings, pulleys and shafts.
fig.1
4. INSTRUCTIONS FOR USE
4.2 Check that the specification of the puller tool you will be using is
compatible with the ram unit.
4.1. Confirm that the workpiece is retained by interference fit
(parallel or taper) only.
4.2. Assemble the ram into the chosen puller, (see typical pullers as
shown in fig.1), and adjust
T-handle (Fig. 2.A) so that
Tommy bar (fig.2.B) is
approximately 80mm (3”) above
top of ram, see fig.2.
4.3. Fit the puller to an appropriate
position behind workpiece and then
screw the ram body down until it
makes contact with the end of the
shaft from which the workpiece is to be pulled. (If the shaft has a
centre position machined into its end surface use a matching centre
adaptor to locate centrally with the shaft.
4.4. Turn T-handle clockwise, by hand only, to pull workpiece from shaft.
4.5. Do not screw T-handle in further than 25mm (1”) from end of the
ram (see fig.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.
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 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 jar it free. Damage to puller/
workpiece and personal injury may result. Use a larger capacity puller.
fig.2
WARNING! Ensure that you read, understand and apply the
safety instructions in Section 3.
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.
PS990.V2 Issue No.1 - 12/12/08

5. MAINTENANCE 5.2.5. Take small seal and piston (fig.5.7 & 8) and gently push them
down the narrow bore of the cylinder ensuring the metal piston
(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). Push
into bore as far as possible.
5.2.6. Pour 15grms of oil into the bore (fig.6). Insert larger seal (fig.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’ (fig.7)
followed by 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 turn a further two or three times.
5.2.9. Remove 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.
Replace the T-handle, wipe clean and
the ram is ready for use.
fig. 3 fig. 4
fig. 7
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 15grms
of oil for a single refill.
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 (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.
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 screw driver (fig.4.9), or a rod of appropriate
diameter, down the small opening in head of 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.
5.2.4. Remove remaining oil from main cylinder, clean all components
and replace any showing signs of damage or wear.
fig. 6
fig.8
6.0. MAINTENANCE OF EARLY MODELS.
Please note that earlier models of the
PS990 were filled with a 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.
6.1 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 on left Part No. PS982.V2-RK.
Do not mix old and new components.
A single 15grm refill of oil may be
obtained by quoting Part No.PS982/OIL
6. SERVICE PARTS & NOTES
01284 757500
01284 703534
[e-mail]
Sole UK Distributor
Sealey Group,
Bury St. Edmunds, Suffolk.
www.sealey.co.uk
Web
email
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 will be required for any claim.
INFORMATION: For a copy of our catalogue and latest promotions call us on 01284 757525 and leave your full name, address and postcode.
PS990.V2 Issue No.1 - 12/12/08
fig. 5