Sealey BSL100 User manual

INSTRUCTIONS FOR:
CV JOINT BOOT TOOL
MODEL NO. BSL100
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.
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1. SAFETY INSTRUCTIONS
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 OR PERSONAL INJURY, AND WILL INVALIDATE THE WARRANTY. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
2. INTRODUCTION & SPECIFICATION
This innovative tool saves time, money and frustration by enabling the installation of flexible steering and CV boots without removing the axle
from the vehicle or the CV joint from the axle. No effort and no mess is involved. Saves on labour time by up to 70% and prevents damage to
the CV joint. The tool has a composite body with simple control valve and works from the standard workshop air supply.
SPECIFICATION.
CV joint diameter . . . . .20-95 mm Weight . . . . . . . . . . . .2.5kg Max air pressure . . . .125psi Air inlet size . . . . .1/4BSP
1.1 GENERAL SAFETY
3Carefully read these operating and safety instructions before commencing assembly and before use. Keep them for future reference.
3This tool should only be used by properly trained operators.
3Keep the work area clean, uncluttered and ensure there is adequate lighting.
3Maintain correct balance and footing. Ensure the floor is not slippery and wear non-slip shoes.
3Remove ill fitting clothing. Remove ties, watches, rings, and other loose jewellery, and contain and/ or tie back long hair.
3Keep children and unauthorised persons away from the working area.
3Keep the boot tool away from fire, heat and chemicals.
7DO NOT use the boot tool for any purpose other than that for which it is designed.
7DO NOT operate the boot tool when you are tired, under the influence of alcohol, drugs or intoxicating medication.
pWARNING! Ensure Health & Safety, local authority, and general workshop practice regulations are adhered to when using this equipment.
1.2 COMPRESSED AIR SAFETY
3Make sure that the air pressure system contains no liquids, including water, but only dry air.
3Keep air hose away from heat, oil and sharp edges. Check air hose for wear before each use, and ensure that all connections are secure.
3When not in use disconnect from the air supply, de-pressurise the boot tool, and store in a safe, dry, childproof area
7DO NOT leave the boot tool unattended when fully pressurised.
7DO NOT carry the by the boot tool hose, or yank the hose from the air supply.
7DO NOT allow the air pressure to exceed 9 bar (125 psi). High air pressure can cause irreversible damage to the tool and/or the surroundings.
pWARNING! Disconnect the boot tool from the air supply before servicing or performing any maintenance.
1.3 MECHANICAL SAFETY
3Maintain the boot tool in good condition (use an authorised service agent).
3If the tool falls or is knocked, stop operation and check for any damage.
3Do not erase or damage any of the markings,symbols or text printed onto or moulded onto the surfaces of the Boot tool.
3In case of mechanical fault and/or breakage and/or cracks, immediately stop operation of the tool and disconnect it from the air
supply. Contact an authorised distributor.
3Replace or repair damaged parts. Use genuine parts only. Non-authorised parts may be dangerous and will invalidate the warranty.
7DO NOT operate the boot tool if any parts are damaged or missing as this may cause failure and/or personal injury.
1.4 OPERATIONAL SAFETY
3Before using the Boot tool, make sure that all the Boot tool parts are correctly assembled and firmly in place. Do not operate it if the arm
retaining pins are not all in place.
3Working with the Boot tool requires protective equipment including safety shoes, work gloves and safety goggles. Do not bring the
tool close to the face while operating.
3When operating the Boot tool, to open a CV rubber boot, turn the Boot tool downwards, at an angle of 45 degrees.
3Keep hands clear of the moving legs when operating the boot tool. Never insert fingers into the tool.
3Do not use the Boot tool without the protective rubber cover (see assembly in section 3) on the arms and covering the arm hinges.
7DO NOT point the Boot tool at any person and/or towards any part of the operator's body.

4. AIR SUPPLY
pWARNING! Ensure the air supply does not exceed 125psi while operating the unit. Too high an air pressure will shorten the life of the
unit and may cause damage and/or personal injury.
4.1 The Boot tool has a female 1/4 BSP thread in the end of the handle. Obtain and fit a suitable air connection fitting that can easily be
disconnected from the tool such as a male threaded adaptor (Sealey part No.AC04).
4.2 Ensure that the air regulator built into the handle is in the Off position before connecting to the air supply.
4.3 Where possible the compressor should be sited in a separate room with the
connecting airline kept as short as possible.
The compressor should have an air filter and water separator (fig.9).
4.4 Drain the compressor air tank daily as water in the air line will damage the unit.
4.5 The recommended hook-up procedure is shown in fig.1.
4.6 The minimum hose diameter should be 1/4" I.D. and fittings must have the
same inside dimensions.
4.7 Keep hoses away from heat, oil and sharp edges. Check hoses for wear and
ensure that all connections are secure.
4.8 Line pressure should be increased to compensate for unusually long air hoses
(over 8 metres).
3. CONTENT & ASSEMBLY
Assembly instructions (figures 1-8):
3.2 Support the Boot tool base in a vertical position as indicated in fig.1.
3.3 Position the 8 guides in the grooves in the Boot tool base with the guide groove facing outwards (see figure 2).
3.4 Insert an arm into one of the guides (see figure 3), with the hole in the arm facing downwards and the camber of the arm facing inwards.
3.5 Insert a pin into the hole in the wall of the Boot tool below the arm (see figure 4) until the end of the pin can be seen on the
other side of the hole.
3.6 Repeat the process until all the arms are in position and secured with pins as shown in figure 5.
3.7 Place the protective rubber boot over the assembled arms as shown in figure 6.
3.8 Push the rubber boot down over the pin area (see fig.7) and insert the bottom rim of the boot into the peripheral groove on the
base of the Boot tool.
3.9 When the tool is properly assembled it should appear as in fig.8.
Double check, before use, that the arms are correctly fixed to the Boot tool base and that the regulator control adjacent to the air
inlet has been rotated to the OFF position. (see fig.A)
3.1 Unpack the boot tool and check that the contents are correct and undamaged. In case of a problem please contact your Sealey dealer.
Contents: a) Safety holder d) Eight arm guides.
b) Boot tool base unit with integral rotary regulator built into handle. e) Eight pins for securing the arms.
c) Eight steel stretching arms. f ) One protective rubber boot.
fig.9
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5.6 When the arms have stretched the boot by the desired amount, turn the regulator back to the OFF position in order to avoid the arms
opening any further. (see figure D)
5.7 Manoeuvre the opened tool and boot over the end of the drive shaft until it is in the required place. (see figure E)
5.8 Check that the regulator is still in the OFF position then press the yellow button located in the grooved regulator control to release the
air pressure within the tool. (see figure F)
5. OPERATION
5.2 Make sure that the air pressure regulator on the Boot tool handle is in the OFF position. Rotate the grooved ring at the base of the
handle until the OFF mark is opposite the static indicator (see figure A).
5.3 Connect the air line to the air connector at the end of the handle.
5.4 Put the flexible rubber boot over the Boot tool arms. Make sure that the ends of the arms are projecting from the top opening of the
rubber boot (see figure B).
When operating the Boot tool, to open the tool "arms", orientate the unit downwards, at an angle of 45 degrees.
5.5 Slowly turn the regulator towards the ON mark (see figure C). The regulator controls the rate and angle of the opening of the arms.
5.0 Before first use lubricate the tool with synthetic pneumatic oil , applied into the connector at the base of the handle
pWARNING! The Boot tool is designed for the installation of flexible rubber CV boots only and should be used with no other products
and for no other purpose.
pWARNING! The Boot tool should only be used with flexible rubber boots which conform to the following specification.
Elongation at break: Minimum 600 % Tensile strength: Minimum 30 N/mm2 Hardness: Maximum 50 Shore A
Boots which do not conform to this specification may tear.
5.1 Adjust the air compressor to give a maximum pressure of 9 bar (125 psi) at its outlet.
5.9 As the air pressure is released the arms will close down onto the drive shaft. (see figure G) Disconnect the air supply.
5.10 Place one hand onto the rubber boot to hold it in place. (see figure H)
5.11 Finally, entirely withdraw the tool from the boot. (see figure I) Do not leave the Boot Tool under air pressure when not in use.
5.12 A purpose designed safety holder is supplied for storing the Boot tool when not in use.
6. MAINTENANCE
6.1 Before first use and regularly thereafter, lubricate the tool with synthetic pneumatic oil , in the connector at the base . (the air pressure
will distribute this eventually inside the tool).
6.2 Damage caused due to incorrect assembly, maintenance or not regularly lubricating the device, will void the warranty.
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BSL100 - 1 - 110603