SPX POWER TEAM PH1002, PH1002J Assembly & Operating Instructions

PORTABLE PULLER

100 Ton Capacity

Form No. 102472

Litho in USA

PH1002
PH1002J

Sheet No. 1 of 4

Rev. Date: 25 May 1994

Assembly &
Operating Instructions
for:

These instructions must be read and carefully followed. Most problems with new equipment are caused by incorrect
assembly, operation, or installation. Carefully inspect all parts upon arrival. The carrier, not the manufacturer, is
responsible for any damage resulting from shipment.

NOTE:

• Flame Out 220

TM

fire-resistant hydraulic fluid is compatible with all Power Team hydraulic equipment. This
fluid, which is available through your local Power Team distributor, does not require changing the seals in
any Power Team pump or ram.

SPX Corporation
5885 11th Street
Rockford, IL 61109-3699 USA

Internet Address:

http://www.powerteam.com

®

Tech. Services: [phone]

Fax: [phone]

Order Entry: [phone]

Fax: [phone]

Assembly & Operating Instructions, Form No. 102472, Back sheet 1 of 4

SAFETY PRECAUTIONS

WARNING: To help prevent personal injury,

●●

The following procedures should only be performed by qualified, trained personnel who are
familiar with this equipment. Operators must read and understand all safety precautions and
operating instructions included with the puller, pump, and ram before using the puller.

●●

The owner of the puller must see that it is installed and operated according to federal (OSHA),
state, and local safety standards.

●●

Safety glasses must be worn at all times by the puller operator and anyone within sight of the
puller. Locate the puller in an isolated area or shield it to minimize danger to others.

●●

It is impossible for the manufacturer to provide practical “all-purpose” shielding, because this is
a general purpose tool that can be used in many different applications. The owner of the press
must fabricate shielding that is practical and necessary for a particular application. A certain
degree of safety is provided by wrapping the work in a protective blanket (available from Power
Team) before applying pressure.

●●

The owner of this tool must ensure that all safety-related decals are installed, maintained, and
replaced if they become hard to read.

Hoses

●●

Before operating the pump, tighten all hose connections with the correct tools. Do not
overtighten. Connections should only be secure and leak-free. Overtightening can cause
premature thread failure or high pressure fittings to split at pressures lower than their rated
capacities.

●●

Should a hydraulic hose ever rupture, burst, or need to be disconnected, immediately shut off
the pump and shift the control valve twice to release all pressure. Never grasp a leaking
pressurized hose with your hands.

●●

Do not subject the hose to potential hazard, such as fire, sharp surfaces, heavy impact, or
extreme heat or cold. Do not allow the hose to kink, twist, curl, or bend so tightly that the oil flow
within the hose is blocked or reduced. Periodically inspect the hose for wear, because any of
these conditions can damage the hose and possibly result in personal injury.

●●

Do not use the hose to move attached equipment. Stress can damage the hose and possibly
cause personal injury.

●●

Hose material and coupler seals must be compatible with the hydraulic fluid used. Hoses also
must not come in contact with corrosive materials such as creosote-impregnated objects and
some paints. Consult the manufacturer before painting a hose. Never paint the couplers. Hose
deterioration due to toxic materials can result in personal injury.

Pump

●●

Do not exceed the PSI hydraulic pressure rating noted on the pump nameplate or tamper with
the internal high pressure relief valve. Creating pressure beyond rated capacities can result in
personal injury.

●●

Retract the system before adding oil to prevent overfilling the pump reservoir. An overfill can
cause personal injury due to excess reservoir pressure created when cylinders are retracted.

Puller

●●

Align the puller on the same centerline as the part being removed. Failure to align parts correctly
can result in a dangerous operating situation because of the high hydraulic pressures used.

●●

Align puller jaw and pushing adapter set-ups on the same centerline as the part being removed.
Failure to align parts correctly can result in a dangerous operating situation because of the high
hydraulic pressures used.

●●

Adjust the puller jaws equally to make flat and square contact with the part being pulled.

●●

The safety chain must be tightly attached to the jaw pin hooks before pressure is applied.

●●

Stand behind and to one side of the puller when applying pressure.

●●

Do not try to pull components that are thicker than 12” or require the jaw to be opened to more
than 48” or less than 15”.

Assembly & Operating Instructions Form No. 102472

ASSEMBLY

Sheet No. 2 of 4

Rev. Date: 25 May 1994

See Figure 1:

1. Position the left leg (60925) and the right leg (60926)
as shown. Set the pump mounting plate (60937) over
the correct holes and bolt loosely.

2. Position the upright (60924) as shown and bolt
loosely. Carefully measure from the end of each leg
to the cross tube. Make any adjustment needed to
equalize the measurements. Securely tighten the
four bolts holding the upright. Securely tighten the
four bolts holding the pump mounting plate to the
legs.

3. Mount and fasten the 8” wheels onto the frame in the
parts sequence shown.

See Figure 2:

4. Assemble the wheel dolly as shown.

See Figure 3:

5. Fasten the wheel dolly to the leg assembly.

6. Using hex head cap screws and washers, attach the pump to the pump mounting plate as shown.

7. Remove the pipe plug from the pump gauge port. Thread the 45° elbow fitting into the gauge port, angled upward

to make room for the gauge.

Note: Seal all hydraulic connections with Power Team HTS6 thread sealant. Teflon tape can be used if only
one layer of tape is used. Apply carefully, two threads back, to prevent the tape from being pinched by the
coupler and broken off inside the pipe end. Loose pieces of tape can travel through the system and obstruct
the flow of oil or cause jamming of precision parts.

8. Install the pressure gauge on the 45° elbow fitting. Turn the face of the gauge so it can be read when standing to

the right rear of the puller.

9. Assemble the hose half coupler on the hose. Thread the other end of the hose into the pump outlet pump.

Figure 2

Figure 3

Figure 1

Next

Page

Assembly & Operating Instructions, Form No. 102472, Back sheet 2 of 4

See Figure 4:

10. Clean and lubricate the threads on the ram body and head
assembly. Thread the ram into the head assembly as shown.

WARNING: To help prevent personal injury, the ram must be

fully threaded into the puller head until threads are visible on the
opposite side of the puller head block.

See Figure 5:

11. Grease the threads on the
acme threaded rod (303108).
Grease both slotted sides on
the inside of the upright tube.

12. Thread the block (303030)
about half-way down the
threaded rod.

13. Slip the block (303032) over
the threaded rod from the
end that has been designated
as the handle assembly end.
Position the blocks as shown.
Lower this assembly into the
rectangular tube.

See Figure 6:

14. Align the countersunk holes in the tube with the threaded

holes in the block (303032). Thread four 3/8-16 x 1” lg.
screws (10518) into the block finger-tight.

15. Look down from the top of the tube. Tighten each screw as

needed until the block is centered with each side parallel to
its corresponding side of the tube. The block should be
centered to about 1/16” tolerance.

16. Lower the rod until the threaded holes in the lower block

(303030) are aligned with the slot in the tube. Thread the
hex socket head shoulder screws (207459) into each side of
the block and tighten to 30 ft. lbs.

See Figure 7:

17. Position the threaded rod as shown. Place the 12” spring (207521), the

spring cap (303033), the thrust bearing (12702), and washer (12330)
over the threaded rod.

18. Insert the 1/4” roll pin (10982) into the drilled hole in the threaded rod.

Center the roll pin until about 3/8” of the roll pin is extended on each
side of the rod.

19. Place the entire spring and rod assembly into the tube.

FIGURE 4

FIGURE 5

FIGURE 6

FIGURE 7

Next

Page

Assembly & Operating Instructions Form No. 102472

Sheet No. 3 of 4

Rev. Date: 25 May 1994

See Figure 8:

20. Place the puller cart in position to fit the puller jaw head
assembly onto the spring-loaded tube upright. Attach a
crane to the lifting hook located near the head of the
puller jaw head assembly. Lift the entire assembly over
the tube upright.

21. Grease the rollers on the puller jaw and head assembly.
Grease the slotted sides of the upright tube. Lower and
slide the entire head assembly down until it rests evenly
on the shoulder bolts. IMPORTANT: The spring cap

(303033) must slide into the tube upright evenly as
pressure from the weight of the puller head assembly
pushes the spring (207521) down over the threaded
rod (303108). See Figure 9.

22. Refer to Figure 7 again. Assemble the handle (25852),
washer (10204), and nut (15013) onto the end of the
threaded rod as shown.

See Figure 10:

23. Install the ram adapter (303040) on the end of the ram
using two 3/8-16 UNC x 2-1/2” socket head screws
(10435). Tighten securely.

OPERATING INSTRUCTIONS

VERTICAL SET-UP: See Figure 11

The head and pulling jaw assembly on this puller is designed to compensate for some degree of error in a job set-up.
The puller head is spring-loaded, permitting 7° flexibility in upward movement and 3° flexibility in downward
movement. Note: Because of this feature, the head and puller jaw assembly may rest at a slight upward angle.

1. Adjust vertical set-up by using the crank handle shown in Figure 1. The centerline of the object being pulled must

be on the same centerline as the puller head. Note: Because of spring loading, you may have to turn the

crank handle several times before the head starts moving.

2. Align the puller horizontally and vertically as close as possible to the same centerline as the object to be pulled.

The head cannot compensate for poor alignment.

FIGURE 8

FIGURE 10

FIGURE 9

FIGURE 11

Next

Page

Assembly & Operating Instructions, Form No. 102472, Back sheet 3 of 4

HORIZONTAL SET-UP: See Figure 12

1. Adjust the horizontal by positioning the puller cart as shown in Figure 12. The centerline of the object being
removed must be at a 90° angle to the flat surface of the jaws and on the same centerline as the puller cart and
the puller head.

JAW and ARM ADJUSTMENT: See Figure 12 Inset

WARNING: To help prevent personal injury, do NOT apply hydraulic pressure to the object being

pulled until the angles of the jaws are set equally.

1. Move the puller arms inward to a minimum width of 15” or outward to a maximum width of 48”. In all adjustments
with the arms, maintain equal angles between the arms as shown in the Figure 12 inset. Note: If the jaw contact

area is flat and even on the object being pulled, an equal amount of threads visible on each screw shaft
would indicate an equal angle between both arms.

2. The puller jaws must also be aligned to establish maximum jaw contact that is as parallel as possible whenever
the setting of the arms is changed.

FIGURE 12

Next

Page

Assembly & Operating Instructions Form No. 102472

Sheet No. 4 of 4

Rev. Date: 25 May 1994

EXTENSION ADAPTERS: See Figure 13

Extension adapters serve as spacers between the ram and the shaft of the object to be
pulled.

Note: Use a pushing adapter (#303045 or #44745) on the end of the ram or on the
end of any combination of extension adapters. When using extension adapters, there

may be sagging away from the centerline as adapters are fitted together.
To correct the alignment, use the following procedure:

1. Before applying hydraulic pressure to an object, lift the pushing adapter to position it

on the common centerline of the object being pulled and the puller head.

2. Lightly apply hydraulic pressure to hold the pushing adapter in position. Check the

alignment. All adapters must be in a straight line and at a 90° angle to the object
being pulled.

3. When not in use, store extension adapters on the puller cart as shown in Figure 11.

SAFETY CHAIN: See Figure 14

1. Use the safety chain (#207516) at all times with this puller.

The puller arms must be hooked and checked before hydraulic
pressure is applied to the object being pulled.

LIFTING INSTRUCTIONS: See Figure 15

WARNING:

To help prevent personal injury, the following steps must be performed if it is necessary to
lift the entire 100 ton puller assembly. The cotterless hitch pin prevents the entire puller head and jaws
assembly from coming off the tube upright.

1. Lower the puller head and jaw assembly

until it is resting on the base.

2. Insert the cotterless hitch pin (#17395)

into the hole located on the tube upright
above the lowered head and jaw
assembly.

3. Hook the crane to the lifting hook located

near the head of the puller jaw assembly.

GENERAL MAINTENANCE

1. Regularly grease the acme screw, wheel zerks, all pivoting pins and the sides of the upright tube.

2. Regularly check the jaw pins for signs of excessive wear.

3. Regularly check the tightness of all nuts and bolts.

4. Look for any obvious signs of damage.

FIGURE 13

FIGURE 14

FIGURE 15