OTC Puller Set Instruction Manual

Product Overview

The OTC Puller Set (Model 4518) is a comprehensive 13-piece combination set designed for a wide variety of pulling jobs, particularly those involving bearings and bushings. It includes two popular bearing splitters (2-inch and 3-inch), four sets of hex push puller legs, and a 5-inch bar-type puller head with a forcing screw. This versatile tool set is engineered for durability and efficiency, providing robust solutions for automotive service challenges.

Key Features:

• Separator tools are used with bar puller and legs for a wide variety of pulling jobs.
• Includes the two most popular bearing splitters - 2 inch and 3 inch - plus four sets of hex push puller legs.
• 5 inch bar-type puller head with forcing screw.
• The 5 inch puller cross-bar with a 6-1/4 inch forcing screw and each of the bearing separators may be used separately or in combination with other pullers or tools.
• Blow-molded plastic storage case keeps set contents organized and protected from loss.

Components and What's in the Box

Your OTC Puller Set comes with the following components, neatly organized within a durable blow-molded plastic storage case:

• Main Puller Unit: Consists of a 5-inch bar-type puller head with a 6-1/4 inch forcing screw.
• Bearing Splitters: Includes two sizes, a 2-inch splitter and a 3-inch splitter. These are designed to separate bearings from shafts or housings.
• Hex Push Puller Legs: Four sets of varying lengths, allowing for adjustable reach and versatility in different pulling applications. These can be joined together to achieve longer lengths.
• Instruction Guide: A detailed manual providing guidance on proper usage and safety.

Setup

Before using the OTC Puller Set, ensure you have identified the correct components for your specific pulling task. Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.

1. Select Bearing Splitter: Choose either the 2-inch or 3-inch bearing splitter based on the size of the bearing or component you need to separate. The splitter should fit snugly around the component.
2. Attach Puller Legs: Securely attach the appropriate length of hex push puller legs to the bearing splitter using the provided nuts and bolts. You may combine multiple legs to achieve the required reach.
3. Connect Bar-Type Puller Head: Thread the bar-type puller head onto the top of the assembled puller legs. Ensure it is securely fastened.
4. Position Forcing Screw: The forcing screw should be aligned with the center of the shaft or component you intend to pull.

Operating Instructions

The OTC Puller Set is designed for safe and effective removal of press-fit components such as bearings, gears, and bushings. Follow these steps carefully:

1. Prepare the Workpiece: Clean the area around the component to be removed. Ensure there is clear access for the puller.
2. Position the Splitter: Place the selected bearing splitter around the component, ensuring its jaws are firmly gripping the component's inner race or a suitable pulling surface. Tighten the splitter bolts evenly to apply initial pressure.
3. Assemble the Puller: Attach the puller legs to the splitter and then the bar-type puller head to the legs. The forcing screw should be centered on the end of the shaft.
4. Apply Force: Slowly turn the forcing screw clockwise using an appropriate wrench. This will apply pressure, gradually pulling the component off the shaft. Apply steady, even pressure. Do not use impact tools unless specifically instructed for a particular application, as this can damage the tool or workpiece.
5. Monitor Progress: Observe the component as it separates. If it resists, do not force it. Re-evaluate the setup, ensure proper alignment, and consider applying penetrating oil if necessary.
6. Component Removal: Continue turning the forcing screw until the component is fully separated and removed.
7. Disassembly: Once the component is removed, carefully loosen the forcing screw, detach the puller head, remove the legs, and finally, loosen the bearing splitter.

Advanced Applications: The bearing splitter can also be used as a support base for pressing out bushings from components like control arms when used with a hydraulic press. Position the control arm on the splitter, ensuring stability, then use the hydraulic press to apply force to the bushing.

Maintenance

Proper maintenance will extend the life of your OTC Puller Set and ensure its continued performance:

• Cleaning: After each use, wipe down all components with a clean cloth to remove dirt, grease, and debris.
• Lubrication: Periodically apply a light coat of machine oil to the forcing screw threads and other moving parts to prevent rust and ensure smooth operation.
• Inspection: Regularly inspect all components for signs of wear, damage, or deformation. Pay close attention to the threads of the forcing screw and legs, and the edges of the bearing splitters. Replace any damaged parts immediately.
• Storage: Always store the puller set in its original blow-molded plastic case in a dry, clean environment to protect it from moisture and physical damage.

Troubleshooting

If you encounter issues while using your OTC Puller Set, consider the following:

• Component Not Moving:
  • Ensure the bearing splitter is correctly positioned and securely gripping the component.
  • Verify the forcing screw is centered and applying direct pressure.
  • Apply penetrating oil to the component and allow it to soak.
  • Ensure the puller legs are of adequate length and securely fastened.
• Tool Slipping:
  • Check that all bolts and nuts are tightened securely.
  • Ensure the component surface is clean and free of excessive grease.
  • Re-position the bearing splitter for a better grip.
• Damage to Component/Tool:
  • Avoid excessive force. If the component is extremely stubborn, consider alternative methods or professional assistance.
  • Ensure the correct size bearing splitter is used for the application.
  • Do not use damaged components of the puller set.

Specifications

Warranty and Support

OTC products are known for their quality and durability. For specific warranty information and support, please refer to the official OTC website or contact their customer service directly. Keep your purchase receipt as proof of purchase for any warranty claims.

You can find more information and contact details by visiting the OTC Store on Amazon.