PRECISION-HAYES INTERNATIONAL PSB05 TH, PSB06 TH PocketShear User manual

Battery Powered PocketShear®
PHI0106
Rev. B
01/15
Series:
PSB05-TH
PSB06-TH
(for 0.5" and 0.6" PC Strand)
• Easy to use in the field
The unit should leave a cut end that is even and free of
burrs, at a specified dimension from the anchor face.
• Does not pull, push or heat the strand,
anchor or wedges
It simply rotates one cutting blade in relation to another.
All of this is accomplished within the confines of the unit
with no external moving parts except the rotation of the
clamp assembly.
• Operation requires standard safety precaution to be
adhered to,
as any trained operator of field hydraulic equipment should
be aware.
Cut Tendon Tails in
All applicable OSHA rules and standards should be applied
when utilizing this device.
• PSB05-TH for 0.5" Strand
the Pocket —
Is manufactured in configuration for most elevated
structures.
The unit is shipped in a configuration to allow 1" of
strand from the anchor face. This also allows caps on
encapsulated anchors to be placed effectively.
Quickly, Safely and Flameless
• PSB06-TH for 0.6" Strand
Is manufactured in configuration for most elevated
structures.
The unit is shipped in a configuration to allow 1¼" of
strand from the anchor face. This also allows caps on
encapsulated anchors to be placed effectively.
Proudly made in the USA.
Battery Powered
PocketShear®
1
Unpacking and Assembly
Series PSB05-TH / PSB06-TH
Assembly / Safety / Operation
2.1
Wear protective eye wear at all times.
The .5" Model PSB05-TH Series is intended for use
ONLY on .5" PC Strand that has been stressed. The
.6" Model PSB06-TH Series is intended for use ONLY
on .6" PC Strand that has been stressed.
Remove the BatteryShear® from the travelbox in
which it was shipped. Remove the 28 VDC LithiumIon batteries from the case. Read the battery
instruction sheets carefully and make sure the
chargers are set for the proper input power based on
your location. Place the battery in the charger to bring
the pack up to full charge, following the instructions
carefully. The BatteryShear® is now ready to be used.
Wear protective eye wear at all time.
Never place hands or fingers near the
tendon or clamp during operation!
The following are parts shipped with the Battery
Powered PocketShear® Model PSB05-TH and
PSH06-TH Series:
2
1
PocketShear®
2
Two 28 VDC Battery Pack
3
One 28 VDC Battery Charger
4
One Carrying Case
5
Grease Gun
6
Tubes of Moly Grease (Part #385355)
7
Instruction Sheet
Check to make sure that the nosepiece mounting
bolts are tight.
Confirm that elongations
have been approved by the
engineer of record prior to
cutting any tendons!!
1. With the PocketShear® in its "Home" position
place the unit over the tendon tail left after the
stressing operation.
2. Push the nose of the PocketShear® into the
pocket, pressing the nosepiece firmly on the
anchor face.
Safety Information
3. The tendon should now protrude through the
BatteryShear® unit and clamp.
The PocketShear® is a special purpose device
designed to cut the remaining tail of a stressed .5" or
.6" PC strand, in the pocket, at a specific dimension
from the face of the ductile iron anchor. Any other use
is considered a misuse and it is the responsibility of
the purchaser to ensure that this does not occur. The
following are important Safety Rules:
• Only trained, qualified operators should use
this device
• Cutting .5" or .6" strand shorter than 16" can cause flying
debris and potentially damage the device
• Cutting .5" or .6" strand without the clamp fully engaged
can cause severe damage to the unit and injury to the
operator
• Wear eye protection at all times
• Do not hang off of edge of building to use this device
• NEVER PLACE HANDS OR FINGERS NEAR THE
OPENING INTENDED FOR .5" or .6" PC STRAND
• Periodically check the mounting bolts on the nosepiece to
make sure they are tight
• Perform cutting test (see Section 4) periodically to assure
proper functioning of unit
• Do not operate unit if in conflict with other .5" or .6" PC
strands
2
Safe Use of the PocketShear®
• Actuate the tool
4. When the cut is complete and tool removed from
the pocket and the risk of dropping the tendon is
over, remove the tendon from the rear clamp and
discard according to job site criteria.
3
Charging the Batteries
When your battery powered PocketShear is first
removed from the case, every effort is made to have
the (2) two batteries charged and ready to use. The
battery level can be determined by using the "fuel
gauge" on the battery pack. If the battery is in need of
charging then charge using the supplied charger for at
least one hour.
CAUTION: The MET 28 VDC are the only
batteries to be used on the Battery PocketShear.
Use of any other type of battery pack will void the
warranty and may result in damage to the unit or
personal injuries.
www.pocketshear.com
Battery Powered
PocketShear®
Series PSB05-TH / PSB06-TH
Operation /Care and Maintenance
CAUTION: The MET 28 VDC batteries must be charged
with the proper charging system. A one-hour fast
charger is provided with the tool and will charge a
discharged battery in approximately 1-hour. Use of any
other charger will void the warranty and may damage
the battery pack and cause personal injuries.
4
The retention clamp in the back of the Shear will
automatically retain the cut tendon. The tendon can
be removed by pulling out the tendon from the back of
the Shear
LED Readout
The Battery Powered PocketShear is designed to
provide feedback to the operator through a panel of
three colored LED’s. This panel is located below
the handle on the right-side of the tool. The panel
features three LED’s, one RED, one GREEN and one
YELLOW. These lights provide status information and
also alert the operator to pending maintenance issues.
Below is a list of the LED information:
• All lights flashing: Unit was powered on and is not
in home position. Pull trigger and release to have
unit seek home position
• Green-solid: Unit is in Home position and ready
to cut
• Green-Flashing: Unit is in cutting cycle
• Yellow-solid: Grease nose piece – Press reset
button two (2) seconds to continue
• Yellow – Flashing: Change fixed shear blade. Press
reset button five (5) seconds to continue
• Red-Solid: Not Ready / Fault condition- Red light
will be on when yellow lights are on
• Red-Flashing: Unit returning to home position
Wear protective eye wear at all time.
5
During the Auto-return part of the cycle, the RED LED
will flash, indicating that the tool is returning to home.
Once in the home position, the GREEN LED will light,
indicating the tool is ready for the next cutting cycle.
Cutting Tendons with the Battery
PocketShear®
Place the Battery PocketShear over the exposed
tendon tail until the nose-piece is fully into the pocket,
and it is pressing up against the anchorage. Holding
the Shear steady, press the trigger and hold until
the Shear finished its cut, or fully rotates and starts
returning. During this time, the trigger can be released
and the return-cycle continues automatically.
Releasing the trigger anytime before the cutting cycle
is complete will cause the tool to automatically return
to the home position. Once in the home position, the
tool will stop and await the next cut-cycle.
6
Care and Maintenance
The BatteryShear® is easy to use and intuitive to
maintain once a qualified operator is properly trained
on the unit.
The BatteryShear® does not require extensive
maintenance. However, a few issues must be dealt
with regularly in order to extend the life of the unit.
Review all subsections of this heading for pertinent
information.
6.1
Storage
Always store the Battery PocketShear® in the travel
box in a safe, dry area that is out of traffic lanes and
not near the edge of any area that could allow it to be
knocked off of a ledge when stored on a job site.
The BatteryShear® should always be cleaned prior to
placement in storage.
6.2
Cleaning and Lubrication
The Battery
PocketShear®
should be kept
clean at all
times. The outer
surfaces are
aluminum and
should need only
water and a clean
Grease fitting for blade liubrication
rag to maintain.
All Enerpac produced units are hard-coated
aluminum. Clean with a damp rag and water.
Approximately every 250 cuts the unit
should be greased using the grease fitting
on the nose piece. Pump injected three or
3
Battery Powered
PocketShear®
more pumps of approved Moly-fortified
multi-purpose grease using the supplied
grease gun. Additional grease cartridges
may be ordered from the factory. This may
be required more frequently if the cutting
conditions are extremely dirty.
6.3
Cleaning the Clamp
The clamp will attract considerable dirt, especially
in Slab-on-Grade conditions. The clamp should be
cleaned regularly, based on the job site conditions.
This can be accomplished by removing the rear clamp
housing and cleaning the clamp cavity, including all areas.
An air hose or stiff brush can be used. The rest of the
components are aluminum and should not be affected.
Series PSB05-TH / PSB06-TH
Care and Maintenance
Upon removal of the nose, the wear plate is
exposed. Check for excessive wear and replace
if necessary prior to reassembly. The wear plate
should be cleaned and lubricated, with an approved
lubricant (Moly-Fortified Multi Purpose Grease,
or equivalent), at the area of contact with the
rotating blade only, prior to reassembly.
Hold the nose vertical with the base at the bottom.
Gently shake the nose, up and down, to help the
rotating blade fall free. The newer the unit, the tighter
the fit. It may be necessary to turn the blade and pull
on the square drive hub with a large pair of channel
lock pliers to remove the blade. Inspect the blade for
cracks and chips at the cutting surface. It is common
to see slight “ding marks” at the cutting surface.
This is not necessarily a cause for replacement of
the rotating blade. Replace if necessary with a new
blade. Over use of the rotating shear blade may
cause poor tendon cutting and excess cutting forces.
Clean and lubricate the blade , with an approved
lubricant, Moly-Fortified Multi Purpose Grease,
or equal, on the surfaces shown in figure 6.3 below
prior to re-assembly.
View of clamp housing removed.
7
DO NOT
lubricate
this area.
Lubrication and Replacement
Shear Blade Replacement and
Lubrication
The cutting blades should be lubricated using the
supplied lubrication gun every 200-300 cuts depending
on the cutting conditions. This is completed by
injecting 3-4 pumps of moly-fortified lube through the
lubrication fitting on the nose piece. The lube will be
distributed most effectively if the unit is cycled once
during the lube process. The unit will need cleaning
and lubrication every 1,000 to 1,250 cuts. This
coincides with the need to replace the fixed shear
blade.
In order to lubricate the rotating blade it is necessary
to remove the nose of the unit. This is accomplished
by removing the six (6) mounting bolts in the nose.
4
Lubricate only along
surface of dashed line.
Gently tap the base of the nose flatly on a clean,
dry surface to cause the small “fixed” blade to drop
out of its pocket. As with the rotating blade, the fit
is tight. The newer the unit, the tighter the fit. Clean
and inspect the fixed blade for cracks. (NOTE: DO
NOT FORCE THE BLADE INTO THE POCKET.
PROPERLY ORIENTED, THE BLADE WILL “FALL”
INTO PLACE.) Lubricate the center hole in the nose
and insert the lubricated rotating blade. Orient the
blade to match the opening in the nose. Re-attach
the nose to the body of the BatteryShear® with the
six bolts previously removed during the disassembly
process.
www.pocketshear.com
Battery Powered
PocketShear®
Series PSB05-TH / PSB06-TH
Troubleshooting
8
Troubleshooting
This section corresponds to the FAQ on the PocketShear®
website, located at: http://www.PocketShear.com. The
latest and most complete list of troubleshooting items are
listed in the FAQ on the website.
NOTE: The most common cause for problems
with a Battery PocketShear® is an operator that
does not fully engage the shear all the way up
to the anchor.
Q The unit doesn’t do anything when I press the switch.
A The battery is either not fully charged or not fully
engaged into the mount.
Q What size strand can I cut with a Battery
PocketShear®?
A The Model PSB05-TH will cut ½" PC strand. The Model
PSB06-TH is used for cutting .6" PC strand.
Q I hear a “clicking” sound when the unit nears the
specification, there is no reference to allowable surface
hardness ranges on the wires that make up the strand.
Hard and soft spots occur randomly along the length of
the strand.
Q Why does blade life seem better in some batches as
opposed to other batches?
A All shear blades are manufactured to strict
manufacturing standards. Each blade is checked
through a detailed QA procedure. The variance you
experience is generally due to the actual strand
hardness variance. See answer above.
Q Why won’t the Battery PocketShear® fit over the
strand?
A There can be several factors:
1. Check to see that the strand has not been
“flattened”, or otherwise deformed, during the
stressing operation. Generally, a pair of channel lock
pliers can fix the problem.
2. Check to see that the Battery PocketShear® is fully
returned to its “HOME” position. If the shear does
not return to "HOME" position, it should be sent
back for service.
end of the cut cycle or the return cycle. Is this OK?
A Yes. This is the sound of the tool shearing the strand,
which sometimes shears one wire at a time.
Q Why did the nose fall off during cutting?
A There are two causes for this occurrence. Both are
considered operator error.
Q The clamp seems too loose to hold the unit in the
pocket.
A Clean the clamp area of debris.
Q One wire was left after I cut the PC Strand. What
went wrong?
A PC Strand is 7 wire strand. This means that six wires
are wrapped around one. The Battery PocketShear®
actually cuts one wire at a time. Incomplete cutting
cycles will leave wires uncut.
1. Put the Battery PocketShear® back in the pocket
and actuate fully to cut the remaining wire.
2. Check for excessive wear on the blades. Worn
blades will also cause this condition.
1. Due to the repeated shock of cutting, the nose
bolts on a unit can tend to work themselves loose
during cutting. Check periodically for tightness of
the bolts.
2. Use “Loctite” to secure bolts.
3. Cutting with loose nose bolts allows the cutting
surfaces of the blades to separate. Loose bolts also
leave fewer engaged threads to accomplish the
designed load transfer to the housing and will lead
to unit damage and/or premature failure.
FOR MORE INFORMATION: See the FAQ (Frequently Asked
Questions) section of the PocketShear® website at:
http://www.PocketShear.com
If you have found issues that should be listed in this manual, please
don’t hesitate to call or write to us in order to have your suggestions
included.
Q Why do I hear a different “popping” sound from time
to time during the actual cutting cycle?
A The PC Strand is manufactured under the ASTM
A416 specification in the U. S. and abroad. Within this
5
BatteryShear™ Series PSB05-TH / PSB06-TH
Repair Parts Section
PSL0106
Rev. A
12/12
PSB05-TH
62 63 66
19 24
22
59 46
60 50
45
16 21 36
31 9 8
18 35
23
7 40
44
3
17 35
47
5 30 32 64 66
20
43 58
25
35 41 42 56 56
14
4 30
28 37
61
12
11
48
26 42 49 54
29 38 39
51 52
1 26 27
10 33
53 59
13
45
44
47
46 59
PSB06-TH
43 58
50 60
35 41 42 56 57
48
26 42 49 54
51 52
53 59
6
www.pocketshear.com
Battery Powered
PocketShear®
Series PSB05-TH / PSB06-TH
Repair Parts Section
Repair Parts List for PSB05-TH
Item
Part No.
Qty.
1
460498
1
PSB0X-TH Main Drive Housing
Description
3
460125
1
PSB0X-TH Gearbox Spline Lock
4
460152
1
PSB0X-TH Battery Shoe
5
385225
1
PSB Battery Connector
6
385226
1
PSB Switch Wire-18GA Blk Strd
7
460115
1
PSB0X-Th Primary Drive Gear
8
460150
1
Repair Parts List for PSB06-TH
Item
Part Number
Qty. Description
26
385135
10
PSB 8-32 Helicoil -.5 l W/TANG
35
385170
14
PSB 8-32 x .75 SHCS
41
460630
1
PSB06-TH Drive Front Housing
42
385200
2
PSB 6812 RS Bearing
43
460135
1
PSB0X-TH Rot Shr Pressure Ring
Psb0x-Th Sensor Adj Plate
44
460605
1
PSB06-TH Fixed Shear Blade
460610
1
PSB06-TH rotatng shear blade
9
385212
2
PSB Sensor Magnet Ø.125X.375
45
10
460145
1
PSB0X-TH Main Drive HSG Cover
46
460600
1
PSB06-TH .6" Std Nose Piece
11
460170
1
PSB0X-TH Hex Motor Coupler
47
385205
1
PSB wave spring
12
460172
1
PSB0X-TH Spline Motor Coupler
48
460640
1
PSB06-TH Drive Gear
13
385216
1
PSB0X-TH 28V Drive Motor
49
460650
14
385222
1
PSB0X-TH Gearbox
15
385380
1
PSB ~16" - 14ga Wire - Red
50
460085
1
PSB0X-wear plate
15
385385
1
PSB ~16" - 14ga Wire - Black
51
460660
1
PSB06-TH .6 wedge clamp 3pc
52
385210
6
PSB O-RING
1
PSB06-TH Front Hsg Mounting Pl
16
385238
1
PSB PCB Assembly
17
460155
1
PSB0X-TH Left Handle
53
460670
1
PSB06-TH .6 Clamp Housing
18
460160
1
PSB0X-TH Right Handle
54
385215
3
PSB Bushing Ø.1890 x 1/2
19
385228
1
PSB Trigger Switch
56
385340
3
PSH & PSB 1/4 X 1 Dowel Pin
20
385115
1
PSB Branding Label - Right
57
385220
4
PSB dowel pin .1875 X .875
21
385130
4
PSB 6-32 X .5 PPH Plastic Scrw
58
385250
1
PSB 8-32 x .375 PH truss screw
22
385120
1
PSB branding label - left
59
385255
8
PSB 1/4-20 x 1.25 SHSC
23
385125
3
PSB LED Light Pipe for PCB
24
385226
1
PSB Switch Wire-18GA Blk Strd
60
385260
3
PSB 10-32 x .50 Ph Btn Hd Screw
25
385236
2
PSB 28V Lithium Battery/MT3544
26
385135
10
PSB 8-32 Helicoil -.5 l w/Tang
27
385140
4
PSB Dowel Pin .1875 X 1.25
28
460165
1
PSB0X-TH Gearbox Mount
29
460175
1
PSB0X-TH Motor Mount
30
385145
4
PSB 6-32x.5 SHSC
31
385150
2
PSB 4-40x.375 Hex Btn Head Scr
32
385155
2
PSB 6-32 x.25, Truss Hd Screw
33
385165
4
PSB 6-32 x .50 SHCS
35
385170
14
PSB 8-32 x .75 SHCS
36
385175
4
PSB 6-32 x .375 SHCS
37
385180
4
PSB 8-32 x .5 SHCS
38
385185
2
PSB 10-32 x .375 SHCS
39
385190
3
PSB 10-32 x .25 SHSS
40
385195
1
PSB 8-32 X .25 SHSS
41
460060
1
PSB05-TH Drive Front Housing
42
385200
2
PSB 6812 RS Bearing
43
460135
1
PSB0X-TH Rot Shr Pressure Ring
44
460080
1
PSB05-TH .5" Fixed Shear Blade
45
460075
1
PSB05 .5' Rotatng Shear Blade
46
460070
1
PSB05-TH .5" Std Nose Piece
47
385205
1
48
460072
1
PSB Wave Spring
PSB05-TH Main Drive Gear
Cont. on next page
7
Repair Parts List for PSB05-TH
49
Item
Part No.
460065
Qty.
1
50
460085
1
Description
PSB05-TH Front HSG Mounting Plate
PSB05-.5" Wear Plate
51
460095
1
PSB05-TH .5" Wedge Clamp 3 pc
53
460090
1
54
385215
3
56
385340
3
57
385220
4
58
385250
1
59
385255
8
60
385260
3
61
385265
4
62
385390
2
63
385395
1
64
385400
1
66
385405
1
PSB05-TH Clamp Housing
PSB Bushing Ø.1890 x 1/2
PSH & PSB 1/4 X 1 Dowel Pin
PSB Dowel Pin .1875 X .875
PSB 8-32 x .375 PH Truss Screw
PSB 1/4-20 x 1.25 SHSC
PSB 10-32 x .50 Ph Btn Hd Scre
PSB Crimp Connector
PSB Connector Pin - Trigger
PSB Connector Plug - Trigger
PSB Lead Wire Assembly-Black
PSB Lead Wire Assembly-Red