STANLEY PBCC40 Cutting Tool User Manual
- June 5, 2024
- Stanley
Table of Contents
STANLEY PBCC40 Cutting Tool User Manual
Important
To fill out a product warranty validation form, and for information on your warranty, visit www.stanleyinfrastructure.com and select the Company tab > Warranty.
Note: The warranty validation record must be submitted to validate the warranty
Warning
SERIOUS INJURY OR DEATH COULD RESULT FROM THE IMPROPER REPAIR OR SERVICE OF THIS TOOL.
REPAIRS AND / OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER.
SAFETY SYMBOLS
Safety symbols and signal words, as shown below, are used to emphasize all operator, maintenance and repair actions which, if not strictly followed, could result in a life-threatening situation, bodily injury or damage to equipment.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Danger: This safety alert and signal word indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Warning: This safety alert and signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Caution: This safety alert and signal word indicates a potentially
hazardous situation
which, if not avoided, could result in death or serious injury
Caution: This signal word indicates a potentially hazardous situation
which, if not avoided,
may result in property damage.
Notice: This signal word indicates a situation which, if not avoided,
will result in damage
to the equipment.
Important: This signal word indicates a situation which, if not avoided, may result in damage to the equipment.
Always observe safety symbols. They are included for your safety and for the protection of the tool.
LOCAL SAFETY REGULATIONS
Enter any local safety regulations here. Keep these instructions in an area accessible to the operator and maintenance personnel.
SAFETY PRECAUTIONS
Tool operators must comply with precautions given in this manual and on the stickers attached to the tool.
These precautions are given for your safety. Review them carefully before
operating the tool.
Supervising personnel should develop additional precautions relating to the
specific work area and local safety regulations.
Place the added precautions in the space provided on page 4.
PBCC40 8.8-Ton cable cutting tool will provide safe and dependable service if
operated in accordance with the instructions in this manual. Read and
understand this manual and stickers attached to the tool before operation.
Failure could result in injury or tool damage.
- Do not operate the tool unless thoroughly trained or under the supervision of an instructor. Establish a training program for all operators to ensure safe operation.
- Always wear safety equipment such as eye protection, ear protection, head protection and safety shoes at all times when operating the tool. Use gloves if necessary.
- The operator must be familiar with all prohibited work areas such as excessive slopes and dangerous terrain conditions. Ensure that your footing is firm and in balance at all times.
- Do not inspect, clean or replace parts while the battery is connected. Accidental engagement of the tool can cause serious injury.
- Do not operate a damaged, improperly adjusted or incompletely assembled tool.
- Never wear loose clothing that can become entangled in the working parts of the tool.
- Keep all parts of your body away from pinch points. Long hair or loose clothing can become drawn into the tool.
- To avoid personal injury or equipment damage, all tool repair, maintenance and service must be performed by an authorized service center.
- Never use the tool in the vicinity of flammable materials or gases.
- Do not use the tool or charge the tool battery in an explosive atmosphere.
- Cutting or severing of body parts is possible if proper procedures are not followed.
- Do not use the tool, battery or battery charger for purposes other than what is described in this manual.
- Always keep critical tool markings, such as labels and warning stickers, legible. Contact STANLEY for replacement labels.
- Do not use the tool while under the influence of drugs or alcohol.
- Do not use accessories or attachments other than those recommended by STANLEY.
BATTERIES
- Only charge batteries with a STANLEY recommended battery charger.
- Do not store batteries with metal objects, such as coins, nails or keys. Fire can result if battery terminals are shorted.
- Do not charge a damaged battery. Recycle damaged batteries and replace them with batteries recommended by STANLEY.
- Do not incinerate or dispose of batteries in the garbage. Recycle the batteries.
- Do not expose the battery to temperatures over 265°F. Batteries may explode at high temperatures.
- Leakage of liquid from the battery may occur under extreme use or high temperatures. If battery liquid gets on your skin:
- Wash quickly with soap and water.
- If the liquid gets in your eyes, flush your eyes with clean water for 10 minutes. Seek medical attention immediately.
- Never open the battery
BATTERY CHARGER
- Do not use the battery charger if the cord is damaged.
- Do not place the charger, or set items on or near the charger, in such a way as to block airflow to the charger.
- Do not use the charger with an extension cord unless absolutely necessary. Use a cord with the proper wire size for its length, as described in Table 1.
Length of Cord (Feet)| 25| 50| 100| 150
---|---|---|---|---
Wire Size (AWG)| 18| 18| 18| 16 - Do not open the charger or attempt to modify it in any way.
- Disconnect the charger from power before attempting to clean it.
- Do not connect the charger to a transformer or engine generator.
TOOL ANATOMY
WHAT IS THE PBCC40 CUTTING TOOL?
The PBCC40 is a battery powered 8.8-ton cable cutting tool with a 1.57 inch guillotine style head. The PBCC40 is capable of cutting aluminum rod up to 1.5 inches in diameter, copper rod up to 1 inch in diameter and steel rod up to 3/4 inch in diameter.
Danger: DO NOT p ut fingers, hands or other body parts between the
cutting head. Serious injury will result!
SPECIFICATIONS & ACCESSORIES
Cutting Force: 8.8 Tons (86.3 kN)
Cutting Capacity: Copper & Aluminum to 2000 MCM ACSR to 1590 Steel Cable
to .75”
Aluminum Rod to 1.5” Copper Rod to 1” Steel Rod to .75”
Jaw Type: 1.57” Guillotine
Estimated Cuts per Battery Charge: 80
Tool Cycle Time: 6.5 Seconds
Battery Type: DEWALT 20V Max, 5 amp/hour
Tool Weight: 16.7 Lbs.
Tool Length: 18.5 Inches
Maintenance Interval: 15,000 Cycles
ACCESSORIES
5 Amp/hour Lithium Ion Battery : 81188
120V AC Charger : 81189
12V DC Charger: DCB119
Note: Only use battery chargers recommended by STANLEY.
Bucket Bag: BB01
OPERATION
CHARGE BATTERY
USING THE PBCC40
Danger:
DO NOT put fingers, hands or other body parts between the cutting head.
Serious injury will resul t!
- Set the trigger lock.
- Insert battery.
- Fasten the cutting head around the cable.
- Release the trigger lock. Press and hold the trigger until the cable is cut. Press and hold the pressure release to open the cutting head.
Note: Release the trigger to immediately stop the tool. Press the pressure
release at
any time to open the jaws.
INTELED SYSTEM
The Intel LED light ring shows the status of the cut in real-time.
White: The tool is cutting. Intel LED will stay lit for 30 seconds
after the cut is complete.
Green: The tool has developed full hydraulic pressure during the cut.
Red: The tool did not develop full pressure during the cut. You may
need to cycle the tool again.
CHECKING BATTERY CHARGE
REPLACING THE BLADES
Danger:
DO NOT install or change blades while the battery is connected to the tool.
Disconnect the battery BEFORE installing or changing blades.
TROUBLESHOOTING
| Problem | Solution |
|---|---|
| The head pin won’t fit through the hole in the cutting head. | Press and hold |
the pressure release. Ensure the two halves of the cutting head are aligned.
Close the cutting head and insert the head pin.
The tool won’t cut when I press the trigger.| Ensure the battery is charged.
Disengage the trigger lock.
The InteLED flashes yellow when I activate the tool.| The maintenance interval
is about to elapse. Have the tool serviced as soon as possible.
The tool repeatedly give me bad cuts / The InteLED flashes red after every
crimp.| Ensure the battery is fully charged. Ensure the blades are in good
condition. If problem persists, have the tool serviced as soon as possible.
The tool is leaking hydraulic oil.| Have the tool serviced immediately.
PBCC40 PARTS ILLUSTRATION
| ITEM | P/N | QTY | DESCRIPTION |
|---|---|---|---|
| 31 | 36056DUB | 1 | Spring |
| 37 | 91649 | 2 | Side Membrane |
| 38 | 91650 | 2 | Rear Membrane |
| 41 | 91655 | 1 | Trigger Lock |
| 42 | 77058-01 | 1 | Shackle |
| 43 | 91593-STA | 1 | Housing Set |
| 44 | 91439 | 1 | LED |
| 46 | JP324060 | 1 | Seal |
| 47 | 77051-01 | 1 | Shackle Holder |
| 48 | 91410 | 1 | USB Cover |
| 49 | AIG4X19.8BP | 1 | Calibrated Pin |
| 50 | 77061 | 1 | Spring |
| 87 | AGEM5.24 | 1 | Elastic Pin |
| 89 | VAV04CB006 | 4 | Screw |
| 93 | VAV05HC025 | 2 | Screw |
| 94 | VAV05HC040 | 2 | Screw |
| 98 | VAV3.5TC014ZN | 13 | Screw |
| 99 | 91350 | 1 | Protection Cover |
| 101 | 91633 | 1 | STANLEY Label |
| 102 | 91642 | 1 | PBCC40 Label |
| 103 | 91634 | 1 | “Powered by De- Walt” Label – Left |
| 104 | 91635 | 1 | “Powered by De- Walt” Label – Right |
| 105 | 91636 | 2 | InteLED Label |
| 106 | ZSETPD337 | 1 | Crush Hazard Label |
| 115 | VAV05CV005 | 1 | Screw |
| 120 | 36052DUB | 1 | Screw |
| 135 | ACKR0204 | 1 | Grooved Pin |
| 136 | 91465 | 1 | Strip Ring |
| 155 | JAE4500125 | 1 | Anti-Extrusion Ring |
| 156 | J3740180 | 1 | O-Ring |
| 161 | VAV05TT006L | 1 | Screw |
| 250 | 91856 | 1 | Motor Reduction Unit |
| 251 | 1 | Cutting Head Unit | |
| 252 | 1 | Reservoir Unit | |
| 253 | 1 | Hydraulic Unit | |
| 263 | 92886 | 1 | Electronic Device |
| 264 | 77853-STA | 1 | Advance Trigger Unit |
| 265 | 77854-DEW | 1 | Release Trigger Unit |
| ITEM | P/N | QTY | DESCRIPTION |
| 270 | 36818C | 1 | Piston Unit |
| 272 | 78805C-01 | 1 | Sleeve Unit |
PBCC40 HYDRAULIC BODY ILLUSTRATION
| ITEM | P/N | QTY | DESCRIPTIO N |
|---|---|---|---|
| 4 | 77504 | 1 | Spring |
| 11 | BILL06.35 | 1 | Ball |
| 12 | 30189DUB | 1 | Spring |
| 21 | 91571 | 1 | Hydraulic Body |
| 28 | 77026-04 | 1 | Spring |
| 63 | 87213 | 1 | Spring |
| 65 | AAIN30 | 1 | Circlip |
| 69 | J0720190 | 1 | O-Ring |
| 71 | BILL04.76 | 1 | Ball |
| 73 | J0290178PU70 | 1 | O-Ring |
| 76 | J4300200 | 1 | O-Ring |
| 77 | JAE0500100 | 1 | Anti-extrusion Ring |
| 82 | JSR1927205 | 1 | Wiper Ring |
| 83 | R1B12.30.08Z | 1 | Ball Bearing |
| ITEM | P/N | QTY | DESCRIPTION |
| 95 | VIV08TT008 | 2 | Screw |
| 96 | VAV06TT008 | 1 | Screw |
| 118 | 77030 | 1 | Spring |
| 119 | 77016 | 1 | Sliding Part |
| 125 | BILL03.175 | 1 | Ball |
| 256 | 77803 | 1 | Release Device |
| 257 | 77805-01 | 2 | Delivery Valve Unit |
| 258 | 77806-01 | 1 | Succion Valve Unit |
| 259 | 77848C-02 | 1 | Spring Collar Unit |
| 260 | 77849C | 1 | Cam Compartment Unit |
| 267 | 77804C | 1 | Commutator |
PBCC40 RESERVOIR PARTS LIST
| ITEM | P/N | QTY | DESCRIPTION |
|---|---|---|---|
| 2 | 30176DUB | 1 | Reservoir Plug |
| 7 | 91569 | 1 | Oil Reservoir |
| 13 | 77009-02 | 1 | Reservoir Body |
| 25 | VAV04CB015 | 1 | Screw |
| 68 | AIG4X29.8BP | 1 | Calibrated Pin |
| 71 | BILL04.76 | 2 | Ball |
| 74 | J0640190 | 2 | O-Ring |
| 75 | 91576 | 1 | Metal Clamp |
| 78 | JAE0700150 | 2 | Anti-extrusion Ring |
| 80 | J0420250 | 1 | O-Ring |
| 81 | ZBINA420 | 1 | Magnet Pin |
| 85 | VAR04W | 1 | Washer |
| 86 | 91232 | 1 | Release Trigger |
| 90 | VAE04 | 1 | Nut |
| 97 | VAV08BP008 | 2 | Screw |
| ITEM | P/N | QTY | DESCRIPTION |
| 254 | 92884-07 | 1 | Overload Valve |
| 262 | 77851C | 1 | Bodies Connector |
| 263 | 77852-DEW | 1 | Release Lever Unit |
PBCC40 CUTTING HEAD
| ITEM | P/N | QTY | DESCRIPTION |
|---|---|---|---|
| 55 | 77495 | 1 | Double Fork Head |
| 56 | 36058DUB | 1 | Locking Pin |
| 62 | VAV04PF | 1 | Ball Headed Dowel |
| 75 | 36051DUB | 1 | Counter Blade Base |
| 76 | 36052DUB | 1 | Blade |
| 77 | 36054DUB | 1 | Slide Way |
| 78 | 36055DUB | 1 | Slide Way |
| 79 | 36057DUB | 1 | Pin |
| 80 | 36059DUB | 2 | Pin |
| 81 | AAEN12 | 2 | Circle |
| 82 | TCA01.5 | .13 | Stainless Steel Cable |
| ITEM | P/N | QTY | DESCRIPTION |
| 83 | VAV10HC030 | 4 | Screw |
| 85 | VAV05TT010 | 2 | Screw |
STANLEY Infrastructure
6430 SE Lake Road
Portland, Oregon 97222 USA
503-659-5660 / Fax
503-652-1780
www.stanleyinfrastructure.com
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