GEARENCH P95-525 User Manual

POP-IT™ Tool

Model P95-525

Warning

Improper use of POP-IT™ Tools may result in injury or
death. Do Not Exceed Rated Load of 10,000 lbs. Always
Chock Your Work. Follow operating procedures.

GEARENCH™

P.O. Box 192

4450 South Highway 6

Clifton, Texas 76634

Phone: [phone]

Fax: [phone]

© 2008 by GEARENCH. All rights reserved

Form P95-525 Revision 07/08/08

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Table of Contents

POP-IT™ Tool Description .............................................................................................. 2

Warranty ........................................................................................................................... 2

Safe Practices and Procedures ......................................................................................... 4

Responsibility ............................................................................................................................................. 4

Safety .......................................................................................................................................................... 4

Warnings .................................................................................................................................................... 4

POP-IT Tool Inspection ............................................................................................................................. 4

Operating Procedure – Flange Work .............................................................................. 5

Operating Procedure – Lifting Work ............................................................................. 6

Replacement Parts ............................................................................................................ 7

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POP-IT™ Tool Description

The POP-IT™ Tool takes the place of the hammer, pry-bars and wedge when working
with flanges. It can also be used as an equipment lifting tool. The Model P95-525 reduces
the risk of injury, is lightweight and compact and requires minimal maintenance. The tool
holds its setting without drifting, has precision adjustment and can spread 5 tons to 5 ¼
inches. The Model P95-525 is unique for tight spots since it has ratcheting action and a
.070 inch entrance. The Model P95-525 comes with all parts attached and external power
is not needed. It’s ready to use out of the box.

Warranty

What Is Covered

GEARENCH
workmanship.

How Long Coverage Lasts

This express warranty lasts for the lifetime of the GEARENCH tool. Warranty coverage ends when the
tool becomes unusable for reasons other than defects in workmanship or material.

How Can You Get Warranty Service

To obtain the benefit of this warranty, contact a GEARENCH sales representative in Clifton, Texas.

What Will We Do To Correct Problems

Warranted products will be repaired or replaced, at GEARENCH’s option, and returned at no charge to
you, the original purchaser; or, if after three attempts at repair or replacement during the warranty period,
the product defect in material or workmanship persists, you can elect to receive a full refund of your
original purchase price for the product.

What Is Not Covered

Defects, failures or conditions that are due to normal wear and tear, abuse or misuse, are not covered by
this limited warranty. In addition, this limited warranty is in lieu of all other warranties, express or implied,
verbal or written. To the maximum e xtent allowed by law GEARENC H disclaims all implied warra nties,
including i mplied warranties of merchantability and/or fitness for a pa rticular purpose. GEARENCH also
specifically denies any liability for any incidental damages and/or consequential damages, including but not
limited to property damage to property other than the product itself, loss of sales profits, down time, costs
or any other damages measurable in money, whether or not included in the foregoing enumeration.

Please be advised that so me states do not allow the e xclusion or limitation of incidental or consequential
damages, so t his l i mita tion or exclu sio n may no t ap p l y to you. This war r a nt y gi ve s you s p e ci fic r i gh ts , a nd
you may also have other r ights, whic h vary from state to state, province to province, o r country to country.

Are Personal Injuries Covered

In the event you, someone wo rking for you, or any o ther person sustai n a personal injur y as a result of
using the GEARENCH tool, GEARENCH limits its potential liability for such a claim or injury to the
fullest extent allowed by law, and discla ims and denies any liability for such personal injury.

Please be advised that some st ates do not allo w the e xclusion or limitatio n of lia bility for per sonal injurie s,
so the above l imitation or exclusion may not apply to you, or the individual claiming injury.

No Other Express Warranty Applies

™

tools are expressly warranted to you, the purchaser, to be free of defects in material and

GEARENCH · 4450 South Highway 6 · P.O. Box 192 · Clifton, TX 76634

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This GEARENCH LIMITED WARRANTY is the sole and exclusive warranty, express or implied for
GEARENCH products. No employee, agent, dealer or other person is authorized to alter, modify, expand
or reduce the terms of this warranty or to make any other warranty on behalf of G EARENCH.

Law Applicable

All matters related to the sale and/or use of the GEARENCH tool that is the subject of this limited
warranty, along with the construction and enforcement of the terms of this limited warranty itself, shall be
subject to the substantive and procedural laws of the state of Texas, not the conflicts of laws provisions of
Texas, but rather the laws of Texas themselves.

Forum Selection Clause

Any dispute arising out o f the sale and/or use of the GE ARENCH tool that is the s ubject of this limited
warranty shall be presented in the form of a claim or lawsuit to the offices of GEARENCH in Clifton,
Bosque County, Texas. No claim or suit may be brought against GEARENCH, arising out of the sale
and/or use of the tool, or arising out of the terms of t his war ranty, excep t in such fo rum. Pur chase and/o r
use of the GEARENCH tool makes you subject to the benefits and limitation s of this limited warranty.
Accordingly, any writ, judgment or other enforcement, obtained from a jurisdiction, county, parish, sta te o r
federal court or other country, other that from the forum identified above, shall be void and unenforceable
against GEARENCH.

Arbitration Clause

In the event of d is pute o r c la im ar ise s o ut of the sa le and /or use of the GE AREN CH to ol that i s the subj ect
of this limited warranty, or arises o ut of the interpretation or enforcement of the ter ms and conditions of
this limited warranty, such di spute shall be submitted to binding arbitration purs uant to the rules of the
American Arbitration Association. If required to accomplish the purpo se of this Arbitration clause, the
purchaser hereby expressly waives any right to demand trial by jury.

Complete Agreement

This express limited warranty contains the entire agreement regarding express or implied warranties related
to the GEARENCH tool that is the subject of it. No writing o r language contained in the p urchase orde r or
any other document of the purchaser, or invoice of GEARENCH or any intermediate seller, shall be
construed as modifying, in any way, the rights and liabilities contained in this limited warranty.
GEARENCH expressly disclaims any obligations expressed in any customer purchase order or document
that are contrary to the terms and li mitatio ns of this warranty.

Severability

If any term or limitation contained in this limited warranty is deemed unenforceable by law, then the term
shall be severed from the remaining portions of the limited warranty which shall remain enforceable.

All communications to GEARENCH re garding the use of the tool and any aspect of the sale of the tool of
this limited warranty should be addressed to GEARENCH.

GEARENCH · 4450 South Highway 6 · P.O. Box 192 · Clifton, TX 76634

4

Safe Pract ices and Procedures

Responsibility

"It is the responsibility of the employer to train the employee in the proper selection and
use of tools, and to ensure that th ey are selected and used in that manner. A part of the
job instruction program should therefore be detailed training in the proper use of POP­IT™ Tools.

"Employers are responsible for the safe condition of tools and equipment used by
employees, including tools and equipment which may be furnished by employees." ­(Source: OSHA 1910.242A)

Safety

While we pride ourselves on the quality and dependability we build into GEARENCH™
tools and products, we caution users that it is only prudent to know and follow the simple
rules of safety when using our products, or anyone else's.

Always follow safe practices and procedures in accordance with the recommendations of
OSHA, The National Safety Council (NSC), The Hand Tools Institute (HTI), etc. All
applicable Governmental rules, regulations or restrictions, now in effect or which may be
promulgated, take precedence over the suggestions in this publication. The information
in this publication is designed to supplement standard safe practices and procedures, not
in lieu of, or replacement thereof.

Warnings

 Always chock your work
 Never use cheaters
 Never place fingers or other body parts between flanges or under equipment
 Do not jerk on the ratchet handle. Always use a steady pulling force
 Insert toes as far as possible into work piece
 If using two tools, always operate the tools in sync with one another
 Always tether the tool to keep it from falling

POP-IT

™

Tool Inspection

Prior to each use:

 Clean serrations on toes with a wire brush
 Inspect toes for possible cracks or chipped surfaces – replace immediately if

either is found.

 Verify that all bolts and screws on the tool are tight.

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Every six months:

 Remove screw assembly. Remove any debris from the screw and apply a thin coat

of anti-seize compound.

Operating Procedu re – Flange W ork

Note: In some cases it will be necessary to use two tools to keep from pinching the blind

or gasket on the opposite side of the flange, or the flange may be so large and rigid that it
requires two tools. When using two tools, it is very important to operate the tools in

sync with one another while opening and closing.

Step 1

Before every use, cl ean t he serrat ions on t he toes with a wire brush. Driv e the toes of the
tool into the flange as far as possible. This is done by striking the rectangular metal plate
at the back of th e POP-IT
The center toe may chip if it is not fully protected when under load.

Step 2

Once the toes are in as far as possible, flip the direction switch on the ratchet to the l eft.
With one hand located on the handle of the tool, take your other hand and begin turning
the ratchet handle clock wise in a slow manner as the flange begins to spread open. DO

NOT USE A CHEATER BAR. The POP-IT Tool is designed to be operated with the
ratchet supplied. Do not jerk on the ratchet handle. A steady even pull ensures smooth

operation. Approximately 120 lbs of force on the end of the ratchet handle will produce
10,000 lbs of force. If this is not enough, you may need two tools to spread the flange.

Step 3
ALWAYS CHOCK YOUR WORK. Never leave the tool in the flanges while

performing maintenance. After the flange is spread to the desired amount, set a chock
between the flanges. Flip the direction switch on the ratchet handle to the right. With one
hand on the tool handle, turn the ratchet handle counter clockwise to close the flanges
onto the chock and remove the tool.

Step 4

Perform necessary flange maintenance.

Step 5

Insert the POP-IT Tool beside the chock. Flip the direction switch on the ratchet back to
the left. While holding the tool handle, turn the ratchet handle clockwise until the chock

™

Tool. Keep the center toe away from bolt hol es if possible.

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comes free. After removing the chock, flip the direction switch to the right. Turn the
ratchet handle counter clockwise until the flange is back to parallel.

Step 6

Remove the POP-IT Tool from the flange. If necessary, remove the tool by tapping
lightly on the side of the tool with a hammer.

Operating Procedu re – Lifting W ork

Step 1

Before every use, clean the serrations on the toes with a wire brush. The tool is designed
to have the toes driven into place with a hammer, yet as a lifting tool, you many find it to
be unnecessary. Make sure that all toes are fully engaged under the equipment to be
lifted.

Step 2

Once the toes are in as far as possible, flip the direction switch on the rat chet to the left.
With one hand located on the handle of the tool, take your other hand and begin turning
the ratchet handle clockwise in a slow manner as the equipment begins to lift. DO NOT

USE A CHEATER BAR. The POP-IT™ Tool is designed to be operated with the
ratchet supplied. Do not jerk on the ratchet handle. A steady even pull insures smooth

operation. Approximately 120 lbs of force on the end of the ratchet handle will produce
10,000 lbs of force.

Step 3
ALWAYS CHOCK YOUR WORK. Never allow the tool to support the load while

working on the equipment. After the equipment is lifted to the desired amount, set a
chock under the equipment. NEVER PLACE YOUR FINGERS OR ANY OTHER

BODY PART UNDER THE EQUIPMENT WHILE THE POP-IT TOOL IS
SUPPORTING THE LOAD. Flip the direction switch on the ratchet handle to the

right. With one hand on the tool handle, turn the ratchet handle to the right. With one
hand on the tool handle, turn the ratchet handle counter clockwise to lower the equipment
onto the chock. Remove the tool.

Step 4

Perform necessary maintenance/task.

Step 5

Insert the POP-IT Tool beside the chock. Flip the direction switch on the ratchet back to
the left. While holding the tool handle, turn the ratchet handle clockwise until the chock

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comes free. After removing the chock, flip the direction switch to the right. Turn the
ratchet handle counter clockwise until the equipment is lowered to its desired position.
Remove the tool.

Replacement Parts

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Item

No.

Qty

Part No.

Description

1

1

PD0502

Body

2

1

PC0501

Riser

3

1

PB0503

Striker plate

4

1

PC0504L

Side plate (left)

5

1

PC0504R

Side plate (right)

6

1

PB0511

Inside toe

7

1

PB0512L

Outside toe (left)

8

1

PB0512R

Outside toe (right)

9

1

HXOR03

O-ring

10

1

LBL-093

Patent label

11

1

LBL-094

Caution label

12

1

PD0505

Handle

13

3

HXS056

Socket head cap screw 1/4-20UNC x 1

14

1

HXS057

Countersunk socket head cap screw 7/16-14UNC x 1

15

1

HXS064

Countersunk socket head cap screw 7/16-14UNC x 1­1/4

16

4

HXS065

Countersunk socket head cap screw 7/16-14UNC x 1­1/2

17

4

HXS058

Countersunk socket head cap screw 3/8-16UNC x 1

18

2

HXS059

Socket head shoulder screw 1/2 x 3

19

2

HXN065

Locking nut 3/8-16UNC

20

1

PC0508

Drive screw

21

2

HXSS006

Cup point set screw 1/4-20UNC x 1/4

22

1

HXB03

Thrust bearing

23

1

PB0507

End cap

24

1

HS33

Wave spring washer

25

1

PB0506

Locking sleeve

26

1

HXSS007

Cup point set screw 1/4-20UNC x 3/16

27

1

PC0509

Ratchet (not shown)