Berkley Tool BT-5020 User manual

Power Threader BT-5020
Owner’s Manual
WARNING!
Read this owner’s manual before assembling and operating the
unit. The moving parts of this unit may cause body injury if it is
not proper operated. Always unplug the Power Cord and switch
the main switch to off position before maintenance or service.
Berkley Tool, Jupiter, Florida, USA

Table of Contents
1. GENERAL SAFETY RULES 1
2. SPECIFICATION 3
3. FUNCTION/OPERATION DESCRIPTION 3
3.1 Using BT-30033 pipe cutter 3
3.2 Using BT-30032 reamer 3
3.3 Using BT-99992 quick-opening die head 4
3.4 Using BT-30033 pipe cutter 4
3.5 Assembly 5
3.6 Locking the Footswitch 5
4. MAINTENANCE 6
5. ACCESSORIES 6
6. Power Threader Exploded View & Parts List 7
7. BT-31043 Power Threader Motor Assembly Exploded View & Parts List 8
8. REGISTRATION FORM 9
9. LIMITED WARRANTY 9

SAVE THESE INSTRUCTIONS
1. GENERAL SAFETY RULES
WARNING! Read and understand all instructions. Failure to follow all instructions listed below may result in
electric shock, fire and/or serious personal injury.
Work Area
Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids,
gases, or dust. Power tools create sparks that may ignite the dust or fumes.
Keep children away. All visitors should be kept at a safe distance from work area.
Electrical Safety
This tool is intended for use on a circuit that has an outlet that looks like the one illustrated in the sketch. The
tool has a grounding plug that looks like the plug illustrated in the sketch. Grounded tools must be plugged into
an outlet properly installed and grounded in accordance with all codes and ordinances. Never remove the
grounding prong or modify the plug in any way. Do not use any adapter. Check with a
qualified electrician if you are in doubt as to whether the outlet is properly grounded. If
the tools should electrically malfunction or break down, grounding provides a low
resistance path to carry away from the user. Improper connection of the equipment-
grounding conductor can result in a risk of electric shock. The conductor with insula-
tion having an outer surface that is green with or without yellow stripes is the equip-
ment-grounding conductor. If repair or replacement of the electric cord or plug is
necessary, do not connect the equipment-grounding conductor to a live terminal.
Safety Instructions
Due to the nature of the machine, safety rule and proper procedure must be followed. Otherwise, the high torque
of the motor, moving parts and electricity could cause body injury and property damage.
•Ground machine. Use approved three-conductor cord and three-prong ground type plug in a grounded
receptacle.
•Use only three-wire extension cords, which have three-prong grounding plugs, and three-pole receptacles
that accept the machine’s plug. Replace or repair damage, frayed, broken or worn cords.
•Use Proper Extension Cord. Make sure your extension cord is in good condition. When using an extension
cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will
cause a drop in line voltage resulting in loss of power and overheating. The following table shows the correct
size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gage.
The smaller the gage number, the heavier the cord.
LENGTH OF CORD WIRE GAGE REQUIRED (120V)
24 FEET 14
50 FEET 12
100 FEET 10
150 FEET 8
200 FEET 6
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The machine is made to thread and cut pipe or bolt. Follow instructions in operator’s manual on machine uses.
Other uses may cause injury.
•Secure machine to bench or stand to keep it from tipping over.
•Tighten chuck hand wheel and engage rear-centering device on the work before turning on machine.
•Support long, heavy work with a pipe support to prevent tipping of machine.
•Use recommended accessories. Use of other accessories may increase the risk of injury. Refer to
operator’s manual for recommended accessories.
•Do not use machine if switches are broken.
•Always use footswitch. Do not block or disconnect the footswitch
•No loose clothes, ties or gloves. Keep sleeves and jacket buttoned.
•Non slip footwear is recommended. Wear protective hair covering to contain long hair.
•Do not over reach. Keep proper footing & balance at all times.
•Operate machine from switch side only. Do not cross over the machine.
•Always set switch to “OFF” position while machine is not being used.
•Make sure switch is on “OFF” position before plugging the power cord in.
••
••
•Unplug the power cord when adjusting, servicing or changing accessories.
•Make sure the machine properly grounded. Please note that the machine is designed to operate at 120 V
and 50-60 Hz.
•Use only three-wire extension cord when it is needed. Refer to the chart for correct gauge.
•For personal safety protection, wear eye safety glasses and ear protection all the time.
•Do not use machine in damp or wet locations. Do not expose to rain.
•Use a pipe stand to support the heavy or long pipe while working with it.
•Maintain Tools With Care. Keep tools sharp and clean for best and safest performance. Follow instructions
for lubricating and changing accessories.
•Never Stand on Tool. Serious injury could occur if he tool is tipped or if the cutting tool is unintentionally
contacted.
•Check for Damaged Parts. Before further use of the tool, a guard or other part that is damaged should be
carefully checked to determine that it will operate properly and perform its intended function – check for
alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions
that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.
•Never Leave Tool Running Unattended. Turn Power Off. Do not leave tool until it comes to a complete stop.
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2. Specifications
Capacity
Threading
Pipe……………….…………………………..1/8” to 2”
Bolt……………………………………………1/4” to 2”
Cutoff
Pipe……………………………………………1/8” to 2”
Bolt……………………………………….……1/4” to 1”
Power Supply
Volt………………....120v 50-60 Hz single phase AC
Motor…………….………………………….…..1/2 HP
Weight (machine only)...………………...…….80 lbs.
3. Function/Operation Description
3.1 Using BT-30033 pipe cutter
•Swing die head and reamer away to out-of-way position.
•Lower pipe cutter down to pipe.
•Move carriage to adjust cutter wheel position to where the pipe will be cut.
•Tighten the pipe cutter handle and make sure the two rollers and cutter wheel touch the pipe
•Turn switch to “forward” position and step on the foot switch.
•Keep turning the pipe cutter handle until pipe is cut off.
•Release footswitch and switch it OFF position.
•Return pipe cutter to out-of-way position.
3.2 Using BT-30032 reamer
•Swing pipe cutter and die head to out-of-way position
•Lower reamer (BT-30032) and align with pipe
•Extend reamer by pushing Latch and sliding knob toward pipe until latch engages square bar
•Switch to forward position and step on foot switch.
•Moving carriage toward to pipe and complete reaming the pipe
•Retract reamer bar ad return reamer to out-of-way position.
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3.3 Using BT-99992 quick-opening die head
BT-99992 quick-opening die head is designed to thread 1/8” to 2” NPT. Choose right die first to make correct
thread.
Install or replace die
•Lay die head on table or bench with numbers face up.
•Flip throw out lever to OPEN position
•Loosen clamp lever enough to lift clamp lever washer up out of slot.
•Lift tongue of clamp lever washer up out of slot under scale plate. Slide throw out lever all the way to end of
slot in the over direction indicated on scale plate.
•Remove dies from die head (if replacing die)
•Insert dies to mark on the side of dies. Make sure the number on the die and cover match up.
•Slide throw out lever back to let clamp lever washer drop in slot under size bar.
•Adjust die head to align index line with right size and tighten down the clamp lever
•Put die head back to carriage and it’s ready to thread.
•High quality threading oil is necessary to protect die while threading.
3.4 Installing Pipe in Power Threader
1) Measure and mark length of pipe being worked.
2) If pipe is long enough to be retained by centering device, insert pipe through front or rear of machine. If pipe
is short, insert into front of machine.
3) Make sure that pipe is centered in centering device, if used, and tighten centering device.
4) Tighten Chuck Jaws with a repetitive counterclockwise snap spin of hand wheel. This hammering action
tightens Jaws on pipe. A clockwise rotation snap spin releases Jaws.
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3.5 Assembly
A Insert rear leg assembly (6) into tray support ring (3). Make sure lip of tool tray (1) is facing up and away
from foot in rear leg assembly and that foot faces away from tray. Lightly hand tighten set screws (4).
B Place front leg assembly (7) in tool tray (1), aligning holes in tool tray with holes in front leg assembly. Slide
tray pin (2) through and set in place by opening “X” washer with pliers and closing around pin.
Repeat for other front leg assembly, making sure lip of tool tray (1) is up and away from foot.
C Place base assembly (8) upside down on ground and place legs into the holes with front leg assemblies (2)
toward handle. Insert leg bolts (5) and secure with nuts and lockwashers (5).
D Turn stand right side up and straighten tool tray. It may be necessary to place foot on tool tray and exert
force to have tray “snap” into place. Readjust and tighten set screw (4) at desired height.
3.6 Locking the Footswitch
We suggest locking the footswitch when leaving the machine unattended. Simply put the footswitch lock rod
through the holes on both sides of footswitch and lock it by using a pad lock.
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4. Maintenance
IT IS VERY IMPORTANT TO UNPLUG THE POWER CORD BEFORE SERVICING THE POWER THREADER.
1. Use sharp cutting tools.
2. Follow instruction for lubricating and changing accessories.
3. Inspect machine cord. Replace damaged, frayed, broken or worn machine cord.
4. Inspect extension cords. Replace damaged, frayed, broken or worn cords.
5. When not being used, store machine in a secured, locked area, out of reach of children and people unfamil-
iar with the threading machine.
6. Jaw insert
Jaw insert is a wear item and should be replaced whenever teeth are worn to maintain best gripping power.
Remove
Turn jaw insert 90 degree by putting slotted screwdriver in the slot on the insert
Replace
Turn jaw insert 90 degree to let teeth face up while placing new insert sideways on locking pin and pressing
down
7. Motor replacement
Disconnect motor from switch box. Remove two screws holding the motor to the body and loosen one
screw close to the main drive output pinion. Carefully lift motor and move out of the body of power threader
8. Motor brush replacement
Check motor brush twice a year. Replace motor brush when is worn to less than 1/2” in length.
9. Lubrication
Main shaft bearings need to be lubricated every 2 months in order to run the power threader trouble-free.
Grease fittings are located on the top of machine. High grade of grease is recommended.
5. Accessories
BT-30031 Carriage with Lever
Holds die head, cutter and reamer
BT-30033 Cutter
Full-floating, wheel-type wide roll.
BT-30032 Reamer
Positive locking, 5 flute cone, right hand 1/8” through 2”
BT-30005
Provides effortless power threader portability.
BT-30006C Oiler
Stops oil waste, keeps dies flooded.
BT-334 Stand
Folding with tray
BT-333 Tri-stand Chain Vise
Folding with tray
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Exploded View & Parts List
BT-5020 Power Threader
Ref # Berkley Qty Description Fits
P/N Ridge #
1 31001 6 Screw
2 31002 6 Lockwasher # 12
3 31003 1 Rear Centering
Head
4 31004 1 Rear Jaw (set of 3) 46500
5 30004 3 Stop Pin
6 31006 1 Rear Scroll
7 31007 1 Rear Plate
8 31009 1 Drive Shaft 44100
9 31009 1 Body
10 30002 2 Front/Rear Bearing 45270/45335
11 31011 Front Bearing
12 31012 2 Grease Fitting
13 31013 Dowel Pin
14 31014 10 Pop Rivet
16 31016 1 Screw
17 30003 1 Thrust Ring
18 31018 2 Set Screw
20 31020 3 Set Screw
21 31021 3 Set Screw
29 31029 1 Hand Wheel
30 31030 1 Scroll
31 31031 1 Cap
32 31032 6 Screw
33 30051 1 Chuck Jaw Set/3
Ref # Berkley Qty Description Fits
P/N Ridge #
34 30052 Chuck Jaw Set/3 w/inserts
30054 3 Jaw Insert 44715
35 31035 1 Strain Relief Plate
36 31036 2 Screw
37 30029 2 Spring Ring 44525
38 31038 2 Screw # 8-32 x 5/8 45280
39 30014 2 Support Bar incl. 31037 44425
40 30023 2 Ring Ass’y 44725
41 31041 2 Set Screw
42 31042 2 Snap Ring
43 31043 1 Motor Assembly 87740/3177
44 31044 2 Screw 46745
45 31045 1 Rear Centering Ass’y 44165
46 31046 1 Drive Ring
47 31047 3 Drive Pin 30022
48 31048 1 Ring Gear 30017
49 31049 4 Hex Bolt 46670
50 31050 4 Hex Washer 44230
51 31051 4 Lock Washer 3/8 40930
52 31052 4 Wing Nut 3/8 - 16 45385
54 73008 1 Cord Grammet 46735
BT-30063 1 Reamer Pin
BT-30085 1 Cutter Pin

BT-31043 Power Threader
Motor Assembly
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Exploded View & Parts List
Ref # Berkley Qty Description Fits
P/N Ridge #
1 32001 1 Housing Ass’y
2 32002 2 Set Screw 39770
1/4 - 20 x 1/4
3 73009 1 Brush Holder set/2 45025
4 73011 1 Brush Cap Set/2 44545
5 73031 1 Brush Set/2 44540
6 32006 1 White Upper Lead 86680
7 32001 1 Red Lower Lead 86685
8 32008 1 Loading Spring
9 32009 1 Locking Screw 83500
1/4 - 20 x 3/4
10 73006 1 Field (115V) 86690
11 73002 1 Armature (115V) 44010
41 73005 1 Armature fan
12 73004 2 Armature Bearing 44565
13 32013 2 Mounting Screw 44555
# 10 - 24 x 3
14 32014 1 Fan Housing Ass’y
Incl fan plate
Ref # Berkley Qty Description Fits
P/N Ridge #
15 32015 1 Dowel Pin
16 32016 1 1st Gear Ass’y
17 32017 1 2nd Gear Ass’y
18 32018 5 Gear Bearings
19 30048 1 Drive Gear Ass’y
20 32020 1 Front Bearing
21 32021 1 Gear Housing
22 32022 4 Lock Washer 1/4”
23 32023 4 Screw 1/4 - 20 x 3 45075
25 32025 2 Pop Rivet
26 32026 1 90 Deg Connector
27 32027 2 Insulator 46890
28 32028 1 Flexible Conduit
29 32029 1 Outlet Jumper 50552

6. Registration form
Please detach and mail back to Berkley Tool Company at
851 Jupiter Park Lane, Jupiter, FL 33458, U.S.A.
Date of Purchase _____________________________________
Model # ____________________________________________
Serial # ______________________________________________
Place of purchase
Name ____________________________________________
Address __________________________________________
Please keep this portion for your record.
Date of Purchase _____________________________________
Model # ____________________________________________
Serial # ______________________________________________
Place of purchase
Name ____________________________________________
Address __________________________________________
7. Limited Warranty
Berkley covers its products with one-year warranty against defects in material or workmanship. To take
advantage of this warranty, the complete product must be delivered prepaid to Berkley Tool or any Berkley
authorized service center. No employee, agent, dealer, or other person is authorized to give any warranty on
behalf of Berkley Tool Company. Warranted products will be repaired or replaced, at our option, at no
charge to you and returned to you via pre-paid transportation. Such replacement or repair is the exclusive
remedy available from Berkley. Berkley is not liable for damage of any sort, including incidental and conse-
quential damages. Some U.S.A. states do not allow he exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply. This warranty gives you specific legal rights,
and you may have other rights, which vary, from state to state.
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