Burndy BKOS5290 User manual

IMPORTANT RECEIVING INSTRUCTIONS: Visually inspect all components for shipping damage. If any shipping damage
is found, notify carrier at once. Shipping damage is NOT covered by warranty. The carrier is responsible for all repair or
replacement costs resulting from damage in shipment.
To prevent injury keep hands away from the punch and die while punching holes. Always wear
approved eye protection.
Avoid dropping the cylinder. During punch operation, support the cylinder to prevent it from
falling after punching is completed.
To prevent thread damage, be sure punch is threaded onto the stud until the stud extends
beyond the punch. Make sure all rods, studs and punches are secured before operating
hydraulic driver.
Do not operate near live circuits. Contact with live circuits can cause injury or death.
Never exceed rated capacity of the tool. Use this tool for its intended use only.
Never operate the pump lever after the ram motion stops. Continued operation after ram motion
stops will damage driver and could result in injury.
Instruction
Sheet
BKOS5290
SELF-CONTAINED
HYDRAULIC
KNOCKOUT SET
IMPORTANT — USER SAFETY AND PROTECTION: In setting up systems to fit your operations, care must be taken to
select the proper components and design to insure appropriate integration with your operations and existing equipment and
that all safety measures have been taken to avoid the risk of personal injury and property damage from your application
or system.
FCI CANNOT BE RESPONSIBLE FOR DAMAGE OR INJURY CAUSED BY UNSAFE USE, MAINTENANCE OR
APPLICATION OF ITS PRODUCTS.Please contact FCI for guidance when you are in doubt as to the proper safety
precautions to be taken in designing and setting up your particular application.
!
WARNING
To Protect Your Warranty, Use Only FCI Burndy®Alfluid™.
BKOS5290 1⁄2” - 2” Self-Contained Right-Angle Hydraulic Knockout Set
Features
• Four-point punches for easy slug removal.
• Right-angle head swivels 360ofor flexible punching
in tight work spaces.
• Punches up to 2-1⁄2” conduit sizes in up to 12-gauge
stainless or 10-gauge mild steel.
• Compact, lightweight size: 71⁄2pounds and 13” long.
• Operating pressure rated at 10,000 psi.
Model Description
BKLP6 Hydraulic Driver
BKPR7520 Pull Rod
BKPS50 Pull Stud
BKSA50 Pull Stud Adapter
BZ88010 Storage Case
BKP500B 1⁄2” Punch
BKD500B 1⁄2” Die
BKP750B 3⁄4” Punch
Model Description
BKPD750B 3⁄4” Die
BKP1000B 1” Punch
BKD1000B 1” Die
BKP1250B 1-1⁄4” Punch
BKD1250B 1-1⁄4” Die
BKP1500B 1-1⁄2” Punch
BKD1500B 1-1⁄2” Die
BKP2000B 2” Punch
BKD2000B 2” Die
Note: Inspect tool and components for wear & damage. Replace worn, damaged, or missing components with genuine
FCI replacement parts. To ensure ease of assembly & operation, keep all threads clean & lightly oiled.
BKOS5290 Kit Components:

Drilling Guide Holes
1. Mark the center position, drill a 1⁄8” pilot hole. Enlarge
the hole with a 7⁄16” drill to provide pull rod clearance.
a. If working to close tolerances, mark the center
position by scribing cross lines shown in Figure 1.
b. When assembling the punch to the pull rod, align
the cross marks with the four marks on the outer
die surface.
NOTE: If pre-punched knockouts are already in
the desired location, drilling a guide hole is not
required.
2. For larger holes 3⁄4” to 2-1⁄2”, the 1⁄2” punch is used to
make the guide hole.
Punching 1⁄2” Holes
1. Thread the pull stud into the pull stud adapter end until
firmly seated. (Figure 2)
NOTE: The pull stud and pull stud adapter are only
used with the 1⁄2” punch. The 1⁄2” punch is used to make
guide holes for larger punch sizes.
2 Attach the pull stud adapter to the cylinder by inserting
the pull stud adapter into the plunger opening and
threading until the pull stud extends beyond the end of
the cylinder. (Figure 3)
3. Slide the 1⁄2” die over the pull stud, flat side toward
the cylinder.
4. Insert the pull stud through the guide hole (Figure 4).
Attach the 1⁄2” punch to the pull stud. Turn the punch
until it is completely threaded onto the pull stud.
5. Close the pump release valve by turning it clockwise
(Figure 5). Hold the punch set in position, work the pump
handle until the punch completely penetrates the metal.
6. Remove the punch set from the hole. Turn pump release
valve counterclockwise to open. The cylinder will retract
and the slug must be removed from between the punch
and die.
Punching 3⁄4” through 2-1⁄2” Holes
1. Drill a pilot hole(7⁄16”)install the 1⁄2” punch and make
guide hole. See
Punching 1⁄2” Holes .
2. Remove the 1⁄2” punch and die set. Also remove the
pull stud and pull stud adapter.
3. Attach the pull rod (BKPR7520) to the cylinder by
inserting the rod into the plunger opening and threading
until the pull rod extends beyond the end of the cylinder.
4. Select the punch set needed. Slide the die over the
pull rod.
5. Place the pull rod into the 1⁄2” guide hole, thread the
punch onto the pull rod. Be sure the pull rod extends
beyond the punch.
6. Operate the hand punch until the punch penetrates the
metal. Open the punch release valve. Remove the slug.
Note: To avoid excessive wear and tear on the pull rod threads during
punching, center the guide hole accurately enough so that the pull rod
does not rest against the metal edge of the guide hole. Also, be sure
that all points of the punch are in uniform contact with the metal surface
when starting to punch.
WARRANTY: FCI warrants its product against defects
in workmanship and materials for 1 year from date of
delivery to user. Warranty does not cover ordinary
wear and tear, abuse, misuse, overloading, altered
products or use of improper fluid.
WARRANTY RETURN PROCEDURE: When question
of warranty claim arises, send the unit to the nearest
FCI Authorized Service Center for inspection,
transportation prepaid. Furnish evidence of purchase
date. If the claim comes under the terms of our warranty
the Authorized Service Center will REPAIR OR
REPLACE PARTS AFFECTED and return the unit
prepaid.
PARTS AND SERVICE: For quality workmanship and
genuine FCI parts, select an Authorized FCI Service
Center for your repair needs. Only repairs performed
by an Authorized Service Center displaying the official
FCI Authorized sign are backed with full factory
warranty. Contact FCI [phone] for the name of
the nearest FCI Authorized Service Center.
REPAIR AND SERVICE INSTRUCTIONS: For repair service and parts contact your nearest FCI Service Center. The FCI Service Center
will provide complete and prompt service on all FCI products.
Littleton Industrial Park, Littleton, NH 03561 • Phone: [phone] RPS-0129 4/07
Pump Release Valve Figure 5
Figure 4
Figure 3
Pull Stud
Adapter
Pull Stud
Pre-drill
7⁄16” Hole
Metal
Box
Dotted line
Indicates
Knock-Out
Die
Cross Lines
6" Long
Lines On
Die Line
Up With
Cross Lines
Center
Drilling of Guide Hole
Figure 1
Pull Stud
BKPS50 Pull Stud Adapter
BKSA50
Figure 2
Draw
Stud
Die