RIDGID HKO-186 User manual

Hydraulic
Knockout Sets
HKO-186
HKO-1810
OPERATOR’S
MANUAL
WARNING!
Read this Operator’s Manual
carefully before using this
tool. Failure to understand
and follow the contents of this
manual may result in serious
personal injury.
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com

HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
Service
•Tool service must be performed only by qualified
repair personnel. Service or maintenance performed
by unqualified repair personnel could result in injury.
•When servicing a tool, use only identical replace-
ment parts. Follow instructions in the Maintenance
Section of this manual. Use of unauthorized parts or
failure to follow maintenance instructions may create a
risk of injury.
Specific Safety Information
WARNING
Read this operator’s manual carefully before using
the RIDGID Hydraulic Knockouts. Failure to under-
stand and follow the contents of this manual may
result in serious personal injury.
Hydraulic Knockout Safety
•The hydraulic components in this set are de-
signed only for punching holes in metal. The
ram, pump, hose or coupling from this system
should not be used for other applications such as
jacking, pulling, pushing or raising loads. Other
uses or modifying the hydraulic components for other
applications may increase the risk of injury.
•The knockouts are designed to punch holes in
low carbon, mild steel up to 10 gauge maximum
thickness or stainless steel up to 16 gauge. Using
this tool for any other purpose can result in serious per-
sonal injury and damage to the tool.
Hydraulic Hose
•Should a hydraulic hose burst or rupture, imme-
diately stop operating the pump before attempting
to remedy the situation. Never attempt to grasp a
leaking hose under pressure with your hands. A
leaking hose should be replaced. The force of the
escaping hydraulic fluid could cause serious injury.
•Avoid any conditions which could damage the
hose and impair the pump’s performance. Never
allow the hose to kink, twist, curl or bend so tight-
ly that the oil flow within the hose is blocked or
restricted. This damages the hose and could possibly
result in serious injury to persons working in the imme-
diate vicinity.
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General Safety Information
WARNING! Read and understand all instructions. Failure
to follow all instructions listed below may
result in serious personal injury.
SAVE THESE INSTRUCTIONS!
Work Area
•Keep your work area clean and well lit. Cluttered
benches and dark areas invite accidents.
•Keep by-standers, children, and visitors away
while operating a tool. Distractions can cause you to
lose control.
Personal Safety
•Stay alert, watch what you are doing and use com-
mon sense when operating a tool. Do not use tool
while tired or under the influence of drugs, alcohol,
or medications. A moment of inattention while oper-
ating tools may result in serious personal injury.
•Dress properly. Do not wear loose clothing or
jewelry. Contain long hair. Keep your hair, clothing,
and gloves away from moving parts. Loose clothes,
jewelry, or long hair can be caught in moving parts.
•Do not overreach. Keep proper footing and bal-
ance at all times. Proper footing and balance enables
better control of the tool in unexpected situations.
•Use safety equipment. Always wear eye protection.
Dust mask, non-skid safety shoes, hard hat, or hearing
protection must be used for appropriate conditions.
Tool Use and Care
•Store idle tools out of the reach of children and
other untrained persons. Tools are dangerous in
the hands of untrained users.
•Maintain tools with care. Keep cutting tools sharp
and clean. Properly maintained tools with sharp cutting
edges are less likely to bind and are easier to control.
•Check for misalignment or binding of moving
parts, breakage of parts, and any other condition
that may affect the tool's operation. If damaged,
have the tool serviced before using. Many acci-
dents are caused by poorly maintained tools.
•Use only accessories that are recommended for
your tool. Accessories that may be suitable for one tool
may become hazardous when used on another tool.
•Keep handles dry and clean; free from oil and
grease. Allows for better control of the tool.

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•Do not over-tighten the connections. Connections
need only be tightened securely and leak-free.
Over-torque may cause premature thread failure and
may cause high pressure fittings to split at pressures
lower than their rated capacities.
•Do not subject the hose to any potential hazard
such as fire, extreme heat or cold, heavy impact or
sharp surfaces. Do not use the hose to lift or
move the equipment connected to it.. Might rupture
or weaken the hose.
•Periodically inspect the hose for signs of wear.
Never use a defective hose with any pressurized
equipment. Escaping hydraulic fluid could cause seri-
ous injury.
•Never paint the couplers, fittings or hose. Make
sure that the hose material and coupler seals are
compatible with the hydraulic fluid used. Avoid
contact with creosote-saturated materials. May
result in hose damage and leaking of hydraulic fluid.
Hydraulic Pump
•Never exceed the rated capacity of the unit. Never
tamper with the internal high pressure relief valve.
May result in pump failure.
•Always retract the system before replenishing the
oil level. Never over-fill the pump reservoir with oil.
Could damage the pump.
Hydraulic Cylinder
•Keep the cylinder clean at all times. Keep the pis-
ton fully retracted when the cylinder is not in use.
Prevents damaging the cylinder.
•Make certain that the hydraulic fluid added to the
system is compatible with the seals and the exist-
ing fluid. Never use brake fluid. May result in leaking
of the hydraulic fluid.
Description, Specifications and
Standard Equipment
Description
RIDGID Hydraulic Knockout Sets are designed for
punching holes of 1/2″ through 4″ (conduit size) diameter
in mild steel of up to 10 gauge (.134″/ 3.40mm) maxi-
mum thickness.
The RIDGID Model HKO-186 Knockout Set includes
the H-18 Hand Pump, 8R111S Hydraulic Cylinder, 3
ft. hose, 1/2″-2″Punch/Die Sets and various accessories.
The Model FKO-186 Knockout Set is the same basic set
except that the HF-18 Foot Pump is included in place of
the hand pump and a 10 ft. hose is provided.
The single-stage hand pump will develop up to 10,000
PSI pressure with a maximum handle effort of 80 lbs.
The two-stage foot pump will develop 10,000 PSI of
pressure with maximum lever effort of 143 lbs. Both
pumps incorporate an internal relief valve set at 10,000
PSI. The ram will develop up to 100 tons of force at
10,000 PSI and has a 1″stroke.
Specifications
Ram:
Capacity.......................11.2 Tons
Stroke...........................1 Inch
Oil Volume....................2.45 cu. in.
Weight..........................5.3 lbs.
Punch Diameter
(Conduit Size)...............1/2″through 4″
Maximum Plate
Thickness.....................10 Gauge (.134″ / 3.4mm)
Pump: ............................H-18..................HF-18
Stage..............................Single................Two
Volume Per Stroke:
Low Pressure.........................................670 cu. in.
High Pressure..............0.061 cu. in........0.061 cu. in.
Valve............................2-Way ...............2-Way
Maximum Pressure......10,000 PSI........10,000 PSI
Reservoir Capacity.......18.6 cu. in.........18.6 cu. in
Useable Volume...........16 cu. in............16 cu. in
Maximum Lever Effort...80 lbs................143 lbs.
Oil Port.........................3/8″NPTF..........3/8″NPTF
Weight (w/o Oil) ...........7.5 lbs. ..............11 lbs.
Relief Valve..................Yes....................Yes
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
Hydraulic Hand Pump
31/2″
243/64″
149/16″
41/4″

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Standard Equipment
Model No. Description
HKO-186 1/2- 2″Hydraulic Kit w/Hand Pump
Includes:
• H-18 Hand Pump
• Hydraulic Cylinder
• 3 ft. Hose
•1/2- 2″Pump/Die Sets
HKO-1810 1/2- 4″Hydraulic Kit w/Hand Pump
Includes:
• H-18 Hand Pump
• Hydraulic Cylinder
• 3 ft. Hose
•1/2- 4″Pump/Die Sets
FKO-186 1/2- 2″Hydraulic Kit w/Foot Pump
Includes:
• HF-18 Foot Pump
• Hydraulic Cylinder
• 10 ft. Hose
•1/2- 2″Pump/Die Sets
FKO-1810 1/2- 4″Hydraulic Kit w/Foot Pump
Includes:
• FF-18 Foot Pump
• Hydraulic Cylinder
• 10 ft. Hose
•1/2- 4″Pump/Die Sets
Tool Assembly and Inspection
WARNING
To prevent serious injury, proper assembly and
inspection of the Hydraulic Knockout Sets is
required. Inspection procedures should be per-
formed before each use
Assembly
1. Clean all the areas around the oil port of the pump
and ram. Inspect all threads for signs of wear or
damage and replace as needed. Clean all hose
ends, couplers and union ends. Remove the thread
protector (if so equipped) from the hydraulic oil outlet.
2. Connect the hose half coupler at the end of the hose
to the ram half coupler on the cylinder. Turn the col-
lar completely on hand-tight (Figure 1).
Figure 1 – Hydraulic Connections
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
Hydraulic Foot Pump
Hydraulic Ram
345/64″
3/16″Dia. 153/8″
43/4″
61/8″
51/2″
27/8″
Ram Half
Coupler
Hose Half
Coupler

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NOTE! Although a high-grade, non-hardening thread
sealant is preferred, PTFE tape may be used to
seal hydraulic connections provided only one
layer of tape is used. To prevent the tape from
being “pinched” and broken off inside the sys-
tem, apply tape carefully avoiding the first one or
two threads. Any loose pieces of tape will trav-
el through the system and obstruct the flow of oil
or cause jamming of precision parts.
Do not over-tighten the connections. Con-
nections need only be tightened securely and leak-free.
Over-torque may cause premature thread failure.
Inspection
1. Inspect pump and ram for signs of wear or damage
which may affect its safe and normal operation. If any
of these conditions exist, do no use the tool until it has
been repaired.
2. Clean any oil, grease or dirt from the handles. This
reduces risk of injury due to a tool slipping from
your grip.
3. Inspect the hose for signs of wear. Never use a
defective hose with any pressurized equipment. Hose
should be replaced before using this tool.
Operating Instructions
WARNING
The Knockouts are designed to punch holes in low
carbon, mild steel up to 10 gauge maximum thick-
ness or stainless steel up to 16 gauge. Never use
pump, hose or ram if damaged, altered or in poor
repair.
Always wear eye protection to protect your eyes
against dirt and other foreign objects. Never exceed
rated capacity of the unit or tamper with the inter-
nal high pressure relief valve.
Set-Up To Punch 1/2″Holes
1. Mark the center of the hole to be punched and drill a
7/16″pilot hole. If accuracy is critical in locating a hole,
scribe center gage lines at 90 degrees to each other
through the center mark. Gage marks on the outside
diameter of the die can then be aligned with the
scribed lines for accurate hole positioning.
2. Screw the short threaded end of the 3/4″draw bolt into
the threaded hole of the ram. The bolt should be
screwed in fully, but only hand-tight.
3. Screw the 3/8″adapter screw into the 3/4″ bolt fully
but only hand-tight.
4. Place three spacers over the 3/4″draw bolt starting
with the shortest and continuing with medium and
long spacers (Figure 2).
NOTE! Be sure ram is fully retracted before assem-
bling punch and die set on ram.
5. Place the 1/2″die over the 3/8″draw bolt, pass the end
of the bolt through the previously drilled pilot hole and
thread the punch on the end of the bolt so that the
points just touch the material (Figure 3) . Operate
the pump as described below.
Figure 2 – Set-Up For 1/2″Holes
Figure 3 – Punching 1/2″Holes
Set-Up To Punch 3/4″Through 4″Holes
1. Mark the center of the hole to be punched and drill a
13/16″or 7/8″pilot hole. If accuracy is critical in locating
a hole, scribe center gage lines at 90 degrees to
each other through the center mark. Gage marks
on the outside diameter of the die can then be aligned
with the scribed lines for accurate hole positioning.
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
3/8″ Adapter Screw
Spacers
Punch 3/8″Adapter Screw
Die
3 Spacers
3/4″Draw Bolt
CAUTION

4. Unscrew the punch from the draw bolt and remove
the slug from the die.
B. Using Model HF-18 Foot Pump
1. Operate the foot pedal until the punch has cut com-
pletely through the material.
Sudden application of hydraulic pressure
may cause punch/die misalignment and damage the
points. Operate the pump at a moderate speed.
As the hole is punched, the ram will
punch and die may fall out of the hole. To prevent injury,
support the ram as the hole is completed.
2. Depress the release pedal to allow punch to be
returned from die. Be sure ram retracts completely.
3. Unscrew the punch from the draw bolt and remove
the slug from the die.
NOTE! When the points of the punch become worn, it
should be replaced immediately. Otherwise,
cuts will not be uniform and damage to the
draw bolt may result. Stop pumping as soon as
the hole has been complete to avoid damaging
the punch set. Never force points of punch into
contact with the die.
Maintenance Instructions
WARNING
Any repairs or service which requires dismantling
the pump or ram must be performed in a dirt-free
environment. All maintenance should be performed
by a qualified technician.
Lubrication
Apply lubrication periodically to all pivot and rubbing
points. Use a good grade of No. 10 motor oil. Do not
use dry lubricants.
Periodic Cleaning
A preventative maintenance program should be estab-
lished to keep the hydraulic components as free from
dirt as possible. Make certain that the hydraulic oil outlet
and all unused couplers are sealed with thread protectors
whenever the hydraulic system is dismantled. Be sure all
hose connections are free of contamination. Use only
an approved, clean hydraulic oil and change as recom-
mended, every 300 hours.
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2. Screw the short threaded end of the 3/4″draw bolt into
the threaded hole of the ram. The bolt should be
screwed in fully, but only hand-tight.
NOTE! Be sure ram is fully retracted before assem-
bling punch and die set on ram.
3. When using 3/4″or 1″die, place the shortest spacer
over the draw bolt and then add the desired die.
When using 11/4″through 4″die, no spacer should be
used since the die is designed to rest directly on the
ram body.
4. Pass the end of the draw bolt and the end of the bolt
through the previously drilled pilot hole and thread the
punch onto the end of the bolt so that the punch
points just touch the material
(Figure 4). Operate
the pump as described below.
Figure 4 – Punching 3/4″Through 4″Holes
A. Using Model H-18 Hand Pump
1. Close the release valve of the pump by turning fully
clockwise.
2. Operate the pump handle until the punch has cut
completely through the material
Sudden application of hydraulic pressure
may cause punch/die misalignment and damage the
points. Operate the pump at a moderate speed.
As the hole is punched, the ram will
punch and die may fall out of the hole. To prevent
injury, support the ram as the hole is completed.
3. Open the release valve of the pump to allow punch to
be returned from die. Be sure ram retracts completely.
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
WARNING
WARNING
3/4″Draw Bolt
Plate Punch
Die
Short Spacer used
with 3/4″and 1″Die
Ram
No spacer used with
11/4″through 4″Die
CAUTION
CAUTION

Do not overfill the pump reservoir as this will
adversely affect pump performance.
Draining and Flushing The Reservoir
Wipe the pump exterior completely clean before attempt-
ing this procedure.
It is important that after 300 hours of operation, the pump
be drained of oil completely and flushed out with a suitable,
compatible flushing solution before refilling it with clean
hydraulic fluid. To do this, unscrew the reservoir cap from
the reservoir and properly discard the used hydraulic fluid.
Flush the reservoir vigorously to ensure that no contami-
nants remain. Clean or replace the pump intake screen at
this time. Refill the reservoir in the manner described
below in the section entitled “Refilling The Reservoir”.
NOTE! Drain and clean the other hydraulic system
components (hoses, cylinders, etc.) before
reconnecting them to the pump. This will prevent
contaminated oil from reentering the pump.
Refilling The Reservoir
NOTE! Always retract the ram completely before
attempting this procedure.
Place and support the pump in a vertical position with the
filler cap facing upward. Unscrew and remove the reser-
voir cap from the reservoir. If additional oil must be added
to the reservoir, use only an approved high grade hydraulic
oil. Clean the entire area around the open rim of the
reservoir cap, visually inspect the o-ring which seals the
cap/reservoir assembly. Replace this o-ring if it is dam-
aged. Reinstall cap to reservoir and tighten securely.
Check for leaks.
Do not overfill the pump reservoir as this will
hinder pump performance.
Tool Storage
WARNING
Tools must be kept indoors or well covered in rainy
weather. Store the Hydraulic Knockout in a locked
area that is out of reach of children and people
unfamiliar with these tools. This tool can cause
serious injury in the hands of untrained users.
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Bleeding Air From The System
During the initial moments of activation or after prolonged
use, a significant amount of air may accumulate within the
hydraulic system. This entrapped air may cause the cylin-
der to respond slowly or behave in an unstable manner.
To remove the air, operate the system through several
cycles (extending and retracing the ram) free of any load.
Make certain the ram is at a lower level than the pump
with the coupling pointing upwards to allow air to be
released into the pump reservoir. Once all the air has been
bled from the system, inspect the oil level and fill the
reservoir to the proper level if necessary.
Inspecting The Hydraulic FluId Level
IMPORTANT: Always retract the ram completely before
attempting this procedure.
Check the oil level in the reservoir after approximately
every ten hours of use. Place the pump in a vertical posi-
tion with the reservoir cap up. While holding the reservoir,
unscrew the cap to determine if the oil level is between the
fill marks on the inside of the reservoir (Figure 5). If oil is
low, add enough to bring level between lines. If oil is
dirty, following instructions below in the section entitled,
“Draining and Flushing the Reservoir”.
NOTE! On Foot Pump Model HF-18, a dipstick is
attached to the filler cap. To check oil level,
hold pump in a vertical position with filler cap up,
remove dipstick and wipe clean. Insert dipstick
and remove to view oil level. Proper oil level is
indicated by upper mark on dipstick (Figure 5).
Figure 5 – Checking Oil Levels
Before replacing the reservoir cap, visually inspect the o-
ring which seals the cap/reservoir assembly. Replace
this o-ring if it is damaged. Reinstall reservoir cap to
reservoir and tighten securely. Check for leaks.
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
Filler Cap
Proper
Oil Level
Filler Cap
Proper
Oil Level
CAUTION
CAUTION

Ridge Tool Company
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Service and Repair
WARNING
Service and repair work on this Hydraulic Knockout
must be performed by qualified repair personnel.
Tool should be taken to a RIDGID Independent
Authorized Service Center or returned to the factory.
All repairs by Ridge service facilities are warranted
against defects in material and workmanship.
WARNING
When servicing this tool, only identical replace-
ment parts should be used. Failure to follow these
steps may create a risk of serious injury.
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets

Ridge Tool Company 9
HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
PROBLEM POSSIBLE CAUSE REMEDY
Erratic Action
Cylinder does
not advance
Cylinder extends
only partially
Cylinder advances
slower than normal
Cylinder leaks oil
Cylinder will not
retract or retracts
slower than normal
Troubleshooting
Troubleshooting Table - Ram
Air in system
Leakage in cylinder
Cylinder sticking or binding
Pump release valve open
Low or no oil in pump reservoir
Air locked in pump
Loose couplers
Plugged hydraulic line
Pump not operating correctly
Pump reservoir is low on oil
Cylinder piston rod binding
Loose connection
Leaky connection
Restriced hydraulic line or fitting
Pump not operating correctly
Leaky seals
Worn or damaged seals
Loose connections
Worn/scored cylinder wall
Pump release valve closed
Couplers not fastened
Blocked hydraulic lines
Weak or broken return springs
Cylinder damaged internally
Pump reservoir too full
Bleed air and check for leaks
Replace worn packings. Check for excessive con-
tamination or wear
Check for dirt, gummy deposits or leaks as above.
Check for misalignment, worn parts or defective
piston seal
Close release valve
Fill with oil and bleed the system
Bleed the system
Tighten couplers and bleed
Flush and clean system
Review Troubleshooting Table for pump
Fill and bleed the system
Check for dirt, gummy deposits, or leaks as
above. Check for misalignment, worn parts or
defective packing
Tighten and bleed the system
Clean connection and use a non-hardening pipe
thread compound or PTFE tape if needed
Clean or replace if damaged
Review Troubleshooting Table for Pump
Replace seals
Replace seals
Tighten fittings
Repair or replace
Open pump release valve
Fasten couplers
Clean and flush
Send to service center
Send to service center
Drain oil to correct level

Ridge Tool Company
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HKO-186/1810, FKO-186/1810 Hydraulic Knockout Sets
Troubleshooting Table - Pump
PROBLEM POSSIBLE CAUSE REMEDY
Pump not delivering oil
Pump losing pressure
Pump does not
reach full pressure
Handle raises
after each stroke
Pump handle can be
pushed down (slowly)
without advancing ram.
Pump handle operates
with a spongy action.
Low oil level in reservoir
Dirt in pump body
Ball check seats worn and not seating properly
Reservoir overfilled with oil
Check valve springs weak or broken
Oil leaking past outlet ball seat
Damaged or dirty control valve seat
Low oil level
Internal relief valve set too low
Reservoir overfilled with oil
Oil leaking past outlet ball seat(s)
The inlet check ball is not seating
Air has been trapped in the line
Reservoir overfilled with oil
Low oil level in reservoir
Check oil level per instructions
Disassemble pump body and clean all parts
Reseat required seats in casting
Check oil level per reservoir instructions
Replace springs
Reseat ball seat
Reseat pressure control assembly and/or replace
assembly
Check oil level per reservoir instructions
Send to service center
Check oil level per reservoir instructions
Replace ball and/or reseat
Check for dirt and/or reseat valve seat
Set ram lower than the pump and extend and
return ram several times
Check oil level per reservoir instructions
Fill to proper level and bleed the system

Printed in U.S.A. 11/13 999-998-013.10
EC 39890 REV. A
99 Washington Street
Melrose, MA 02176
Phone [phone]
Toll Free 1-800-517-8431
Visit us at www.TestEquipmentDepot.com