Current Tools 254 Assembly Operation Maintenance Manual Download Page 1

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MODEL 254

Hydraulic Conduit Bender

for bending 2

" thru 4"

RIGID - EMT - IMC Conduit

CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606

800.230.5421 or 864.721.4230 • FAX 864.721.4232

www.currenttools.com

Assembly, Operating, Maintenance, Safety

and Parts Manual

1/2019

This manual is free of charge. All personnel who assemble, operate or service this Hydraulic Bender

should have a copy of this manual and read and understand its contents. To request a copy, call or

write to the address below. All information, specifications and product designs may change due to

design improvements or updates and are subject to change without notice. Current Tools does not

assume any liability for damages resulting from misuse or incorrect application of its products.

Read and understand this material before assembling,

operating or servicing this Hydraulic Bender. Failure

to understand how to safely assemble, operate and

service this unit may result in serious injury or death.

Summary of Contents for 254

Page 1: ...of this manual and read and understand its contents To request a copy call or write to the address below All information specifications and product designs may change due to design improvements or updates and are subject to change without notice Current Tools does not assume any liability for damages resulting from misuse or incorrect application of its products Read and understand this material b...

Page 2: ... Bending Radii 7 Assembly Operating Instructions 8 13 90 Bending Information and Charts 14 15 Cylinder Travel and Bender Calibration 16 Common Bends Layout 17 19 Values for Layout of Common Bends 20 23 Calculating C Values for Offsets Past An Obstacle 24 Exploded View and Parts Lists Follow Bars 25 Exploded View Saddles 26 Explode View Parts List Hydraulic Cylinder 27 Troubleshooting 28 29 ...

Page 3: ...mmediate hazards which if not avoided WILL result in serious personal injury or death DANGER THIS SAFETY SYMBOL is used to call your attention to instructions that concern your personal safety It means ATTENTION BE AWARE THIS IS AN IMPORTANT SAFETY INSTRUCTION Read understand and follow these safety instructions Failure to follow these safety instructions may result in injury or death Safety Alert...

Page 4: ...WAYS wear approved safety glasses when the bender is in operation ALWAYS wear proper apparel Do not wear loose clothing gloves neckties rings bracelets or other jewelry which may get caught in moving parts Non slip footwear is recommended Wear protective hair covering to contain long hair NEVER stand in direct line with the hydraulic cylinder while operating or servicing the bender Some parts of t...

Page 5: ...d remain a safe distance from work area The bender and some accessories exceed 50 lbs and will require more than one person to lift transport and assemble Only use the bender for its intended purpose as specified in this manual ALWAYS maintain bender with care Keep bender clean for best and safest performance CHECK all hose connections prior to use and ensure they are properly connected Improper c...

Page 6: ... 2 1 2 254 101 CYLINDER MOUNTING BLOCK WITH SET SCREW 1 3 254 107 CLEVIS PIN 1 4 254 148 CYLINDER BLOCK PIN 2 5 254 006 SPRING CLIP 6 6 254 104 FRAME SIDE ASSEMBLY 2 7 254 151 ROLLER ASSEMBLY 1 8 254 103 CLEVIS 1 9 254 108 CLEVIS RETAINING CLIP 1 10 254 149 SADDLE PIN 1 11 105 STORAGE BOX 1 12 506 CASTER SET 2 RIGID 2 SWIVEL 1 13 291 HYDRAULIC HOSE 1 MAJOR COMPONENTS PARTS LIST 7 5 4 3 1 2 9 8 10 ...

Page 7: ... 1 2 3 254 128 Saddle 3 1 2 CONDUIT CENTERLINE BENDING RADII MAJOR COMPONENTS SHOE GROUPS 3 Size 2 1 2 3 3 1 2 4 EMT 13 1 2 16 1 8 18 5 8 21 IMC 13 1 2 16 1 8 18 5 8 21 RIGID 13 1 2 16 1 8 18 5 8 21 254 117 For bending 3 EMT IMC and Rigid conduit Key Catalog Description 1 254 118 Bending Shoe 3 2 254 119 Follow Bar 3 3 254 121 Saddle 3 254 131 For bending 4 EMT IMC and Rigid conduit Key Catalog De...

Page 8: ...ing clips 2 Place one frame side onto the roller assembly as shown and secure with a spring clip NOTE The collar in the end of the frame side must be facing outward ROLLER ASSEMBLY FRAME SIDE SPRING CLIP COLLAR COLLAR 3 Place the second frame side onto the roller assembly and secure with a spring clip NOTE The collar in the end of the frame side must be facing outward ...

Page 9: ...d secure each with a spring clip NOTE The hydraulic cylinder with mounting block in Figure 9 is shown pinned in the position for bending 4 conduit The frame side holes are marked to indicate where to pin the mounting block for each size FIGURE 9 6 Rotate the frame and hydraulic cylinder so the long side of the cylinder mounting block is resting on the floor See Figure 9C Then place the clevis onto...

Page 10: ...ure with a spring clip see Figure 10 NOTE Arrows on the bending shoe indicate the correct hole for bending either Rigid IMC or EMT conduit see Figure 10A CLEVIS PIN SPRING CLIP CONDUIT SIZE 8 Remove the spring clip from the roller assembly as shown in Figure 10B SPRING CLIP 9 Raise the frame side and place the correct follow bar for the size conduit to be bent between the frame sides as shown in F...

Page 11: ... CLIP 10 Lower the frame side and secure with the spring clip NOTE Wipe the groove of both the shoe and follow bar and ensure they are clean and free of any debris 12 Place the conduit into the bender as shown CONDUIT 11 Connect the hose to the pump and hydraulic cylinder ...

Page 12: ...t of the follow bar The bending mark on the conduit should be aligned with the front edge of the saddle insert lip see figure 12A Rotate the pump valve lever to the closed position and activate the hydraulic pump until the shoe contacts the conduit and the saddle and follow bar are snug 15 DO NOT BEGIN BEND Before bending To determine the amount of cylinder travel for the size type and degree of b...

Page 13: ...raulic cylinder has retracted remove the saddle pin spring clip Remove the saddle pin and saddle Next remove the bent conduit from the bending set up 17 When the desired degree of bend is complete rotate the pump valve lever to the open position to release the hydraulic pressure and the hydraulic cylinder will retract ...

Page 14: ...tub length on the conduit stub length mark See figure 14B 3 Subtract Deduct Length from the stub length mark and make a second mark Bending Mark See figure 14B NOTE Check corresponding chart on page 15 for the deduct length of the type and size conduit being bent NOTE Check corresponding chart for the type and size conduit being bent and ensure the Bending Mark is equal to our greater than the Min...

Page 15: ...90 BENDING INFORMATION AND CHARTS continued Chart B EMT Conduit Conduit Size Deduct Length Minimum Stub Length Minimum Distance from End of Conduit 2 1 2 21 1 2 24 2 1 2 3 24 27 3 3 1 2 27 3 4 31 1 4 3 1 2 4 32 1 4 36 1 4 4 Chart C IMC Conduit Conduit Size Deduct Length Minimum Stub Length Minimum Distance from End of Conduit 2 1 2 21 1 2 24 2 1 2 3 24 1 4 26 3 4 2 1 2 3 1 2 28 1 4 30 3 4 2 1 2 4 ...

Page 16: ... 2 90 3 90 3 1 2 90 4 90 0 tight 4 3 16 3 7 8 2 7 8 2 3 16 10 4 7 8 4 7 8 3 15 16 3 3 8 15 5 3 16 5 3 16 4 3 8 3 3 4 30 6 1 8 6 1 4 5 7 16 4 7 8 45 7 1 16 7 1 8 6 1 2 6 1 16 60 8 8 3 16 7 5 8 7 3 16 90 9 1 2 10 3 8 9 7 8 9 1 2 IMC CONDUIT DEGREE OF BEND 2 1 2 90 3 90 3 1 2 90 4 90 0 tight 2 7 8 2 1 4 1 5 8 1 1 16 10 4 3 9 16 2 15 16 2 7 16 15 4 3 8 4 1 16 3 7 16 3 30 5 3 16 5 5 8 4 7 8 4 5 8 45 7 ...

Page 17: ...desired height H and length L for the U bend See figure 17B 2 Locate the chart see pgs 20 23 that corresponds to the size and type conduit you are going to bend 3 Under the row corresponding to 90 locate the M value corresponding to the length L of the U bend NOTE For a U bend the L value is labeled HEIGHT in the charts 4 Make a mark the distance M from the end of the conduit This is your first be...

Page 18: ...our second bending mark Mark 2 5 You may now proceed with the bend NOTE For offsets of heights other than those listed refer to Calculating C Values for Offsets Past an Obstacle on pg 24 OFFSETS WORKING TOWARDS AN OBSTACLE 1 Determine the length to the end of bends L offset height H and angle for the offset See figure 18B 2 Locate the chart see pgs 20 23 that corresponds to the size and type condu...

Page 19: ...th the bend FOUR POINT SADDLES 1 Determine the length to the start of the flat section L the length of the flat section F saddle height H and angle for the saddle See Figure 19B 2 Locate the chart See pgs 20 23 that corresponds to the size and type conduit you are going to bend 3 Using the desired angle locate the E value that corresponds to the desired height H Deduct this value from the length L...

Page 20: ...16 K 51 7 8 57 7 8 63 7 8 75 7 8 E 33 15 16 33 15 16 33 15 16 33 15 16 VALUES FOR LAYOUT OF COMMON BENDS Chart E 2 1 2 RIGID IMC D 6 1 8 HEIGHT ANGLE DIM 10 12 16 20 24 30 36 42 48 60 15 M 25 1 8 32 13 16 48 5 16 63 3 4 79 3 16 102 3 8 125 9 16 148 3 4 171 15 16 218 5 16 C 38 5 8 46 5 16 61 13 16 77 1 4 92 11 16 115 7 8 139 1 16 162 1 4 185 7 16 231 13 16 K 42 1 4 50 65 7 16 80 7 8 96 3 8 119 1 2 ...

Page 21: ...5 16 K 60 13 16 66 13 16 78 13 16 E 38 3 4 38 3 4 38 3 4 VALUES FOR LAYOUT OF COMMON BENDS Chart G 3 RIGID IMC D 6 HEIGHT ANGLE DIM 10 12 16 20 24 30 36 42 48 60 15 M 23 11 16 31 7 16 46 7 8 62 5 16 77 13 16 101 124 3 16 147 3 8 170 1 2 216 7 8 C 38 5 8 46 5 16 61 13 16 77 1 4 92 11 16 115 7 8 139 1 16 162 1 4 185 7 16 231 13 16 K 42 15 16 50 5 8 66 1 8 81 9 16 97 120 3 16 143 3 8 166 9 16 189 3 4...

Page 22: ... 16 63 3 8 90 M 8 1 4 14 1 4 20 1 4 32 1 4 C 39 3 4 51 3 4 K 69 7 8 81 7 8 E 44 15 16 44 15 16 VALUES FOR LAYOUT OF COMMON BENDS Chart I 3 1 2 RIGID IMC D 7 HEIGHT ANGLE DIM 10 12 16 20 24 30 36 42 48 60 15 M 21 3 8 29 1 8 44 9 16 60 75 1 2 98 11 16 121 13 16 145 168 3 16 214 9 16 C 38 5 8 46 5 16 61 13 16 77 1 4 92 11 16 115 7 8 139 1 16 162 1 4 185 7 16 231 13 16 K 43 5 8 51 3 8 66 13 16 82 1 4 ...

Page 23: ... 75 5 8 89 1 2 E 50 5 8 54 1 8 57 9 16 61 1 16 67 15 16 90 M 9 3 4 15 3 4 27 3 4 C 50 3 4 K 84 9 16 E 51 1 2 VALUES FOR LAYOUT OF COMMON BENDS Chart K 4 RIGID IMC D 8 3 4 HEIGHT ANGLE DIM 10 12 16 20 24 30 36 42 48 60 15 M 18 3 8 26 1 16 41 9 16 57 72 7 16 95 5 8 118 13 16 142 165 3 16 211 9 16 C 38 5 8 46 5 16 61 13 16 77 1 4 92 11 16 115 7 8 139 1 16 162 1 4 185 7 16 231 13 16 K 44 1 4 51 15 16 ...

Page 24: ... 3 16 25 1 4 45 3 8 4 3 3 4 10 1 8 18 13 16 29 1 16 51 3 4 CALCULATING C VALUES FOR OFFSETS PAST AN OBSTACLE To determine C value for laying out bending marks for offset heights other than those listed use the following formula C A H B A is a multiplier corresponding to the angle of bend and can be found in chart M B is a deduct value and can be found in chart N for the size of conduit and angle o...

Page 25: ... BAR LESS RAILS 4 254 192 1 RAIL RH 5 99 60 4 SCREW SKT HD CAP 5 16 18 1 3 ITEM PART QTY DESCRIPTION 1 254 004 2 SCREW SKT HD CAP 5 16 18 1 2 254 127 2 RAIL 3 254 168 1 FOLLOW BAR LESS RAILS 4 99 60 4 SCREW SKT HD CAP 5 16 18 1 4 ITEM PART QTY DESCRIPTION 1 254 004 2 SCREW SKT HD CAP 5 16 18 1 2 254 134 2 RAIL 3 254 145 1 FOLLOW BAR LESS RAILS 4 99 60 4 SCREW SKT HD CAP 5 16 18 1 TORQUE ALL SCREWS...

Page 26: ...54 005 2 WASHER LOCK 3 8 3 254 115 1 INSERT SADDLE 2 4 254 116 1 STRAP SADDLE 2 5 99 59 2 SCREW SKT HD CAP 3 8 16 1 25 ITEM PART QTY DESCRIPTION 1 2 1501 4 2 NUT NYLON INSERT 3 8 16 2 254 005 2 WASHER LOCK 3 8 3 254 136 1 INSERT SADDLE 4 4 254 137 1 STRAP SADDLE 4 5 99 59 2 SCREW SKT HD CAP 3 8 16 1 25 ITEM PART QTY DESCRIPTION 1 2 1501 4 2 NUT NYLON INSERT 3 8 16 2 254 005 2 WASHER LOCK 3 8 3 254...

Page 27: ...2 RING RETAINING EXTERNAL INTERLOCKING 13 254 009 2 NUT HEX THIN 3 8 24 14 254 188 1 PLATE GAUGE ROD 15 254 189 1 ROD GAUGE 16 291 2A 1 FITTING HYDRAULIC FEMALE 17 254 007 1 O RING RUBBER PARTS LIST HYDRAULIC CYLINDER NOTE Part 254 RPR is the rebuild kit for the hydraulic cylinder and includes item 5 9 10 and 11 See below for part numbers and descriptions Kit items not sold separately REBUILD KIT ...

Page 28: ...eplace as necessary Side marking of EMT conduit Conduit is not level Floor set up only Level the conduit in the set up Shoe and or follow bar grooves are dirty or damaged Clean grooves of shoe and follow bar Replace if damaged Carriage with vise on the Model 281 bending table is clamped too close to the bender Adjust the position of the carriage with vise further from the bender Follow bar groove ...

Page 29: ...tighten Too long of an extension cord causing voltage drop to the hydraulic pump Pump not properly vented Hydraulic cylinder pinned too high in the frame for the size conduit being bent Pump valve lever in wrong position Pump not operating properly Use heavier gauge extension cord and or shorter extension cord Remove the plug used during shipping and replace with the correct vent plug Reposition h...

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