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Current Tools 254 Assembly Operation Maintenance Manual

Hydraulic conduit bender
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Hydraulic Conduit Bender
for bending 2
RIGID - EMT - IMC Conduit
Assembly, Operating, Maintenance, Safety
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.
CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606
800.230.5421 or 864.721.4230 • FAX 864.721.4232
MODEL 254
and Parts Manual
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.
www.currenttools.com
½
" thru 4"
1/2019

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Summary of Contents for Current Tools 254

  • Page 1 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safety Alerts ..................3 Important Safety Information .............4,5 Specifications ...................6 Major Components – Bender ............6 Major Components – Parts List .............6 Major Components – Shoe Groups ..........7 Conduit Centerline Bending Radii ..........7 Assembly & Operating Instructions ........8-13 90˚...

  • Page 3: Safety Alerts

    SAFETY ALERTS Safety Alert Symbol 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.

  • Page 4: Important Safety Information

    RETAIN SAFETY INFORMATION This manual should be read and understood by all personnel who assemble, operate or service this hydraulic bender. Failure to understand how to safely assemble, operate and service this unit could result in injury or death. This unit should only be assembled, operated and serviced by qualified personnel.
  • Page 5 DANGER IMPORTANT SAFETY INFORMATION continued — WARNING NEVER stand in direct line with the follow bar while operating DANGER the bender. The follow bar is under high pressure during use and can be propelled with considerable force. DANGER CAUTION DANGER WARNING ALWAYS read and understand the safety and operating instructions supplied with your hydraulic pump.

  • Page 6: Specifications

    SPECIFICATIONS – 254 CONDUIT BENDER Model Number Storage Box Size 60"W × 24"D × 28 1/2"H Weight (w/Storage Box) 993 lbs. Bending Capacity 2 1/2", 3", 3 1/2", 4" EMT, IMC and Rigid conduit MAJOR COMPONENTS – BENDER NOTE: For complete shoe, follow bar and saddle listing see page 7.

  • Page 7: Major Components - Shoe Groups

    MAJOR COMPONENTS – SHOE GROUPS 2 1/2" 3" 254-110 254-117 – For bending 2 1/2" EMT, IMC and Rigid conduit — For bending 3" EMT, IMC and Rigid conduit Key Catalog# Description Key Catalog# Description 254-111 Bending Shoe – 2 1/2"...

  • Page 8: Assembly & Operating Instructions

    ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER FOR OPERATING ON THE FLOOR FRAME SIDE 1. Locate the two frame sides, roller assembly and two spring clips. ROLLER ASSEMBLY SPRING CLIP 2. Place one frame side onto the roller assembly as shown and secure with a spring clip.
  • Page 9 ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER (CONTINUED) 4. Place the hydraulic cylinder with the cylinder mounting block between the frame sides as shown in Figure 9. Insert the two cylinder FIGURE 9 block pins into the appropriate frame side...
  • Page 10 ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER (CONTINUED) 7. Select the shoe for the size conduit you will be bending. Place the shoe CONDUIT SIZE between the frame sides as shown, CLEVIS PIN with the conduit size facing upward.
  • Page 11 ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER (CONTINUED) SPRING 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.
  • Page 12 ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER (CONTINUED) 13. Place the correct size saddle around the conduit as shown and rotate the shoe as needed so that the saddle FIGURE 12 hole and the shoe hole align. Insert the saddle pin and secure with the spring clip as shown in Figure 12.
  • Page 13 ASSEMBLY & OPERATING INSTRUCTIONS – 254 CONDUIT BENDER (CONTINUED) 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. 18. Once the hydraulic pressure is released and the hydraulic cylinder has retracted, remove the saddle pin spring clip.

  • Page 14: 90˚ Bending Information And Charts

    90˚ BENDING INFORMATION AND CHARTS NOTE: Current Tools Model #254 bending shoes and follow bars are designed to make up to 90° bends with one extension of the hydraulic cylinder (one shot bends). The Greenlee Model #881CT CamTrack * hydraulic bender shoes and ®...
  • Page 15 90˚ BENDING INFORMATION AND CHARTS — continued Chart A – RIGID Conduit/Schedule 40 Pipe Conduit Deduct Minimum Stub Minimum Distance Size Length Length 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"...

  • Page 16: Cylinder Travel And Bender Calibration

    CYLINDER TRAVEL AND BENDER CALIBRATION NOTE: Read the gauge rod at the edge of the cylinder mounting block. Gauge rod should read zero ø ) when cylinder is fully retracted. 1. The bender must be calibrated prior to bending. To calibrate, rotate the pump valve lever to the closed position and activate the pump to advance the hydraulic cylinder until the shoe, conduit and follow bar tighten up.

  • Page 17: Common Bends Layout

    COMMON BENDS LAYOUT INFORMATION STUBS 1. Determine the desired stub height (H) and angle for the bend (See figure 17A). 2. Locate the chart (see pgs. 20 - 23) that corresponds to the size and type conduit you are going to bend.
  • Page 18 COMMON BENDS LAYOUT INFORMATION continued — OFFSETS: WORKING PAST AN OBSTACLE 1. Determine the desired length (L), height (H) and angle for the offset (See figure 18A). 2. Locate the chart (see pgs. 20 - 23) that corresponds to the size and type conduit you are going to bend.
  • Page 19 COMMON BENDS LAYOUT INFORMATION continued — THREE-POINT SADDLES 1. Determine the length to the center of the saddle (L), saddle height (H) and angle for the saddle (See Figure 19A) 2. Locate the chart (see pgs. 20 – 23) that corresponds to the size and type conduit you are going to bend.

  • Page 20: Values For Layout Of Common Bends

    VALUES FOR LAYOUT OF COMMON BENDS Chart D – 2 1/2" EMT D = 6 1/8 HEIGHT ANGLE 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 38 5/8 46 5/16 61 13/16 77 1/4...
  • Page 21 VALUES FOR LAYOUT OF COMMON BENDS Chart F – 3" EMT D = 5 3/4 HEIGHT ANGLE 23 15/16 31 11/16 47 1/8 62 9/16 101 3/16 124 3/8 147 9/16 170 3/4 217 1/8 38 5/8 46 5/16 61 13/16 77 1/4 92 11/16 115 7/8...
  • Page 22 VALUES FOR LAYOUT OF COMMON BENDS Chart H – 3 1/2" EMT D = 6 9/16 HEIGHT ANGLE 21 13/16 29 9/16 60 7/16 75 15/16 99 1/8 122 1/4 145 7/16 168 5/8 38 5/8 46 5/16 61 13/16 77 1/4 92 11/16 115 7/8...
  • Page 23 VALUES FOR LAYOUT OF COMMON BENDS Chart J – 4" EMT D = 8 1/2 HEIGHT ANGLE 18 5/8 26 5/16 41 13/16 57 1/4 72 11/16 95 7/8 119 1/16 142 1/4 165 7/16 211 13/16 38 5/8 46 5/16 61 13/16 77 1/4 92 11/16...

  • Page 24: Calculating "C" Values For Offsets Past An Obstacle

    CALCULATING “C” VALUES FOR OFFSETS PAST AN OBSTACLE NOTE: Refer to chart L below and ensure desired height (H) is greater than the minimum height for the size and type of conduit being bent. Chart L – Minimum Offset Height ANGLE 15°...

  • Page 25: Exploded View And Parts Lists - Follow Bars

    EXPLODED VIEW AND PARTS LIST — FOLLOW BARS 2½" ITEM # PART # QTY. DESCRIPTION 254-004 SCREW, SKT. HD. CAP – 5/16-18 × 1¼" 254-113 RAIL 254-157 FOLLOW BAR LESS RAILS 99-60 SCREW, SKT. HD CAP – 5/16-18 × 1"...

  • Page 26: Exploded View - Saddles

    EXPLODED VIEW — SADDLES PARTS LIST — SADDLES ITEM # PART # QTY. DESCRIPTION 2-1501-4 NUT – NYLON INSERT 3/8-16 2½" 254-005 WASHER – LOCK, 3/8 254-115 INSERT – SADDLE, 2½" 254-116 STRAP – SADDLE, 2½" 99-59 SCREW – SKT. HD CAP, 3/8-16 × 1.25 ITEM # PART # QTY.

  • Page 27: Explode View & Parts List - Hydraulic Cylinder

    EXPLODED VIEW — 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. PARTS LIST — HYDRAULIC CYLINDER ITEM # PART # QTY.

  • Page 28: Troubleshooting

    TROUBLESHOOTING WARNING ALWAYS disconnect the bender from the hydraulic pump before servicing and when not in use. Problem Cause Cure Kinking or rippling of Clevis pin is inserted in the shoe hole Move clevis pin to the shoe hole EMT conduit. for Rigid/IMC conduit.
  • Page 29 TROUBLESHOOTING — CONTINUED WARNING ALWAYS disconnect the bender from the hydraulic pump before servicing and when not in use. Will not bend Rigid or Clevis pin is inserted in the shoe hole Move clevis pin to the shoe hole IMC conduit. for EMT conduit.

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