Current Tools 152, 152 PM, 154, 154 PM Operating, Maintenance, Safety And Parts Manual

Current Tools™ Hydraulic Knockout Sets

Model 152 – ½" to 2" Model 154 – ½" to 4"

and

Model 152 PM – ½" to 2" Model 154 PM – ½" to 4"

Operating, Maintenance, Safety

This manual is free of charge. All personnel who operate or service the Hydraulic Knockout Set should have a copy of this manual and read and understand its contents. To request a copy, call or write to the address below.

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

800.230.5421 or 864-721-4230 • FAX 864-721-4232

and Parts Manual

08/10 - REV. 3

Read and understand this material before operating the Hydraulic Knockout Set. Failure to understand how to safely operate and service this unit may result in serious injury or death.

www.currenttools.com

Hazards or unsafe practices which, if not avoided, COULD result in serious personal in

jury

or death

ARNIN

Hazards or unsafe practices which, if not avoided, COULD result in minor personal in

jury

or property damage

UTI

Immediate hazards which, if not avoided, WILL result in serious persona

injury or death

DAN

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 safet

instructions may result in injury or death.

Safety Alert

Symbol

TABLE OF CONTENTS

Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Set-Ups Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Components List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Section View & Parts List — Model 1522 Ram . . . . . . . . . . . . . . . . . . 8

Specifications — Model 1521 Hand Pump. . . . . . . . . . . . . . . . . . . . . . 9

Operating Instructions — Model 1521 Hand Pump . . . . . . . . . . . . . . 9

Maintenance — Model 1521 Hand Pump . . . . . . . . . . . . . . . . . . . . . . 9

Exploded View — Model 1521 Hand Pump. . . . . . . . . . . . . . . . . . . . 10

Parts List — Model 1521 Hand Pump. . . . . . . . . . . . . . . . . . . . . . . . . 11

Repair Kit — Part No.1521-RPRKIT. . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SAFETY ALERTS

This manual should be read and understood by all personnel who operate or service this Hydraulic Knockout Set. Failure to understand how to safely operate and service this unit could result in injury or death. This unit should only be operated or serviced by qualified personnel.

RETAIN SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION

Follow ALL safety information provided by the manufacturer.

DANGER

ARNIN

WARNING

NEVER use the Knockout Set or any of its components near live circuits.

ALWAYS stand to the side of the ram when punching. This will help avoid injury should there be a component failure.

The model 1521 Hand Pump is pre-set at the factory to operate at pressures up to 8,000 PSI. Do NOT connect any pump to the Current Tools model 1522 Ram that will exceed 8,000 PSI. Doing so may cause component failure which may result in injury or death. Only use a hand or foot operated pump with the model 1522 Ram. Never operate the ram with an electric pump.

Be sure to support the ram while punching. An unsupported ram could fall causing injury.

Do NOT continue to operate pump after the ram completes the punch. Doing so will damage the ram and could cause component failure resulting in serious injury or death.

If the ram motion stops before the punching process is completed, Do NOT continue to operate the pump. Release the pump pressure and disassemble the set-up and determine the cause before continuing.

Hydraulic tools create tremendous pressures and hydraulic oil can easily puncture skin. If your skin is pierced by oil you must seek medical attention immediately! NEVER touch the hydraulic hose or fittings while the unit is under pressure.

WARNING

ALWAYS thread the punch COMPLETELY onto the draw stud ( or adapter ) to avoid thread failure. If the punch tightens before it is completely threaded onto the draw stud, disassemble the set-up and determine the cause. Then reassemble the set-up.

WARNING

ALWAYS release the hydraulic pressure before removing any hoses or before servicing any component of the hydraulic system.

WARNING

ONLY replace the hoses and fittings with Current Tools replacement parts.

WARNING

NEVER attempt to exceed the punching capacity of this knockout set. Doing so may cause component failure and possibly serious injury or death.

continued on next page . . .

IMPORTANT SAFETY INFORMATION continued . . .

WARNING

CAUTION

NEVER attempt to punch a hole through more than a single layer of material. Doing so may cause component failure and possibly serious injury or death.

NEVER use this knockout set or any of its components except for its intended purpose.

Hand pressure is sufficient to activate the pump. NEVER attempt to apply additional pressure to the pump handle.

The Model 1521 Hand Pump is designed for use ONLY with Hydraulic Knockout Sets and Cable Cutters.

ALWAYS inspect every component of the punch set-up including the ram, pump, fittings, punch, die, draw stud, adapter, and spacer(s) before each use. Replace any worn or defective parts with Current Tools replacement parts. NEVER use dull punches.

NEVER use any component that has worn or damaged threads.

ALWAYS check to ensure all components are properly assembled before punching.

New punches are sharp. Be careful when handling them.

ALWAYS wear safety glasses when punching.

SPECIFICATIONS

B E N D I N G

Model No. 152 and 152PM 154 and 154PM Overall Dimensions 4 Capacity

⁄8" x 101⁄2" x 17 3⁄4" 41⁄8" x 14" x 173⁄4"

⁄2" to 2”conduit size holes 1/2” thru 4” conduit size holes

Weight 25 lbs. 54 lbs.

The model 1521 Hydraulic Hand Pump has a maximum operating pressure of 8,000 PSI.

NOTE: All models are designed to punch a maximum of 10 gauge mild steel (.134 in. thick)

™

Current Tools

split the slug into two pieces for easy removal from the die after punch completion.

Models 152PM and 154PM — Piece Makers™ — are designed to

OPERATING INSTRUCTIONS

B E N D I N G

1. Match the punch, die, draw stud, adapter ( if needed ) , and spacer(s) as required for the size hole to be punched. ( See Figures 1a, 1b, 1c. )

2. After marking the hole location, drill a hole approximately larger than the draw stud or adapter being used.

NOTE: Alternate Method — Drill a

stud (Part #1581) and use the accept the

⁄4" draw stud (Part #1582). Then, if needed, use 1" punch and die

to increase the hole size to accept the 1

⁄16" hole to accept the 3⁄8" adapter draw

⁄2" punch and die to increase the hole size to

⁄8" adapter.

⁄32" to 1⁄16"

continued on next page . . .

ead failure

jury.

OPERATING INSTRUCTIONS continued . . .

3. When using 3⁄4" through 3" punch and die, thread the end of the

⁄4" draw stud (Part #1582) with the shortest thread length into the ram until

snug. (See Figure 1b. )

When using the

⁄8" adapter draw stud (Part #1581) directly into the ram until snug.

⁄2" punch and die, thread the larger 3⁄4" end of the

(See Figure 1a. )

When using the 3

(Part #1552) over the end of the 1

⁄2" and 4" punch and die, thread the 11⁄8" adapter

⁄4" draw stud (Part #1582) until snug. The threaded

⁄8" adapter should face away from the ram. (See Figure 1c. )

4. Determine spacer(s) needed (if any) and install. (See Spacer Chart below.)

SPACER CHART

Punch & Die Size Spacers

1⁄2" SHORT (#1553)

⁄4" thru 11⁄4" MEDIUM (#1554)

⁄2" SHORT (#1553)- L

2" thru 4" No spacers

5. Slide the die onto the draw stud with the open end of the die facing away from the ram.

6. Place the draw stud through the hole you drilled in step 2. Then thread the punch onto the draw stud (or adapter) with the cutting face toward the material to be punched. Thread the punch onto the draw stud until the punch, die and spacers are snug against the material.

ALWAYS thread the punch COMPLETELY onto the draw stud (or adapter) to avoi thr stud, disassemble the set-u

. If the punch tightens before it is completely threaded onto the draw

7. Complete the punching process by activating the hand pump. (See hand pump operating instructions on page 9.)

DO NOT continue to operate the pump after the ram completes the punch. Doing so will

e the ram and could cause component failure resulting in serious injury or death

dama

If the ram motion stops before the punching process is completed, DO NOT continue to

erate the pump. Release the pump pressure and disassemble the set-up and determine

o the cause before continuin

Be sure to support the weight of the ram while punching. An unsupported ram could fall causing in

ARNIN

and determine the cause. Then reassemble the set-u

ARNIN

1/2"

DIE

PUNCH

3/8"

ADAPTER

STUD

MATERIAL

PUNCH

DIE

3/4"

DRAW

STUD

1 1/8"

MATERIAL

3/4"

ADAPTER

PUNCH

DRAW

STUD

3 1/2" & 4" DIES REST

ON RAM SHOULDER

MATERIAL

SHORT

SPACER

RAM WITH

3/8"

ADAPTER

PUNCH

STUD

DIE

MATERIAL

Page 5

See SPACER CHART

SPACERS AS NEEDED

RAM

PUNCH

DIE

MATERIAL

DIE

RAM

PUNCH

MATERIAL

FIGURE 1

DIE

THREADED

END

SHORT

SPACER

3/8"

ADAPTER

STUD

RAM

1/2"

PUNCH

SET UPS

EXPLODED VIEW COMPLETED VIEW

Page 5

See SPACER CHART

SPACERS AS NEEDED

SHORTEST

THREAD

LENGTH

3/4" DRAW

STUD

RAM

& DIE

3/4"-3"

PUNCH

& DIE

1-1/8"

ADAPTER

3/4" DRAW

STUD

RAM

3-1/2"

AND 4"

PUNCH

SHORTEST

& DIE

THREAD

LENGTH

COMPONENTS

KNOCKOUT SET

11 thru

COMPONENTS LIST

& 1

ITEM# CATALOG# DESCRIPTION #152 #152PM #154 #154PM

⁄2" to 2" 1⁄2" to 2" 1⁄2" to 4" 1⁄2" to 4"

1 ...............1522 ................... Ram (Includes #2) ..................1 ..................1 ................. 1 ................. 1

2 ...............1582 ........................

3 ...............1552 ......................... 1

4 ...............1581 ................

⁄4" Draw Stud ......................1 ..................1 .................1 .................1

⁄8" Adapter ................................................................1 ................. 1

⁄8" Adapter Draw Stud ............... 1 ..................1 .................1 ................. 1

5 ...............1553 ....................Short Spacer – S .................1 ..................1 .................1 .................1

6 ...............1554 .................Medium Spacer – M ..............1 ..................1 .................1 .................1

7 ...............1521 .................Hydraulic Hand Pump ...............1 ..................1 .................1 .................1

8 ...............1523 ................

9 ............1500-PC ...Plastic Carrying Case –

10 ..............1501 .......Metal Carrying Case –

11 ..............1524 ................

12 ..............1525 ..............................

13 ..............1526 ................

14 ..............1527 ..............................

15 ..............1528 ................ 1" Piece Maker

⁄4" x 3' Hydraulic Hose ..............1 ..................1 .................1 ................. 1

⁄2" Piece Maker™ Punch ................................... 1 .....................................1

⁄4" Piece Maker™ Punch ................................... 1 .....................................1

⁄2" Die ............................1 .................. 1 .................1 .................1

⁄4" Die ............................1 ..................1 ................. 1 .................1

⁄2" to 2" Set ....1 ..................1 ......................................

⁄2" to 4" Set .............................................. 1 .................1

™

Punch ...................................1 ..................................... 1

16 ..............1529 .............................. 1" Die.............................1 ..................1 ................. 1 .................1

17 ..............1530 ...............1

18 ..............1531 ............................. 1

19 ..............1532 ...............1

20 ..............1533 ............................. 1

21 ..............1534 ................ 2" Piece Maker

⁄4" Piece Maker™ Punch .................................. 1 .....................................1

⁄2" Piece Maker™ Punch .................................. 1 .....................................1

⁄4" Die ...........................1 ..................1 ................. 1 ................. 1

⁄2" Die ...........................1 .................. 1 .................1 .................1

™

Punch ...................................1 ..................................... 1

22 ..............1535 .............................. 2" Die ............................. 1 ..................1 .................1 ................. 1

23 ..............1560 ...................

24 ..............1561 ...................

⁄2" Standard Punch .................1 ......................................1 ..................

⁄4" Standard Punch .................1 ......................................1 ..................

25 ..............1562 ....................1" Standard Punch ..................1 ......................................1 ..................

26 ..............1563 .................. 1

27 ..............1564 .................. 1

⁄4" Standard Punch ................1 ......................................1 ..................

⁄2" Standard Punch ................1 ......................................1 ..................

28 ..............1565 ....................2" Standard Punch ..................1 ......................................1 ..................

29 ..............1566 ...........................2

30 ..............1567 ............................. 2

⁄2" Punch ..................................................................1 ................. 1

⁄2" Die ....................................................................1 ................. 1

31 ..............1568 ............................3" Punch ................................................................... 1 ................. 1

32 ..............1569 .............................. 3" Die ...................................................................... 1 ................. 1

33 ..............1570 ...........................3

34 ..............1571 ............................. 3

⁄2" Punch ..................................................................1 ................. 1

⁄2" Die ....................................................................1 ................. 1

35 ..............1572 ............................4" Punch ................................................................... 1 ................. 1

36 ..............1573 .............................. 4" Die......................................................................1 ................. 1

SECTION VIEW

MODEL 1522 RAM

PARTS LIST — Model 1522 Ram

ITEM# PART# QTY DESCRIPTION

1 ............................ 1522-11 ............................1 ....................................... CYLINDER

2 ............................ 1522-12 ............................1 ......................................... PISTON

3 ............................. 1522-2 .............................1 ......................................... SPRING

4 ............................. 1522-4 .............................1 ............................................ CAP

*5 ............................. 1522-5 .............................1 ................................. RETAINING RING

6 ...............................1582 ..............................1 ..................................

*7 ............................. 1522-7 .............................1 ...................................BACK-UP RING

*8 ............................. 1522-8 .............................1 ..........................................O-RING

*9 ............................. 1522-9 .............................1 ..........................................O-RING

*10 ............................ 1522-10 ............................1 ...................................BACK-UP RING

* Included in Repair Kit Part Number 1522-RPR

⁄4" DRAW STUD

Hand pressure is sufficient to activate the pump. attempt to apply additional pressure to the pump handle

ARNIN

SPECIFICATIONS — MODEL 1521 HAND PUMP

B E N D I N G

WARNIN

The Model 1521 Hand Pump is designed for use ONLY with Hydraulic Knockout Sets and Cable Cutters.

Model No. 1521 Hand pump Overall Dimensions 2 Capacity 8,000 PSI max — .069 cu. in. of oil per stroke Weight 4.5 lbs. (with oil) Oil Capacity 16 cu. in.

⁄8" Wide x 3 7⁄8" Tall x 123⁄4" Long

OPERATING INSTRUCTIONS

B E N D I N G

1. Turn knob clockwise.

2. Pump handle to activate hand pump.

3. When operation is complete, turn knob counter-clockwise.

MAINTENANCE

B E N D I N G

Oil Requirements: We recommend a high quality automatic transmission fluid such as Shell DONAX TG or equivalent

Filling the Pump with Oil:

1. Secure the pump in a vise by clamping lightly onto the hex body with

the reservoir and end cap facing upward, and unscrew the end cap.

2. Remove the rubber plug located in the center of the reservoir follower, and then remove the reservoir follower. Check the reservoir follower O-ring and the rubber plug for damage or wear, and replace as needed.

3. Fill the reservoir until the oil level is

4. Push the reservoir follower into the reservoir until oil begins to come out of the hole.

5. To remove trapped air from the pump, turn the release knob clockwise to the closed position and pump the handle 5 times. Slowly turn the release knob counterclockwise while keeping light pressure with your finger over the hole in the reservoir follower. This allows air to escape under your finger and prevents ejecting oil. Repeat this procedure if needed.

6. Replace the rubber plug in the reservoir follower.

7. Remove and clean the felt vent located inside the reservoir end cap. Then screw the reservoir end cap back onto the reservoir.

⁄4" from the top.

ITEM 2

EXPLODED

VIEW

MODEL 1521 HAND PUMP EXPLODED VIEW

SEE

EXPLODED

VIEW

PARTS LIST — Model 1521 Hand Pump

B E N D I N G

ITEM # PART # QTY DESCRIPTION

1 ............................ 1521-1 .............................1 ...........................................BODY

2 ............................ 1521-2 .............................1 ..............................RELEASE ASSEMBLY

2a .......................... 1521-2a ............................1 .................................. RELEASE BODY

2b .......................... 1521-2b ...........................1 ..........................................SCREW

2c .......................... 1521-1d ........................... 1 ........................................... BALL

2d .......................... 1521-2d ...........................1 .................................SPRING RELEASE

2e .......................... 1521-2e ............................1 ...................................BACK UP RING

2f ............................1521-2f ............................1 ..........................................O-RING

2g .......................... 1521-2g ..........................1 ..........................................O-RING

2h .......................... 1521-2h ...........................1 ..........................................O-RING

2j ............................1521-2j ............................1 ........................................ROLL PIN

2k .......................... 1521-2k ............................1 ......................................SET SCREW

2m .........................1521-2m ........................... 1 ...........................................KNOB

3 ............................ 1521-3 ...........................1 ........................................... FOOT

4 ............................ 1521-4 .............................1 ................................PISTON RETAINER

5 ............................ 1521-5 .............................1 ..................................PISTON DOWEL

6 ............................ 1521-6 .............................1 ....................................HANDLE LINK

7 ............................ 1521-7 .............................1 .........................................HANDLE

8 ............................ 1521-8 .............................1 .........................................SCREEN

9 ............................ 1521-9 .............................1 ................................SCREEN RETAINER

10 .......................... 1521-10 .......................... 2 ....................................CHECK VALVE

11 .......................... 1521-11 ............................1 ......................................RESERVOIR

12 .......................... 1521-12 ............................1 .................................... RELIEF VALVE

13 .......................... 1521-13 ............................1 ......................................SPRING PIN

14 .......................... 1521-14 ............................1 ..........................................O-RING

15 .......................... 1521-15 ............................1 ...................................BACK UP RING

16 .......................... 1521-16 ............................1 ...................................BACK UP RING

17 .......................... 1521-17 ............................1 ..........................................O-RING

18 .......................... 1521-18 ............................2 ..................................... HANDLE PIN

19 .......................... 1521-19 ............................1 ..........................................O-RING

20 .......................... 1521-20 ............................1 ..................................RESERVOIR CAP

21 .......................... 1521-1B ...........................1 .................................. RETAINING CLIP

22 .......................... 1521-1C ...........................1 .......................................FELT VENT

23 .......................... 1521-23 ............................1 ........................................... PLUG

24 ..........................1521-1A ...........................2 ..........................................SCREW

25 .......................... 1521-25 ............................1 ...............................RESERVOIR PISTON

26 .......................... 1521-26 ............................1 ..........................................O-RING

27 .......................... 1521-27 ............................1 ................................... RUBBER PLUG

28 .......................... 1521-28 ............................4 ................................. RETAINING RING

29 .......................... 1521-29 ............................1 ........................................ROLL PIN

REPAIR KIT PART #1521-RPRKIT Contains the following: