Current Tools 252 Assembly, Operating, Safety And Parts Manual

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Current Tools™ Model 252

Mobile Bending Station

for use with Model #254 Hydraulic Conduit Bender

Assembly, Operating, Safety

and Parts Manual

8/2019

Read and understand this material before assembling, operating or servicing the 252 Mobile Bending Station and 254 Hydraulic Bender. Failure to understand how to safely assemble and operate this equpment may result in serious injury or death.

This manual is free of charge. All personnel who assemble, operate or service this equipment 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 www.currenttools.com

TABLE OF CONTENTS — 252 MOBILE BENDING CART

Safety Alert

Symbol

THIS SAFETY SYMBOL is used to call your attention to instructions

hat 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

hese safety instructions may result in injury or death.

Safety Alert

Symbol

Safety Alerts ..............................................................................................2-4

Components ..................................................................................................4

Features ......................................................................................................... 5

Major Components and Parts List – 254 Bender ......................................6

Mounting Bender Components Onto Mobile Bending Station ............7-8

Bender Assembly and Mounting Instructions ..................................... 9–25

Lifting and Transporting ............................................................................25

Exploded Views and Parts List ...........................................................26, 27

RETAIN SAFETY INFORMATION

This manual should be read and understood by all personnel who assemble, operate or service this mobile bending station and hydraulic bender. Failure to understand how to safely assemble and operate these units could result in injury or death. This mobile bending station and hydraulic bender should only be assembled, operated and serviced by qualiﬁed personnel.

When using the 252 Mobile Bending Station with Greenlee®

SAFETY ALERTS

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 my result in injury or death.

* Greenlee® and CamTrack® are registered trademarks of Greenlee Tools, Inc., which has no afﬁliation with Current Tools.

881 CamTrack® Bender, read and understand the bender manufacturer’s operating and safety instructions before attaching to or operating with the 252 Mobile Bending Station. Failure to do so many result in serious injury or death.

WARNING

DANGER

Immediate hazards which, if not avoided, WILL result in serious personal injury or death.

WARNING

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

CAUTION

Hazards or unsafe practices which, if not avoided, COULD result in minor personal injury or property damage.

IMPORTANT SAFETY INFORMATION

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

NEVER operate the bender in an explosive atmosphere.

NEVER operate the bender in wet or damp locations. DO NOT expose the bender to rain.

ALWAYS disconnect the bender from the hydraulic pump before servicing and when not in use.

WARNING

ALWAYS inspect the bender before operating. Replace any damaged, missing or worn parts. Check for alignment of moving parts, binding of moving parts, breakage of parts and any other conditions that may affect its operation.

Before lifting, be sure all components and parts are secured on the 252 Mobile Bending Station. There are fork pockets provided on the 252 Mobile Bending Station. The maximum height using these fork pockets is 5 feet. DO NOT attempt to lift the 252 Mobile Bending Station by any other means, as there are no lifting points provided.

Before transporting by vehicle, be sure all components and parts are secured on the 252 Mobile Bending Station.

NEVER alter this equipment. Doing so will void the warranty.

ALWAYS keep hands and feet away from pinch points such as bending shoes, follow bars, saddles, conduit and other moving parts.

ALWAYS use appropriate bending shoe, follow bar and saddle for the size conduit to be bent.

ALWAYS keep conduit under control when unloading.

ALWAYS keep the path of the bending conduit clear of obstructions. Make sure all obstacles are clear of the bending path BEFORE you bend the conduit.

WARNING

ALWAYS 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 the cylinder are under high pressure and can be propelled with considerable force.

NEVER stand in direct line with the follow bar while operating the bender. The follow bar is under high pressure during use and can be propelled with considerable force.

IMPORTANT SAFETY INFORMATION — continued

WARNING

DANGER

CAUTION

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

DANGER

WARNING

CAUTION

ALWAYS read and understand the safety and operating instructions supplied with your hydraulic pump.

ALWAYS keep children away. All visitors should 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.

ALWAYS keep the bender under control when adjusting to or from the transport position

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 connections may not allow the hydraulic cylinder to operate.

ONLY roll on a firm, flat smooth surface.

NEVER sit, ride or stand on the Mobile Bending Station.

COMPONENTS – 252 MOBILE BENDING STATION

KEY NO. DESCRIPTION QTY

281-221 Carriage with vise 1

252-200 Bender mounting unit 1

281-3 Ram positioning unit 1

252-132 Pump pedestal 1

280-7 Magnetic protractor 1

281-CPLNGASSY 90˚ Coupling assembly 1

FEATURES – 252 MOBILE BENDING STATION

For use with Model #254 Hydraulic Conduit Bender. Can also be used with Greenlee® Model #881 CamTrack® Benders.*

ITEM DESCRIPTION

1 CARRIAGE WITH VISE

2 PUMP PEDESTAL

3 BENDER MOUNTING UNIT

4 CONDUIT – 2" RIGID

5 FOLLOW BAR RETAINER BRACKET

6 SPRING CLIP

7 90˚ COUPLING ASSEMBLY

8 MAGNETIC PROTRACTOR

9 RAM POSITIONER

10 H.D. CASTER SET – 2 RIGID, 2 SWIVEL

11 FORK POCKETS

* Greenlee® and CamTrack® are registered trademarks of Greenlee Tools, Inc., which has no afﬁliation with Current Tools.

MAJOR COMPONENTS – BENDER

For complete shoe, follow bar and saddle listing, refer to Model #254

operating manual.

All major components will ﬁt Greenlee® Model #881 CamTrack® Bender*

MAJOR COMPONENTS – PARTS LIST

ITEM CATALOG DESCRIPTION QTY.

1 254-100 HYDRAULIC CYLINDER (INCLUDES ITEM #2) 1

2 254-101 CYLINDER MOUNTING BLOCK 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

* Greenlee® and CamTrack® are registered trademarks of Greenlee Tools, Inc..

MOUNTING BENDER COMPONENTS ON MOBILE BENDING STATION

MAJOR COMPONENTS – BENDER

FOLLOW BARS

(ALL 4 THIS SIDE)

FOLLOW BAR

RETAINER BRACKET

(2 PER FOLLOW BAR)

SADDLES

NOTE: Lock casters before mounting

or removing components.

1. Pull the pawl release pin on the follow bar retainer brackets and lower the brackets. Decals on the mobile bending station identify the correct location for each follow bar. Slide each follow bar into the correct location with the “ears” to the inside and the rails facing upward. Then, lock the follow bar retainer brackets into the upright position, making sure the pawls “click” into place.

2. Pull the spring clips out of the mounting holes in the saddle mounting pins. A decal above the mounting pins identiﬁes the correct location for each saddle. Slide each saddle onto the correct mounting pin with the saddle straddling the mounting plate as shown above. Install all spring clips.

3. Pull the spring clip out of the mounting hole for the 2 1/2" bending shoe. A decal on the Mobile Bending Station identiﬁes the correct orientation for hanging the shoe. Hang the shoe and install the spring clip.

STORAGE TRAY

SHOE – 2½"

4. Loose pins, spring clips, etc. can be placed on the storage tray located underneath the saddle storage area.

MOUNTING BENDER COMPONENTS ON MOBILE BENDING STATION

SHOE – 3"

PUMP

PEDESTAL

MAJOR COMPONENTS – BENDER

PEDESTAL

LOCKING PIN

SHOE – 4"

RAM

POSITIONER

SHOE – 3½"

5. Pull the spring clips out of the mounting holes in the remaining shoe mounting pins and the ram positioner mounting pin. Decals on the mobile bending station identify the correct location and hanging orientation for each size shoe. A decal also identiﬁes where to hang the ram positioning unit. Hang all shoes and the ram positioning unit as shown and install all spring clips.

6. Insert the pump pedestal into the pedestal reciever tube while pulling out the pedestal locking pin. Place the hydraulic pump onto the pump pedestal. The ﬁgure above shows the pump pedestal locked in the transport position. Prior to setting up for a bend, the pump pedestal must be rotated outward so that the controls of the hydraulic pump face the operator. To do so, pull the pedestal locking pin and rotate the pedestal.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

FRAME SIDE

1. Locate the two frame sides, roller assembly and the two spring clips.

ROLLER

ASSEMBLY

SPRING CLIP

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

COLLAR

outward.

CONDUIT CENTERLINE BENDING RADII

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.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

GATE IN

SUPPOR

GATE IN RAISED

POSITION

GATE PAWL

RING

BENDER

MOUNTING

UNIT

CONDUIT

SUPPORT TUBE

4. Ensure that the bender mounting unit is installed within the 4 conduit support tubes as shown. Pull the gate pawl ring on both sides of the bender mount unit and raise the gates. Using the pedestal locking pin, rotate the pump pedestal (not shown) to the outside of the Mobile Bending Station frame.

RAISED POSITION

GATE PAWL

RING

BENDER MOUNTING

UNIT

CONDUIT

T TUBE

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

90° COUPLING

BENDER MOUNTING

CAUTION

Ensure the casters remain locked throughout the bender assembly and mounting process.

UNIT

PUMP PEDESTAL

TURNED OUTWARD

ASSEMBLED FRAME SIDES

WITH ROLLER ASSEMBLY

5. Ensure the pedestal with pump is turned outward. Place the assembled frame sides onto the bed of the Mobile Bending Station with the roller assembly resting in the bender mounting unit.

ASSEMBLY

6. Insert and secure the 90° coupling

COUPLER BOD

assembly into the coupler body on the top of the hydraulic cylinder.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

CYLINDER BLOCK

HYDRAULIC CYLINDER

WITH BLOCK

HYDRAULIC HOSE

7. Insert the hydraulic cylinder with block into the frame sides and pin together, using the two cylinder block pins, in the correct holes for the size conduit you are bending. The frame side holes are marked to indicate where to pin the mounting block for each size. (For illustration purposes the 4" hole has been selected).Then, attach the hydraulic hose to the 90° coupling assembly on the hydraulic cylinder and the coupling on the hydraulic pump.

NOTE: Ensure that the hose and couplings are clean and free of debris

prior to assembly.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

GATE CLOSED

ON BOTH SIDES

8. Lift the frame side assembly with hydraulic cylinder while making sure that the roller slides into the bottom of the bender mounting unit. When the roller is fully seated into the bender mounting unit and the frame sides are vertical as shown, lower the gates of the bender mounting unit until the pawls “click” and they are securely closed.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

TABLE

RAILS

RAIL

START

ROLLER

ASSEMBLY

9. Select the follow bar for the size conduit you will be bending. Angle the follow bar and insert it between the frame sides with the end marked “START” as shown. Turn the follow bar so that the rails rest on the roller assembly. Push the end of the follow bar marked “START” towards the frame side assembly until the opposite end of the follow bar is resting on the table of the Mobile Bending Station.

NOTE: For illustration purposes, the 4" follow bar has been selected.

NOTE: To insert and remove the 3½" follow bar, the cylinder and block

must be removed.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS

SADDLE PIN HOLE

CLEVIS

RETAINING

CLIP

CLEVIS

10. Place the clevis onto the end of the hydraulic cylinder and secure with the clevis retaining clip as shown.

11. Place the correct size bending

shoe between the frame sides, making sure the saddle pin hole is located as shown.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

CLEVIS PIN

RIGID/IMC

12. Rotate the pump valve lever on the hydraulic pump to the closed position and advance the cylinder until the clevis holes are aligned with the correct conduit type hole (Rigid/IMC or EMT) in

CLEVIS

SPRING CLIP

BENDING SHOE

NOTE: Arrows on the bending shoe indicate the correct hole for bending either Rigid/IMC or EMT conduit.

the bending shoe. Insert the clevis pin and secure with a spring clip.

13. Rotate the pump valve lever on the hydraulic pump to the open position to retract the hydraulic cylinder and raise the shoe.

NOTE: Wipe the groove and mating surfaces

of both the shoe and follow bar and ensure they are clean and free of any debris.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

CARRIAGE WITH VISE

14. Slide the carriage with vise to the far end of the Mobile Bending Station.

CARRIAGE WITH VISE

CONDUIT

15. Place the conduit between the shoe and follow bar, resting the conduit on the carriage with vise. Rotate the pump valve lever on the hydraulic pump to the closed position and activate the pump until the shoe almost makes contact with the conduit

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

VISE CHAIN

CONDUIT

17 . Push the end of the follow bar

marked “START” towards the bender mounting unit until the “ear” of the follow bar touches the bender mounting unit (See illustration at right). Place the correct saddle and saddle pin

START

within reach for assembly to the bending shoe.

CARRIAGE WITH VISE

16. Place the vise chain around the conduit and tighten to secure.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

18. While rocking the bender frame, push the bottom of the bending shoe to the position shown for attaching the saddle and saddle pin.

PUSH

SADDLE

INSERT LIP

SADDLE

HOLE

19. While holding the shoe against the conduit, place the saddle under the conduit with the saddle insert lip facing away from the follow bar. Slide the saddle towards the shoe and align the saddle holes with the shoe hole. Insert the saddle pin through both the saddle and shoe and secure it with a spring clip.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

INSER

CONDUIT

BENDING

CONDUIT

SADDLE

T LIP

MARK

20. Once the saddle is pinned onto the shoe, lean the bender forward. Make sure the follow bar moves with it and that the follow bar is ﬂush with the saddle and the bending mark is aligned with the front edge of the saddle insert lip.

LEVEL

BENDING MARK

SADDLE

INSERT LIP

SADDLE

BAR

21. Ensure the pump valve lever is in the closed position and operate the pump until the bending shoe touches the conduit. The saddle and follow bar should be snug against the conduit and the follow bar should be touching the saddle as shown. The front of the saddle insert lip should be aligned with the bending mark on the conduit. Attach the level to the conduit.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

22. Operate the pump to start the bend.

WARNING

NEVER allow the carriage with vise to

contact the conduit support tubes of

the Mobile Bending Station.

23. Showing a 45° bend.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

24. Showing a 90° bend.

25. Once the desired degree of bend is complete, remove the level from the conduit.

WARNING

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

26. Rotate the pump valve lever to the open position and allow the hydraulic cylinder to retract and raise the bending shoe.

PUSH

27. Push the follow bar back towards the starting position so that it rests on the table of the Mobile Bending Station.

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

28. Remove the saddle from the bending shoe.

SADDLE

29. While keeping the conduit under control, release the vise chain.

VISE CHAIN

BENDER ASSEMBLY AND MOUNTING INSTRUCTIONS — continued

30. Keep conduit under control and remove the conduit from the bender set up.

LIFTING AND TRANSPORTING

LIFTING Before lifting, be sure all components and parts are secured on the 252 Mobile Bending Station. There are fork pockets provided on the 252 Mobile Bending Station. The maximum height using these fork pockets is 5 feet. DO NOT attempt to lift the 252 Mobile Bending Station by any other means, as there are no lifting points provided.

TRANSPORTING Before transporting by vehicle, be sure all components and parts are secured on the 252 Mobile Bending Station.

IMPORTANT

Refer to the Current Tools Model #254 Assembly, Operating

and Maintenance, Safety and Parts Manual for complete

bending instructions, charts, etc.

When using the #252 Mobile Bending Station with Greenlee®

#881 CamTrack

manufacturer’s operating and safety instructions before

attaching to or operating with the #252 Mobile Bending Station.

Failure to do so may result in serious injury or death.

Bender, read and understand the bender

* Greenlee® and CamTrack® are registered trademarks of Greenlee Tools, Inc..

EXPLODED VIEW — CARRIAGE WITH VISE

PARTS LIST – CARRIAGE WITH VISE

ITEM CATALOG DESCRIPTION QTY.

1 280-1A ROLLER 4 2 280-1B ROLLER – FLAT BENDING TABLE 2 3 280-2E SPACER 4 4 281-004 SCREW – FILLISTER HEAD SLOTTED

(5/16–18 × 2") 5 281-003 SCREW – SHOULDER SOCKET (1/2 × 3") 1 6 281-113 ROLLER – CHAIN 1 7 281-114 SPACER BUSHING 2 8 281-124 JAWS 1 9 281-1D SCREW – SHOULDER SOCKET (3/4 × 2.75) 6

10 281-1 11 281-220 FRAME – VISE UNIT 1 12 281-222 ACME STUD 1 13 412-11 WASHER – LOCK MEDIUM 5/16 ZINC 2 14 610-25 NUT – HEX NYLON INSERT (3/8–16) 1 15 8094-2A ROLL PIN 3/16 × 1.5 1 16 281-223 TIE DOWN ASSEMBLY 1 17 281-012 SCREW – SOCKET HEAD CAP (M6 × 20) 1 18 281-224 WRENCH CHAIN 1 19 281-013 NUT – HEX NYLON INSERT THIN (M6) 1

NUT – HEX NYLON INSERT THIN (5/8–11) 6

EXPLODED VIEW — BENDER MOUNTING UNIT

PARTS LIST – CARRIAGE WITH VISE

ITEM CATALOG DESCRIPTION QTY.

1 252-004 SCREW, HX HD CAP – 5/8"-11 × 1 1/2" 4 2 252-005 WASHER, LOCK – 5/8" 4 3 252-209 BAR, CONNECTING 2 4 252-211 END, FRAME – RH 1 5 252-212 END, FRAME – LH 1 6 33-22 SPRING, PAWL 2 7 33-485 PAWL 2 8 77-025 SCREW, HX HD CAP – 1/2"-13 × 1 1/4" 2 9 8099-3 RING, PULL 2

Current Tools 252 Assembly, Operating, Safety And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual