Current Tools 292 User manual

Model 292
Hydraulic Power Pump
CURRENT TOOLS • P. O. BOX 17026 GREENVILLE, SC 29606
800.230.5421 or 864-721-4230 • FAX [phone]
www.currenttools.com
Operating, Maintenance, Safety
and Parts Manual
09/2019
This manual is free of charge. All personnel who operate the Hydraulic Pump should have a copy of
this manual and read and understand its contents. To request a copy of this manual, call or write to the
address below or visit our website. 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 operating or
servicing the Hydraulic Pump. Failure to understand
how to safely operate and service this unit may result
in serious injury or death.

2
TABLE OF CONTENTS
Safety Alerts ..................................................................................... 3
Important Safety Information ......................................................... 4
Specifications.................................................................................... 5
Grounding Instructions.................................................................... 6
Operating Instructions..................................................................... 7
Electrical System Diagram .............................................................. 8
Maintenance ................................................................................9-11
Exploded View and Parts List ..................................................12-14
Troubleshooting ............................................................................. 15

Hazards or unsafe
p
ractices which, if not avoided, COULD result in serious
personal in
j
ur
y
or death
.
W
ARNIN
G
Hazards or unsafe
p
ractices which, if not avoided, COULD result in minor
personal in
j
ur
y
or propert
y
damage
.
CA
UTI
ON
Immediate hazards which, if not avoided, WILL result in serious
p
ersonal
in
j
ur
y
or death
.
DAN
G
E
R
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
Symbol
SAFETY ALERTS
3

ONLY use hoses and accessories that are rated for a minimum of 10,000 psi.
NEVER operate the pump in an explosive atmosphere.
NEVER operate the pump in wet or damp locations. DO NOT
expose to rain.
Hydraulic fluid under pressure can easily puncture skin causing
serious injury.
Read and understand the operating and safety manual for this
pump prior to use.
The pump has internal factory adjusted relief valves which must be repaired
or adjusted by a factory technician. DO NOT alter these settings. Doing so will
change the maximum pressure that the pump can develop which can cause
component failure and injury to personnel.
ALWAYS wear approved safety glasses when operating or servicing this
pump.
ALWAYS inspect the pump and all hoses, couplers and fittings before
operating. Replace any damaged, missing or worn components with Current
Tools parts.
ALWAYS check the hydraulic oil level in the reservoir prior to using the pump.
An insufficient oil level will result in damage to the pump.
The pump exceeds 50 lbs. and will require more than one person to lift and
transport.
Avoid damage to the hydraulic hose. DO NOT drop heavy objects onto the
hose or lift, move or carry any hydraulic equipment with the hose.
DO NOT operate or store hydraulic equipment near flames or high heat.
BEFORE adding hydraulic oil to the reservoir, fully retract the cylinder to return
all hydraulic oil in the system back to the reservoir. Check fluid level and add
as necessary. DO NOT overfill. An overfill can cause excessive pressure and
possible damage to the equipment as well as injury to personnel.
Check all hose connections prior to use and ensure they are properly
connected. Improper connections may not allow the hydraulic cylinder to
retract after the bend is complete.
To depressurize the hydraulic system, first, unplug the power cord. Then,
rotate the pump valve lever to the open position and allow the hydraulic
cylinder to fully retract. Slowly disconnect the hydraulic hose.
RETAIN SAFETY INFORMATION
4
4
IMPORTANT SAFETY INFORMATION
This manual should be read and understood by all personnel who operate or service
this Hydraulic Pump. Failure to understand how to safely operate and service this unit
could result in serious injury or death. This unit should only be operated and serviced
by qualified personnel.
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
IMPORTANT

SPECIFICATIONS – 77 SERIES ELECTRIC BENDER
The Current Tools Model #292 Hydraulic Power Pump is designed to be
used with single acting hydraulic cylinders rated for 10,000 P.S.I.
length 15 1/2"
width 11 1/2"
height 18"
weight 89 lbs. — empty
106 lbs. — with oil
Power Requirements: 120V AC, 60HZ, single phase, 20 amps
Motor Data: 1 1/2 HP
1725 RPM
Pump Output: Fast advance – 480 cubic inches per minute
at 150 P.S.I.
Full pressure – 56 cubic inches per minute
at 10,000 P.S.I.
Hydraulic Oil: Full capacity 9.5 quarts
Usable capacity 8 quarts
NOTE: ONLY fill with AW32 or equivalent hydraulic oil.
DO NOT use brake fluid.
ATTENTION: This pump is shipped from the factory with an
unvented fill plug to prevent leakage. Prior to use,
remove the unvented plug and install the vent
plug provided. Failure to install the vent plug will
result in poor performance.
5
SPECIFICATIONS

6
GROUNDING INSTRUCTIONS
In the event of a malfunction or breakdown, grounding provides a path of least
resistance for electric current to reduce the risk of electric shock. The hydraulic
pump is equipped with an electric cord having an equipment grounding conduc-
tor and a grounding plug. Only connect the pump to a 20 AMP GFCI protected
receptacle which is properly installed and grounded to meet all applicable elec-
trical codes. Do NOT use an adapter.
Do NOT modify the plug provided. If it will not fit the receptacle, have the
proper receptacle installed by a qualified electrician.
Improper connection of the equipment grounding conductor can result in risk
of electric shock. The conductor with insulation having an outer surface that is
green with or without yellow stripes is the equipment grounding conductor. If
repair or replacement of the electric cord or plug is necessary, do not connect
the equipment grounding conductor to a live terminal.
Check with a qualified electrician or service personnel if the grounding
instructions are not completely understood, or if in doubt as to whether
the hydraulic pump is properly grounded.
Use only 3-wire extension cords that have 3-prong grounding plugs and
3-pole receptacles that accept the pump’s plug.
Repair or replace damaged or worn cord immediately.
This pump is intended for use on a circuit that has a receptacle that looks
like the one illustrated in Figure 9a above. The pump has a grounding plug
that looks like the plug illustrated in Figure 9b above.
P
L
UG
RE
C
EPTA
C
L
E
ELECTRIC SHOCK HAZARD! Only connect the hydraulic pump to a 20 AMP GFCI
protected circuit. DO NOT modify the plug which is provided with the unit.
Failure to follow these warnings can result in serious injury or death.
WARNING
Figure 9a Figure 9b

7
OPERATING INSTRUCTIONS
Read and understand the operating and safety manual
for this pump prior to use.
NEVER operate the pump in an explosive atmosphere.
NEVER operate the pump in wet or damp locations.
DO NOT expose to rain.
Hydraulic fluid under pressure can easily puncture skin
causing serious injury.
ALWAYS wear approved safety glasses when operating or
servicing this pump.
ATTENTION: This pump is shipped from the factory with an unvented fill plug
to prevent leakage. Prior to use, remove the unvented fill plug and
install the vent plug provided. Failure to install the vent plug will
result in poor performance.
IMPORTANT: Starting the motor without the cylinder properly attached to
the pump will cause the pump to immediately build an internal
pressure of 10,000 P.S.I. To depressurize the hydraulic system,
first unplug the power cord then rotate the valve lever to the open
position and allow the hydraulic cylinder to fully retract. Slowly
disconnect the hydraulic hose.
1. Ensure the unvented fill plug that was used during shipping has been removed
and the vented fill plug provided has been installed.
2. Check the oil level in the reservoir. Add approved hydraulic oil if necessary.
(See “Adding Hydraulic Oil” section on page 10).
3. Rotate the pump valve lever to the open position.
4. Ensure that the hose and couplings are clean and free of debris prior to
assembly.
5. Attach the hydraulic hose to the coupling assembly on the hydraulic cylinder
and the coupling on the hydraulic pump. Hand tighten all connections firmly.
DO NOT use tools.
6. Plug the pump into the correct power supply.
To advance the hydraulic cylinder
1. Rotate the pump valve lever to the closed position.
2. Depress the jog switch on the pendant assembly.
To retract the hydraulic cylinder
Rotate the pump valve lever to the open position to release the pressure
Removing the hydraulic cylinder
Prior to removing the hydraulic cylinder that is connected to the pump, the system
must be depressurized.
1. Unplug the power cord.
2. Rotate the pump valve lever to the open position and allow the hydraulic
cylinder to fully retract.
3. Slowly disconnect the hydraulic hose.
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION
WARNING
DANGER
CAUTION

8
ELECTRICAL SYSTEM DIAGRAM
TO POWER INPUT
NEMA 5-20P
ROCKER SWITCH
GROUND LUG
OF MOTOR
TO PENDANT ASM
292-101
WIRE NUT WIRE NUT
MOTOR
120V AC, 60 HZ
Single phase, 20 AMPS

WARN
9
MAINTENANCE
Unplug the hydraulic pump prior to performing
any service on the pump.
WARNING
Prior to performing service on the pump, the system
must be depressurized. To depressurize, first unplug the
power cord. Then, rotate the pump valve lever to the
open position and allow the hydraulic cylinder to fully
retract. Slowly disconnect the hydraulic hose.
IMPORTANT
BEFORE EACH USE:
– Ensure the vented fill plug has been installed and is in place.
– Check the oil level in the reservoir. Add approved hydraulic oil if necessary. (See
“Adding Hydraulic Oil” section on page 10).
– Ensure that the hose and all couplings are clean, free of debris and not worn or
damaged. Replace if necessary.
– Ensure that all electrical cords, plugs, connectors, etc. are not worn or damaged.
Replace if necessary.
– Pay attention to unusual sounds or other changes in performance that may
indicate a need for maintenance or repairs.
REGULARLY
– Check the hydraulic oil in the reservoir for discoloration, changes in viscosity, dirt
or other contaminants. These conditions most likely indicate a need to replace
the oil. Failure to change the oil when needed can damage system components.
– Wipe down the exterior of the pump, motor and reservoir and vacuum all
ventilation openings.
– Ensure the vented fill plug in the reservoir is clean and not obstructed by debris.

WARN
10
MAINTENANCE — CONTINUED
ADDING HYDRAULIC OIL:
*Use only an AW32 or equivalent hydraulic oil. DO NOT use brake fluid.
1) Unplug the power cord.
2) Rotate the pump valve lever to the open position and allow all oil in the system
to flow into the reservoir.
3) Make sure the area around the vented fill plug is clean.
4) Remove the vented fill plug.
5) Using approved hydraulic oil as noted above, pour the oil through a clean
funnel with a filter screen into the reservoir.
6) Fill the reservoir until it is approximately 2" from the top of the reservoir.
7) Re-install the vented fill plug.
REMOVING AIR FROM THE SYSTEM (BLEEDING):
– Air trapped in the hydraulic system can cause inconsistent performance. Follow
the steps below to bleed the trapped air from the system.
NOTE: Make sure the vented fill plug is installed on the pump reservoir prior to
performing the bleeding process.
1) Remove the hydraulic cylinder from the bender frame.
2) Ensure the cylinder is properly connected to the hydraulic pump with a hose
rated for 10,000 p.s.i.
3) Secure the hydraulic cylinder in the vertical position with the hose coupler
facing up. The cylinder should be positioned lower than the pump if possible.
4) Rotate the pump valve lever to the closed position.
DO NOT start the pump motor without the cylinder properly attached
to the pump. DO NOT attempt to operate the pump to full pressure by
restricting the travel of the hydraulic cylinder (Dead Heading).
CAUTION
The hydraulic cylinder should not be advanced more
than 3/4 of its full stroke.
IMPORTANT

WARN
11
MAINTENANCE — CONTINUED
5) Operate the pump to advance the cylinder, stopping the pump once the cylinder
has traveled 3/4 of its full stroke. DO NOT overextend the cylinder.
6) Rotate the pump valve lever to the open position. This will force air in the
system to move through the pump reservoir and out of the vented fill plug.
7) Ensure proper oil lever. Add approved hydraulic oil if necessary. (See “Adding
Hydraulic Oil” section on page 10).
DRAINING AND FLUSHING:
NOTE: Ensure the pump exterior is clean prior to draining and flushing.
1) Drain the reservoir by removing the drain plug located at the bottom of the
reservoir. Once the oil has drained from the reservoir, reinstall the drain plug
and tighten.
2) Remove the pump motor from the reservoir.
3) Wipe the interior of the reservoir to clean.
4) Unscrew the filter screen from the bottom of the pump motor and clean.
Re-install after cleaning.
5) Re-install the pump motor onto the reservoir and tighten all screws.
6) Remove the vented fill plug and fill the reservoir with new hydraulic oil to within
2" of the top.
7) Next, you will need a hose with a coupler on one end and open on the other
end. Connect the coupler on the hose to the coupler on the pump.
8) Insert the open end of the hose into the reservoir fill hole.
9) Rotate the pump valve lever to the closed position and operate the pump for 1
to 2 minutes so that the clean oil circulates through the system.
10) Stop the pump and rotate the pump valve lever to the open position. Remove
the hose from the pump and reservoir fill hole.
11) Drain the reservoir as noted in Step #1.
12) Refill the reservoir according to the instructions in the “Adding Hydraulic Oil”
section on page 10.

WARN
12
EXPLODED VIEW AND PARTS LIST
ITEM # PART # DESCRIPTION QTY.
1 BP1007 RESERVOIR COVER PLATE 1
2 X-7443-1 RESERVOIR GASKET 1
3 X-7439 GASKET, MOTOR TO COVER 1
4 X-7445-1 RESERVOIR PLUG – VENT 1
5 X-7445 NYLON WASHER 1
6 X7931-MOD SINGLE SPEED RESERVOIR 1
7 2220555 BHCS 10-24 ×1.0 10
8 X-9505 KEY 3/16 SQ ×1 1/4 LG 1
9 BP1008 VALVE GASKET 1
10 2220600 SHCS 3/8–16 ×2 4
11 292-001 MOTOR – HYD. PUMP 1
12 X12-158 VALVE LEVER ASSEMBLY 1
13 BP1044 CONNECTOR 1
14 X-7878-10 BACK-UP RINGS 2
15 X-6477-57 O-RING .504 ×.364 ×.06 70D 2
16 292-103 BOX COVER ASSEMBLY 1
17 292-011 STRAIN RELIEF – PENDANT 1
18 292-012 STRAIN RELIEF – POWER CORD 1
19 747-39 WASHER, LOCK – #8 EXT. TOOTH 1
20 292-010 GASKET – BOX 1
21 2470172 PLUG – DRAIN 1
22 77-004A SCREW – HX FLANGE, 8–32 4
23 291-2A COUPLER – HYDRAULIC 1

WARN
13
EXPLODED VIEW AND PARTS LIST
ITEM # PART # DESCRIPTION QTY.
1 BP1013 HIGH PRESSURE PLATE GASKET 1 2 X-6862 THRUST BEARING 1 3 X-6863 BEARING RACE 2 4 BP1015-1 ECCENTRIC SHAFT 1 5 BP1018 BEARING IKO#BRI62416 1 6 BP1020-A BEARING RACE THICK (TWA 1018) 1 7 BP1020-C BEARING RACE THIN (TWC 1018) 1 8 BP1020 THRUST BEARING (TC 1018) 1 9 H-4360 WOODRUFF KEY 1
10 BP1021 SNAP RING 1 11 BP1047 TUBE FITTING (90 DEG) 1 12 BP1037 1/4–20×2" SHCS 6 13 BP-1036 LOW PRESS. PLATE (3 PISTON) 1 14 BP6063 GEROTOR ASSEMBLY 1 15 BP1038 GEROTOR HOUSING 1 16 2470339 PIPE PLUB 1/8 NPTF 3 17 BP1049 TUBE FITTING (STRAIGHT) 1 18 BP1048 TUBING 1
19 BP1040 HHCS 5/16–18 3 20 2350167 CONDUIT LOCKNUT 3/8 2 21 BP1055-A HIGH PRESSURE PLATE ASSEMBLY 1 22 BP1022-A PISTON BLOCK ASSEMBLY 3 23 BP1002 SHCS 3/8–16 ×1-3/4 4 24 X-9488 FILTER ADAPTER 1 25 X-8226 FILTER DISC 2 26 X-7454 FILTER ADAPTER PLATE 1 27 X-7382 FILTER SCREEN PLATE 1 28 X-7383 FILTER SCREEN 1
29 2220601 BHCS 10–24 ×3/4 3
1
21
23
22
3 2 3 4
5
10
6
8
7
16
13
12
11
9
16 16
17
18
14
15
19
24
20 26
25
27
28
25
29

WARN
14
EXPLODED VIEW AND PARTS LIST
ITEM # PART # DESCRIPTION QTY.
1 292-110 COVER – MOTOR 1
2 99-98 TRANSFORMER 1
3 99-99 SOLID STATE RELAY 1
4 292-006 SPACER 4
5 77-061 SCREW – PAN HEAD SLOT (6–32 ×3/8) 4
6 77-053 SCREW – PAN HEAD SLOT (8–32 ×3/8) 2
7 77-036A NUT – HEX ZINC (#6–32) 4
8 453-16A NUT – HEX ZINC (#8–32) 2
3
8
7
4
1
6
5
2
9
10
12
11 4
13
7
5
8
6
3
2
1
ITEM # PART # DESCRIPTION QTY.
1 292-004 PENDANT CORD – COILED 1
2 292-012 CORD GRIP 1
3 292-008 PLUG – HEX 3/4 NPT 1
4 292-009 ROCKER SWITCH 1
5 292-106 GASKET – LARGE PENDANT 1
6 292-107 PENDANT BODY – 3/4" LB 1
7 292-109 PENDANT COVER 1
8 451-21 NUT – HEX ZINC (#10–32) 1
9 451-22 10–32 X .37 SCREW, MACH. SLOTTED 1
10 747-19 MAGNET 1
11 747-39 WASHER, LOCK – #8 EXT. TOOTH 1
12 77-065 FISH PAPER – INSULATING 1
13 77-072 SCREW – ROUND HEAD PHILLIPS
(8–32 ×1/2") 2
14 77-3B QUICK DISCONNECT 2
15 77-3D TERMINAL – RING 1

WARN
15
TROUBLESHOOTING
ALWAYS disconnect power supply before removing any guards or covers and
before servicing this pump. Failure to do so many result in serious injury or death.
WARNING
Problem Cause Cure
Motor does not start or
motor stops under load
No power being supplied to
motor
Check voltage at power
supply
Voltage supplied to motor is
too low
Check voltage at power
supply
Improper extension cord
used
Replace extension cord with
a properly rated extension
cord
Damage to pendant,
transformer or relay
Inspect and replace as
necessary
Cylinder will
not advance or
advances slowly
Reservoir fill plug is blocked
or incorrect
Remove the unvented fill
plug and replace with vented
fill plug or clean the vented
fill plug
Insufficient oil level Add oil according to the
“adding approved hydraulic
oil’ section in this manual
Improper oil used or oil is
dirty
Replace oil with an approved
type as listed in the “adding
approved hydraulic oil’
section this manual
Pump valve lever is not fully
in the closed position
Rotate the pump valve lever
to the fully closed position
Pump filter screen is clogged Clean the filter screen
according to the “draining
and flushing” section in this
manual
Hydraulic couplers are not
properly engaged
Check all couplers and
ensure they are fully seated
and secure
Hydraulic oil leak – external Replace hose or couplers
Hydraulic oil leak – internal Return to factory for repair
External relief valve set too
low
Tighten relief valve as
needed
Erratic cylinder movement Air trapped in the hydraulic
system
Bleed air from the system
according to the “removing
air from the system” section
in this manual