Bennet-Naw mani, Inc. TC aa Rebar Cutter Instruction & Parts Breakdown DC SERIES PORTABLE REBAR CUTTERS DC-16LZ, DCC-1618, DC-16W, DC-20WH, DC-25X, DC-32WH BN Products USA, LLC 13450 Sabin Brown Road Wickenburg, AZ 86380 (800) €92-9833 Fax: (928) 664.7081 rmall@bnproducts.com wuwbnrebsrtocls.com Cotte IstractionsFEB_2011 Full SizeIMPORTANT: READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO USE YOUR TOOL! Not knowing the proper operating procedures can lead to accidents. If you have any questions about any procedures, contact the nearest au- thorized distributor/agent or call Benner-Nawman, Inc.(800) 992-3833 or 928-684-2813. CONTENTS General Safety Precautions Bleeding Instructions Operation Instructions Pre-use Checks Parts and Specifications ‘Warm-up Stopper Adjustment Cutting Points of Attention ‘Maintenance of Cutter Blocks Cleaning Oil-level Check Oil Change Bolt tightness Carbon Brushes General Safety Rules Power Tool Care DCC-1618 DC-16LZ, DC-16W DC-20WH 10 CEVADUVAAHR ERE w OY DC-25X DC-32WH 12 CUSTOMER SERVICE TOLL -FREE NUMBER: (800) 992-3833 WICKENBURG, ARIZIONA: (928) 684-2813GENERAL SAFETY PRECAUTIONS Use rebar cutters on maximum Grade 60 steel reinforcing barsonly. These tools are not to be used in cutting other kinds of metal or materials. Do not cut ungeaded rebar IMPORTANT: Do not attempt to cut rebar by locking the oft/on switch to the on position. ‘This locking procedure is to be used only to ‘warm the tool in cold climates or used with our hands free electrical box and foot operated switch. This is a safety is- sue and may cause damage to your rebar cutter. Alveays pull the on/off switch by hand for each individual cut. foot op- erated switch and special electrical box are available if you want to use these cut- tersas production tools. Contact your lo- cal distributor of Benner-Nawman, RESTRICT USE TO DESIGNATED MATERIALS ‘There is always a chance that the cut end may shoot out, especially if less than Senn (1 foot) in length. Exceeding dex ignated material specifications greatly in- creases this risk and will aso damage the tool. Do not attempt to cut rebars harder, thicker or thinner than specified. USE EYE PROTECTION Wear safety goggles, safety glasses with side shields or a face shield when using cutter. PROVIDE SAFETY BARRIERS Erect safety screens to protect coworkers, from possible flying ends. Place a safety sercen under the rebar when working in high places. EXERCISE PROPER CONTROL, Hold cutter firmly and maintain proper footing and balance. Do not overreach When working in a high place, secure cutter to scaffolding with a safety rope. Check that power cord is not fouled and. keep cord away from sharp edges and heat. Check that all adjusting wrenches have been removed before using cutter. GUARD AGAINST ELECTRIC SHOCK ‘Toavoid possible shock, do not handle catter with wet hands or use cutter in the rain or damp places. Be aveare of all powerlines, electric circuits and other hazards that may be contacted, espe- cially those that are below the surface or otherwise hidden from view. Never attempt to pick the tool up by use of the electric cord UNPLUG TOOL Disconnect cutter from outlet when not in use and before cleaning, adjusting or servicing. Do not disconnect plug from outlet by pulling the cord. Always check: that the switch lock is OFF before plug, singin. DONOT CUT UNGRADED REBAR MAINTAIN CUTTER WITH CARE Inspect cutter before each application. Faulty or loose cutter blocks could result is personal injury. Keep handle dry, clean and free from oil and/or grease. Keep housing and piston free of diet and iron filings. Check that no screws or bolts are loose or missing, Follow instructions for maintenance. Inspect switch, cord, plug, and any extension cable at regular inter vals. It is a good idea to inspect the hous- ing for any cracks before operating DO NOT EXCEED MAXIMUM CUTTING PRESSURE BY ADD- ING TO OR MODIFYING THE HYDRAULIC PUMP. BLEEDING YOUR PORTABLE REBAR CUTTER You may have to bleed the hydraulics on your cutter ifthe tool runs unusually slow or doesn't have the pressure to cut nor mally. Do not run tool with low or no oil. For best results please follow these direc- tions: 1 If piston is still moving, run the tool for 2 minutes to warm the oil inside. If the piston is not moving, add oil before warming up for 2 minutes. 2, When the oil is warm, run the piston, ‘out just before it returns and stop. 3. Remove the oil plug and top it off with oil 4, Make a scal with your thumb over the oil plug opening. 5. Run the tool so that it makes a com- plete cycle. 6, When the piston is completely retract- cd in the open position, gently roll your ‘thumb to let the unwanted air escape. 7, Repeat step #5 and #6 at least three times: {8 Add oil only when the piston is at least halfway out 9. Ifyou have to add additional oil, repeat #5.and #6, 10, Replace the oil plug and tighten it. 1. Make three or four cuts with rebar. ‘The machine should now be working properly. Make sure that you observe ex- actly at what point the rebar is actually breaking, 12, Pinch a piece of rebar stopping just before it actually breaks. 13, Remove the oil plug again and top off the reserve one more time. 14, Replace the oil plug and tighten 15, The operation is now complete. ‘We recommend the following 20-wieght Non-Detergent Hydraulic Oils for use ‘with our tools (anti-foam anti-abrasion): Tellus 68 (Shell), Rando HD 68 (Texaco) ‘or Chevron AW 68 (Chevron). Hydraulic oil can also be ordered in quart contain- cers from your Diamond Tool Distributor. OPERATING INSTRUCTIONS CAUTION: Indicates hazard that could result in minor personal in- jury and/or product damage. CARE: Indicates hazard that will result in product damage.PRE-USE CHECKS 1. Check oil level. (See Maintenance) 2. Check condition of cutter blocks and tightness of cutter block bolts. (See Maintenance) - CHECK FOR CRACKS IN HOUSING CAUTION: Using loose or cracked cutter blocks may result in injury 10 operator as well as damage to the tool. 3. Check that the power source is appro- priate to the eutter, CARE: If voltage is too high, the motor will burn out. If voltage is too low, insufficient power will be generated. Never use DC current. 4. Check that power supply is properly grounded, CAUTION: Failure to. ground power supply may result inelectric shock to operator (DC-16LZ, DC-I6W and DC-32WH have double-insulated motors and do not require grounding.) 5. Check that cord isundamaged and that plug is not loose. CAUTION: Cut or abraded cover- ing could result in a short and Electric shock to operator. 6. If an extensions cable is to be used, ‘make sure that it is undamaged and that itis the proper wire gauge thickness for the length. See table below. engi otis S060 He Cable Size (AWG) Upto Term 0) 14 Upto 30mm (100) 2 Upto 45mm (1508) 0 7, Before plugging in the tool, make sure that the switch lock is OFF CAUTION: If switch lock is ON, cutter will start as soon as it is plugged in. To disengage lock, pull trigger-switeh and press lock-but- ton, which will pop out. WARM-UP In cold weather you should warm up the tool unit for 30-60 seconds so that the hydraulic oil reaches the proper viscosity Pall trigger-switch to extend piston and release when it has reached its fll stroke. Repeat 15-20 times. STOPPER BOLT. ADJUSTMENT THE STOPPER BOLT IS PROB- ABLY THE MOST IMPORTANT. PART OF YOUR PORTABLE CUTTER... ‘Theadjustable stopper functions to main: tain the rebar in the correct position duu- ing cutting and must be properly set for each size of rebar before use 1, Screw in stopper to provide sufficient clearance for rebar, 2. Insert rebar fully into U-shaped sup- port. Make sure that rebar is resting on the base of the support: 3. Keeping rebar at right angles (90 de- grees) to front cutter block, screw out stopper until it is just touching the rebar. Once set, the stopper needs no farther adjustment while cutting rebar of the same diameter, but must be reset for a different size rebar. CAUTION: Failure to correctly set the stopper bolt will result in ex- cessive wear of cutter blocks and ‘may cause cut end to fly out. This will also lead to piston and cylinder damage. CUTTING 1 Insert rebar between stopper and front cutter block, making sure that it is prop- erly seated in U-shaped support. 2. Pull trigger-switch and keep depressed. while piston advances and rebar is cut. (f switch is released at an intermediate point, piston will stop.) 3. When cut is completed, release switch. Piston retracts automatically (Note that switch cannot be reactivated until piston hha fully retracted.) POINTS OF ATTENTION 1, Be especially careful when cutting off short lengths (30cm/12" or less) as the ceut end tends to fly out. CAUTION: Flying ends are a haz- ard to all personuel in the vicinity. Erect safety sereens. 2. Do not cover air vents or operate the tool on dirt — use a plywood base under the rebar cutter to keep armature and fan lean, CARE: Ifthe vents are covered, the motor will overheat and may burn out. 3. If hydraulic oil execeds 70 degrees C (158 degrees F) in temperature, power will drop. Allow unit to cool before re- suming operation. (Be particularly care- ful in summer, when the aluminum pump cease heats up quicker) 4. Ifa drop in power is observed and mo- toris unusually hot, check carbon-beush- es, (See maintenance) 5. Ifpiston should ever fal to retract com- pletely, push rear cutter block backwards to manually retract piston or check under piston to remove and debris keeping the piston from retracting, CAUTION: Use a rebar or flat metal bar for this purpose. Never push cutter block with any part of the hand, even if gloved. NOTE: Rebar cutters manufactured in after 2007 have a safety release valve for retracting the piston ifit doesn't return to the start position. This is usually caused by cutting improperly seated rebar that becomes jammed between the cutting Blocks. On these newer models simply ro- tate the Allen set serew a quarter turn to retract the piston. On the DC-20WH, see parts breakdown part #64 for location of this release valve Once piston has been retracted, pull trigger-switch long enough to. partially advance piston. Unplug unit. Check pis- ton and housing for accumulated dirt and iron filings that may be jamming the pis ton. (See Maintenance) If, after cleaning, piston still docs not automatically retract ‘when fully extended, the piston itself may be damaged. Return the unit to an autho- rized repair center or Bennet-Nawman for repair.MAINTENANCE ON CUTTER BLOCKS Before using, always check that the two bolts on each cutter block are properly tightened. Using a loose block will result in damage to block and housing. Also check condition of cutter blocks. If either cutting edge is dull or chipped, remove retaining belts and rotate both blocks so that two new edges come into use. Re- place and tighten bolts. (Each block has four cutting edges.) When all four eutin tcges have been used orf either block = cracked or otherwise damaged, replace both blocks CAUTION: A loose or cracked block may result in injury to op- erator. CLEANING Clean your tool every day, preferably im mediately after use. CAUTION: Wear gloves to protect hands from metal splinters. Do not use an air gun: blasting with air can cause metal filings and/or dust to get into eyes and respiratory system. Disconnect the unit. Wipe or brush away all dirt and metal filings. Pay particular attention to the lower half of the piston, where dirt is more easily accumulated. NEVER USE YOUR CUTTER TO CUT REBAR IN WET CONCRETE. OIL-LEVEL CHECK As the cutters are hydraulically operated the oil-level must be checked at frequent intervals, preferably every day. Failure to ‘maintain the oil at the proper level results, ina drop in pressure and loss of cutting power, CAUTION: Hydraulic oil is high- ly flammable. Keep away from sparks and naked flame. Do wot smoke. CAUTION: Hydraulic oil may cause inflammation of the eyes and skint. If ingested, it will cause diarrhea and vomiting. In case of eye contact, rinse in clean water forat least 15 minutes and consult ‘aphysician. In case of skin contact, wash thoroughly with soap and water: In case of ingestion, consult a physician immediately. Do not induce vomiting. 1. Oil should be warm but not hot. Warm up unit if cold. 2. Adjust stopper and make three or four cuts, noting exactly at what point the re- bar is actually breaking. 3. Pinch a short piece of rebar, stopping just before it breaks off. Unplug unit from power source, 4, With partially severed rebar in place, oil-plug should be straight up. (If unit is, hot, allow cooling down.) 5, Remove oil-plug and seal-washer (packing). CAUTION: Never remove oil-plug when unit is hot or oil will spurt out. 6. Check that oil is level with bottom of plug hole (i. that pump case if full to the brim). Ifoil levelistoolow, top up with 20-weight hhydranlic oil with anti-foam and anti- abrasion properties (ISO viscosity grade VGd6, eg. Shell oil Tellus 68, Mobil oil DTE-25 or Esso Uni power SQ46). 7. After topping off, extract air from sys- tem. Gently tilt cutter lengthwise and re- turn it to a level position. Top off again and tilt in the opposite direction. Repeat this process until all air has been extract- ed. CARE: Cutter cannot function property if oil contains air bub- bles. 8, Replace scal washer (packing) and oil plug. Connect cutter to power source and completely sever rebar. OIL-CHANGE The hydraulic oil should be changed. at least once a yeat, sooner if it appears dirty NOTE: Hydraulic oil should be warm before draining 1. Unplug unit from power source. Re: move oil-plug and packing. Turn cutter ‘over and drain oil into a suitable recepta- cle. When oil ceases to drain out, tilt unit to rear so that oil trapped in the piston housing can run out. When housing is ‘empty, tlt unit in the opposite direction, to empty the residue in the pump case. 2. With drain-hole uppermost, slowly fill the unit with fresh oil. Replace plug and. lightly tighten. Connect unit to power source and advance piston two or three es. Unplug unit and remove oil-plug. ‘Top off il-level and replace plug 3, Finally, follow procedure for oil-level check. (Steps 2-8) NOTE: Dispose of hydraulic oil in accordance with local regulations. Do not pour into the sea, a river, a lake or drains. BOLT TIGHTNESS ‘Once a week, or after every 500 cuts, check the tightness of all bolts; especially those bolts securing the housing to the cylinder. Loose bolts will result in a loss ‘of power. Make sure that the bolts hold- ing both cutter blocks are also tight CARBON BRUSHES Inspect the two carbon brushes at least ‘once every two months. (Nominal brush life is 200 hours) CARE: Worn brushes will result in power loss, cause the motor to run hot and inreparably damage the armature. 1. Disconnect unit 2. Unscrew both brush caps and pull out carbon brushes. 3. Replace brushes if less than 6mm ‘or1/4" in length.OVERHAUL Return the unit to an authorized agent for overhaul atleast once every two years, sooner if subjected to heavy use. Call (800) 992-3833, GENERAL SAFETY RULES WARNING: Read all instructions. Fail- ture to follow all instructions listed below may result in electric shock, fire and/or serious injury. ‘The term “power tool in all of the warnings listed below refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool SAVE THESE INSTRUCTIONS WORK AREA SAFETY Keep work area clean and well lit. Clut- tered or dark areas invite accidents, Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools ereate sparks which may ignite the dust or fumes. Keep children and bystanders away while ‘operating a power tool. Distractions can cause you to lose control ELECTRICAL SAFETY Power tool plugs must match the outlet Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. Avoid body contact with earthed or grounded surfaces such as pipes, radia- tors, ranges and refrigerators. ‘There is in increased risk of electric shock if your body is earthed or grounded. Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. When operating a power tool outdoors, use an extension cord suitable to outdoor use, Use a cord suitable for outdoor use reduces the risk of electrie shock. PERSONAL SAFETY Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influ- ence of drugs, aleohol or medication. A moment of inattention while operating power tools may result in serious per- sonal injury. Use safety equipment. Always wear eye protection, Safety equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for ap- propriate conditions will reduce personal injuries, Avoid accidental starting. Ensure the switch is in the off-position before plug «ging in, Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites ac- cidents. Remove any adjusting key or wrench be- fore turning the power tool on. A-wrench ora key let attached to a rotating part of the power tool may result in personal in jury. Do not overreach. Keep proper footin, and balance at all times This enables better control of the power tool in unex- ons.Dress properly. Do not clothing or jewelry. Keep your Init clothing and gloves away from mov ing parts. Loose clothes, jewelry or long. hair can be caught in moving parts If devices are provided for the connec tion of dust extraction and collection fa- cilities, ensure these are connected and properly used. Use of these devices can reduce dust-related hazards. POWER TOOL USE AND CARE Do not force the power tool. Use the cor rect power tool for your application. ‘The correct power tool will do the job better and safer at the rate for which it was de- signed Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be re paired Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjust- ments, changing accessories, oF storing power tools. Such preventative safety measures reduce the risk of starting the power tool accidentally. Store idle power tools out of the reach of children and do not allow persons un- familiar with the power tools or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users Maintain power tools. Check for mis- alignment or binding or moving parts, breakage of parts and any other condition that may affect the power tools operation. If damaged, have the power tool repaired before use. ‘Many accidents are caused by poorly maintained power tools. Keep cutting tools sharp and clean. Prop- erly maintained cutting tools with sharp ccutting edges are less likely to bind and. are easier to control Use the power tool, accessories and tool bits ete., in accordance with these in- structions and in the manner intended, for the particular type of power tool, tak- ing into account the working conditions and the work to be performed. Use ofthe power tool for operations different from. those intended could result in a hazard- ‘ous situation, SERVICE Have your power tool serviced by a quali- fied repair person using only identical re~ placement parts. 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[= wasner wo BS] 11027007 [oyinser Gea] 75505008 — [Cop bot 56 @ | 7505020 [Cap bot v2 35162510 [Ram 5] Tav2a54 —[oearng ouen me SE ir] 161320 | Ram rata epg 165 7200367 —[oruen rraer Bf rcx258 ——[arrbog e_]1cra7e1 [denen vane G7] 1026128 | Coroon brush B | tcssrsa0t [area nt 38) 161991 | Deven vawve sina Sa] 7510510 [ors cop 50,[ 162171601 | Rous cap So] sc19952 [Spang use 9 | 7901060 [rence 54] 73706035 —[ spre pin | 113262 | Pump nena waa Ta] Tosr067 —[rensie 5 sa 102028 —[ Seton | aP10aa [ogre iter | 7980082 — [Suppor 53 | 7or1170080 | BencaTT) RD 45] 162509 [621 earn 505 Saf wcres1 [Suen Sy EE Ba] ic2525 [Bearing guae sa Testa | Conaeneer 55] 72008035 —| cap bor MOGs 5] 102531 | Neede bearing Ga [ro 160.00 [rence sy S| RE-sVFH | Cuter iocks @e] 102525 —[searng gue | ices [cers armar S| icisi10 — | Capron wonao Br 1c2506 ——[ snap rng roe 7a | 7520510 — [Distance piece S| 162171700 | Hanate spacer Bar] 1ca65n00 [Pump case pacing | 72505095 — [op vot M535 49| 72506025 —| Cap bor wer2e aap 161001001 [Pump case Tar] 7606025 [Flange sooket WOE Bo] 7CHi003 —[ Capon wi 30] 161905 | Seat washer WFD Fa avooow [cov set Be] 1cs093500 | cyincer pacrng Bx] 1c1008 [cap nor 0-15 Wor] 7956696 | Tapping screw D7 Ba] 164177900 | Rew spring a1] 76170005 | Teetnos warner NE fax] 102956007 [Tune Ba] 7ov0ss7KO[seatpaciing Ueeasses | [a] Toa060ss [cap von Mons, ia] 7e000s —[P rasher ne Ba] cise [capror vaso Ba] 102512 [or seat 5020-356 Ba] 750005 —[s-wasner ns | 162056500 [Piston a | 1cr0s1 [par pearng soosvy 194 | 7aw0008 | Tesined washers Ba] 164150000 | Piston ay 35] 1517835 [Fan cover Bey 7310005 [= wasner we Bp) 7FUWTELO | seaipaangosTonse | [Ee| renner [Ames a Ba] 162532 [Wave ena sng Bel] 1025121 [801 beonng BO02RT=~ USA, LEC) Reon moor ee ee HOMIES o MADCON o MIMOSA DBD-20X MINI REBAR BENDER Tool Manual DBD-Series 0-180 degree Rebar Benders BN Products-USA, LLC. 3450 Sabin Brown Road Wickenburg, AZ 85390 (800) 992-3833 + (928) 684-2813 FAX: (928) 684-7041 mail@bnproducts.com + www.bnrebartools.com DAD-20% Render Manual | Page 13450 Sabin Brown Road » Wickenburg. Arizona 85390) (ODORS 0 GANIC AED o MITTEE NOTE: When using electric tools, basic safety precautions should always be followed to reduce the risk of electric shock and personal injury, including the followings items: READ ALL INSTRUCTIONS AND SAVE THEM FOR FURTURE REFERENCE Keep hands away. From all moving parts and rollers while operating Dress properly. Loose clothing or jewelry can get caught in moving parts. Wear sturdy boots with non-skid soles. Stee! toed boots and safety glasses are recommended. Keep children and bystanders away. Distractions can cause you to lose control Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. Stay alert. Watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs or alcohol. A moment of inat- tention while operating power tools may result in serious personal injury. Do not exceed the maximum number of bars that can be bent at one time. Please refer to specifica tions on page 3-4. When positioning the bar between rollers, make sure to lay it flat on the machine surface. Failure to do so may cause the rebar to fly out. Do not expose tool to rain or use in damp locations... Do not use tool in presence of flammable liq- uids or gases. Keep work area well lit, Ifthe tool is used outdoors, keep it covered when not in use and protect it from rain or water Do not try to bend materials harder than “Grade 60 or 600N/mm2" as they will ether crack and fly out or cause machine failure. Disconnect tool from receptacle when not in use. Disconnect when servicing or changing rollers to prevent accidents. Keep tool clean at all times for best and safest performance. Follow instructions for lubricating and changing parts. Keep hands dry and free of oil or grease. Inspect switches, tool cords periodically and have them repaired or replaced by an authorized service center if damaged. Check moving parts for alignment and binding as well as for breakage and improper mounting. Damaged parts should be repaired or replaced by an authorized service facility unless otherwise indicated in this instruction book, READ ALL INSTRUCTIONS AND SAVE THEM FOR FUTURE REFERENCE ‘DAD-20% Render Manual | Page2=~ USA, LEC) Reon moor ee ee HOC o MADINA o MNOS DBD-20X Mini Rebar Bender Moving bending roller Center roller Adjustable stopper Main switch Pilot lamp Operation button On/Off Angle setter (dial type) Angle stopper (two) Emergency stop button 10. Plug-in for foot switch 11. Roller set 12, Foot Operated Switch SPECIFICATIONS Model DBD-20X Max. Bending Capacity 3/4” (#6) (19 mm) Grade 60 Rebar Bending Angle 0-180" Bending Speed 7 seconds for 180° bend Electric Power Supply. 115 Volts, 50/60Hz, 15 amps, 1725 watts Dimensions L x Wx H 16.4" x 18" x 16.2” (mm) (420) x (462) x (415) ‘Weight (Kg) 134 Ibs. (61) DBD-20X Rebar Bender Roller Selection Chart Rebar Diameter Size [Center Roller Moving Roller [_# of Grade 60 Rebar Bent #6 (3/4") (19mm) _[ #4 (3.71" diameter) | #2 (2.65" diameter) 1 piece at one time #5 (5/8") (lomm) | #4(3,71" diameter) | #3 (2.93 diameter) [2 pieces at one time #4(1/2") (3mm) _| #3 (2.93" diameter) | #5 (3.90" diameter) 3 pieces at one time #3 °(3/8") (10mm) | #1 (2.22” diameter) | #6(4.80" diameter) [ 4 pieces at one time ‘DAD-20% Render Manual | Page3BN Products - USA, LLC 3450 Sabin Brown Road » Wickenburg. Arizona 85390) (ODORS 0 GANIC AED o MITTEE WARNING: ALWAYS UNPLUG THIS TOOL BEFORE ATTACHING OR REMOVING ROLLERS OR ACCESSORIES. Select and set the correct rollers for the bars to be bent. See the table. Plug the electrical power cord into an appropriate outlet. Lay the bar on the machine surface between the center roller and bending roller. Adjust the stop- per so that the bar is parallel to the front edge of the machine, Turn the main switch on and check that the pilot lamp has lit up. Set the angle and make a test bend. Ifthe bent angle is not exact, adjust the angle setter slightly to the right or left. Lock in the angle stoppers to duplicate the same angle each time. Push the operation button or foot switch. The moving bending roller will automatically return to the start position once the bend has been completed. If itis necessary to stop the machine in an emergency, push the emergency stop button or release ‘your foot from the foot operated switch. ‘The bending roller will return to the start position auto- ‘matically BENDING ANGLES CAN BE PRESET Set the angle setter to 135° then tighten the right angle stopper to lock the 135° position. Set the angle setter to 90° then tighten the left angle stopper to lock the 90° position. Set the angle setter to 135°. Push the operation button to make your first bend. Slide the rebar to the desired length and set the angle setter to 90°. Push the operation button to complete your second bend. For stirrups, cut your rebar to the desired length before bending, Then make both bends for your turn- downs. Finally make your (3) 90° bends to connect your ends together. See below. WARNING: Never touch any moving parts or rollers while the rebar bender is being operated. oo oh CL. ‘D ‘DAD-20% Render Manual | Page 43450 Sabin Brown Road » Wickenburg. Arizona 85390) (ODORS 0 GANIC AED o MITTEE INSPECTION AND MAINTENANCE WARNING: ALWAYS UNPLUG TOOL BEFORE PERFORMING MAINTENANCE. DO NOT USE PARTS OR ACCESSORIES THAT ARE NOT GENUINE DIAMOND BRAND from BN Products-USA At least once a month remove the bottom plate and grease all the visible gears and pinions. At the ‘same time, check the carbon brushes for wear or damage. Replace with new brushes if they are ‘worn out. 1C1961A Carbon Brush ‘Wear Limit --»Replace Carbon Brushes fe 6mm (") —> 17mm (21/32”) total length Check that there are no loose nuts and bolts before starting the operation. After operation is completed, be sure to remove metal dust, dirt, ol, etc... adhering to the ma- chine surface. In order to empty the metal dust from the bender, (remove side cover DBD-25X and DBD-32X models) then tilt the machine to one side allowing the debris to fall out of the catch pan. Be sure to blow out any remaining dirt and dust with compressed air prior to using the tool again (wear safety goggles to block blowing debris). ‘Wiring Diagram ‘DAD-20% Render Manual | Pagesbd %e Taco3450 Sabin Brown Road » Wickenburg. Arizona 85390) (ODORS 0 GANIC AED o MITTEE art Name PartNo, Part Name TL S4010900 SWIVEL SHAF 7cBI2020 ‘CAP BOLT MI2X20 15301300 MAIN SHAFT 115402000 WASHER, TALS100100 FRAME, 762052. BALL BEARING THLS<01400 "ANGLE GEAR (i) TL SG01800 KEY@ 7H. 03025, TAPPING SCREW M2.3X25 TCROSOIS, ‘CAP BOLT MSXIS, 75RS30 SNAP RIN e207 BALL BEARING LIMIT SWI 7SRH2 (AP RING SPRING WASHER M23 TBIS402300 IAP COLLAR NUT MDS TBLS102400 BASE PLATE. 1BL5401700 ‘MAIN SHAFT SUPPORT 1BL5402703 "ADJUSTABLE STOPPER TLS403100 ‘OVER/ LINE LS STAY TBRSO64 ‘ADJUSTABLE NUT 7SS5G12 LIMIT SWI TBRSO6S, ADJUSTABLE HANDLE 7504005 SETSCREW MAXS, TSPSI0 ‘SPRING PIN TL9401300 "ANGLE GEAR (A) 7oBIO020 (CAP BOLT MIOX20 TL9303802| ANGLESTAND, TLSA03502 ROLLER NO. 1 7SRSI2 SNAP RING TBLSH03702 ROLLERNO.3 1319403900 FAR, T5403802 ROLLER NOM 1819404200 "ANGLE SHAFT 1TLS403600 ROLLER NO.2 75P420 SPRING PIN 1815403902 ROLLERNO.5 TBLOAOD6OT KEY) 1BL5404000 ROLLERNO.6 1HHL.9403900 PALSTICGEAR 15402000 WASHER, 75PA20 SPRING PIN 7812020 BOLT MI2X20 THHL9405900 "ANGLE SPRING Te207HL BALL BEARING TBL5403001 "ANGLE SHAFT THSLO7 NEEDLE BEARING, 1BL9408100 "ANGLE COLLAR, TBLSA04400 [STOPPER STAY. 1BL5404200 ANGLEPLATE, 1BL5404300 ‘ARM STOPPER 73804005 SET SCREW MANS 7CBO5020 ‘CAP BOLT MSX20 THWOOOS ‘WAVE WASHER MS TBI5100300 (GEAR CASE 70008 NUT MS. 1315301300 PINION) 7CwOSURO CAP BOLT MBX20 1BLSA01401 KEY @) TEQI2ORS BALL BEARING 760002. BALL BEARING 1mHL5502101 RETURN SPRING, 115401202 GEAR (3) 15101500 SWIVEL GEAR 7SRS3O SNAP RING 76810035 P BOLT MIOX35 72007 BALL BEARING 75W0010 SPRING WASHER, TCRIOLIO (CAP BOLT MIOXI10 7Pwo010) PLATE WASHER Tawo10 "TEETHED WASHER 7CBOSOIO ‘CAP BOLT MSXI0 TCBORDSS ‘CAP BOLT MBX, 7SWO005 SPRING WASHER MS Tawoo8 TEETHED WASHER TPWOO0S PLATE WASHER MS THLS100000 “GEAR CASE (A) 15403200 ISO TWO V RING 10S 1 5402200 762037 BALL BEARING ‘DAD-20% Render Manual3450 Sabin Brown Road » Wickenburg. Arizona 85390) (ODORS 0 GANIC AED o MITTEE Part Name PartNo, Part Name TRLS101002 [PINION @) 7NSOSDIS | TAPPING SCREW S45 TaLsionior [KEY @) 1815302000 _ | BOTTOM PLATE Tatsin0902 [GEAR @) B06? BOLT M6xi2 SRR SNAP RING 525 7swo006 SPRING WASHER Mie e203 BALL BEARING 62032 1815203301 [ CONTROL PANEL. 76002 BALL BEARING 60022 TAys1018 MAIN SWITCH THLS100802 [PINION @) TNBIOGPWE | PILOT LAMP TaLowo1so1 | KEY (#) TACTO3FBO3 | SOCKET FOR FOOT SWITCH 700 BALL BEARING 60017 THLSI00700__[ CLUTCH COLLAR 7305015, BUTTON SCREW MSX15, SRS? SNAP RING H37_ 119404501 | ANGI R Tess TALL BEARING OID TBNISMOIR | EMERGENCY BOTTON, TBNISEIO | OPERATION SWITCH 7ESO5010 SCREW MSX10 1RLS30800 [HANDLE 7CBORDIS, CAP BOLT MAXIS TADLANORAD, UTCH GEAR, TADLANII62 _[ CLUTCH TEUORSC, UNUT 7805080 CAP BOLT MSX80 TNOOOS NUTMS TaLs402801 [BRUSH COVER 7TSOBOI2 SCREW MBXIZ 7GTBAT RELAY 7RO904 RELAY CLAMP 7PRIOADIS rAISIOZ | NEEDLE BEARING 7SRS20 SNAP RING 520 TpLst00402 [GEAR (I) TRLSANNSOL_[ PINTON () ipiswono1 | KEYG) 6WOGLL BALL BEARING 600622 7sMa7Ro245 | MOTOR 76Q02VV BALL BEARING 6202VV TORMOSODES 7PROADIS ‘DAD-20% Render Manual | Page 8