Rapidtool Industrial Rebar Benders and Cutters User Guide

Rapidtool Industrial Rebar Benders and Cutters

WARNING: READ ALL SAFETY WARNINGS,

• INSTRUCTIONS, ILLUSTRATIONS AND SPECIFICATIONS ARE PROVIDED WITH THIS POWER TOOL.
• Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
• Save all warnings and instructions for future reference.
• Machine is not rated and should not be used for commercial rebar production purposes.
• Do not operate the bender and cutter at the same time.
• FOR INDUSTRIAL USE ONLY.

Rebar Bender Models

Safety

This machine is a high performance, industrial machine. Failure to follow safety instructions may result in serious injury or death.

1. Take note of all warning signs on the machine.

2. Keep work area clean and free from obstruction.

3. Mount the machine on an even surface capable of carrying the weight of the machine. The machine must be mounted so supply disconnecting device, actuators, and emergency stop button is at least 600mm above the servicing level. The machine should not vibrate on the surface during operation.

4. Ensure the power supply is properly earthed.

5. Keep body parts well clear of moving parts and protected areas when the machine is switched on.

6. Authorized personal protective equipment must be worn when operating the machine (minimum requirement – safety glasses (when operating the cutter), protective gloves and class
   2 hearing protection).

7. Indoor use only – never operate a machine in wet conditions.

8. Stand well clear of the machine when in use (opposite the direction of the bend).

9. Use away from others, particularly children.

10. Ensure power & pedal switch cords are securely fastened before switching on the machine.

11. Use the emergency stop button immediately if issues arise during operation.

12. Only lift via marked locations on base.

13. Never attempt to bend rebar outside of the model’s prescribed diameter range (refer to the table in the Specifications & Parts section).

14. Do not bend short lengths.

15. Clean the machine of loose debris after use.

16. Never attempt to service the machine (other than general maintenance procedures outlined in the Maintenance section). Contact the supplier if an issue arises.

17. Only use RAPIDTOOL-approved spare parts and accessories with the machine.

18. Keep away from sparks and naked flames.

19. Always check power cords for damage and safe placement before use.

20. Disconnect the machine from the power outlet when not in use.

21. Inspect the machine before each use. Do not use it when quality has been compromised.

22. Do not cover air vents on a machine.

23. Store out of reach of children.

Transporting Machine

Specifications & Parts

Power Supply
Ensure the machine is connected to the correct power supply (check the machine label to confirm the power supply).
Extension Leads
Where possible, connect the machine directly to a power outlet. If an extension lead is required, ensure the lead is under 50m in length. Minimum extension lead diameters are prescribed below:

Machine Specifications

__

Rated Input Power

– Current

220-240V

| Bender| 1050W

– 4.4A

| 1050W

– 4.4A

| 2400W

– 10A

| 2400W

– 10A

Cutter| –| 1550W

– 6.5A

| –| 3000W

– 12.5A

Net Weight| 91kg| 136kg| 175kg| 225kg
Dimensions (cm)| 45L x 50W x 44H| 50L x 45W x 79H| 60L x 58W x 47H| 60L x 58W x 98H
Bending Range| 6-25mm| 6-25mm| 6-32mm| 6-32mm
Cutting Range| –| 4-25mm| –| 6-32mm

• Check machine label to determine correct power supply.
• Refer to machine model data sheet for maximum tensile strength/grade.

Note: Location of features on the machine face may vary with the machine model.

Operating Machine

Do not operate the bender and cutter at the same time.
General notes:

• Machine is equipped with an emergency stop button.
• Ensure pedal switch cords are securely fastened to inputs (if a pedal switch is required).
• Always ensure the point 1 angle is set at least 5 degrees higher than the point 2 angle.
• Ensure angle control dials are securely fastened.
• Wait until bending cycle is completed before starting the new cycle.
• If pedal switches are not required, press the start switch to bend to point 1 angle.

Pre-use Checks

1. Check power supply is properly earthed.
2. Check that the power cord is undamaged and the plug is not loose (also applies for extension leads).

Bending Procedure

1. Secure required fixed bending pin and gyre bending pin combination as per the table below.

2. Modify the adjustment block to suit the required bar size.

3. Securely fasten pedal switch cords to machine inputs (if required).

4. Connect to a power source and observe the power indicator light on the machine’s face indicating the machine is ready for use.

5. Adjust point 1 and point 2 angle control dials to required angles ensuring point 1 angle is set at least 5 degrees higher than point 2 angle. Securely fasten the angle control dial once the required angles are set.

6. Stand well clear of the machine (in the opposite direction of the bend).

7. Press the pedal switch connected to pedal switch point 1 input to bend to point 1 angle.
   Note: Pressing the start switch will also bend to point 1 angle.

8. Press the pedal switch connected to the pedal switch point 2 input to bend to the point 2 angle.

9. Bender/cutter model also has pedal switch point 3 input to operate the cutter (see Additional Instructions for Rebar Cutter section).

CRB-25/CRBC-25

CRB-32/CRBC-32A

CRB-25/CRBC-25

CRB-32/CRBC-32A

Note: Refer to RAPIDTOOL specifications where fixed/gyre bending pin diameters provided are not included in tables above.

Working Conditions

• Do not use or store the machine outside of the environmental conditions below:

Maintenance

Always ensure power is disconnected before performing maintenance.
Cleaning

• Always wear gloves to protect your hands from metal splinters when cleaning.
• Wipe or brush away all dust and metal filings from the Band Table after use to prevent debris entering the machine (can use compressed air).

Bend Table Bolts

• Ensure Bend Table Bolts are tightened before use.

Carbon Brushes
Inspect carbon brushes monthly. Worn brushes will result in power loss and cause irreparable damage to the armature’s commutator. Check brushes immediately if a loss of power or electrical fault is experienced.

Replacing Carbon Brushes

1. Open the access side panel and locate the motor housing(s) with black lid.
2. Locate the brush caps on both sides near the top of the motor housing(s).
3. Open the brush caps with a screwdriver and remove carbon brushes from the machine.
4. Inspect the carbon brushes and replace where worn or damaged.
5. Reinstall new carbon brushes and brush caps securely.
6. Replace access side panel.

Lubrication

• Lubricant shall be checked every 2 months for heavy usage or when loss of power is experienced.

• Always use approved lubricant with high corrosion and friction resistance properties.

• Apply lubricant via grease gun to lubricant hole to ensure lubricant chamber remains full.

• Additional Instructions for Rebar Cutter (Rebar Bender/Cutter Model)

• Do not operate bender and cutter at the same time.

Safety

1. Keep body parts well clear of cutting blocks when the machine is switched on.
2. Never attempt to cut rebar outside of the model’s prescribed diameter range (refer to table in Specifications & Parts section).
3. Do not cut short lengths.
4. Inspect cutter before each use (refer to the Maintenance section). Do not use it when quality has been compromised.
5. Beware of ejected objects during the cutting process. Always wear approved safety glasses.
6. Use protective gloves when cleaning machine or handling cutter blocks as edges are very sharp.
7. Do not touch pump housing after use as it will be hot. Wait for machine to cool.
8. Where available, safety guard should be installed.
9. Use Allen Key to loosed and activate Release Valve function when required.

Cutter Parts

Note: Cutter body varies with different models – use as a general guide.

Operating Machine

Pre-use Checks
Check condition of cutter blocks and tightness of cutter block bolts (refer to Maintenance section).
Warm Up
In cold weather, warm up cutter by repeating cut cycle for 60 seconds to ensure hydraulic oil reaches proper viscosity.

Stopper Adjustment
Adjustable stopper must be set in correct position dependent on size of rebar.

1. Insert rebar into U-shaped support.
2. Keeping rebar at 90˚ to machine, screw in stopper until it is just touching the rebar.

Cutting Procedure

1. Securely fasten the pedal switch chord to the pedal switch point 3 input.
2. Connect to a power source and observe the power indicator light on machine’s face indicating the machine is ready for use.
3. Insert rebar between the stopper and front cutter block, making sure it is horizontally seated in U-shaped support.
4. Press the pedal switch connected to pedal switch point 3 input while cutter rod advances and fully cuts the rebar.
5. Release the pedal switch only once the rebar has been fully cut to allow the cutter rod to retract.

Note: Power will be compromised if hydraulic oil exceeds 70˚C. Allow the machine to cool before resuming operation.
Note: Do not cut rebar on an angle. Incorrect placement of rebar may cause damage to cutter blocks and/or cutter rod, voiding the warranty.

Maintenance

Always ensure power is disconnected before performing maintenance.
To access Rebar Cutter

1. Open the access side panel and locate the rebar cutter with a black cover.
2. Remove the screws to lift the cover and access the rebar cutter.

Cutter Blocks
Check cutter blocks for damage before each use. If cutter block is damaged, replace block before the next use as per the following diagram:

• Check cutter block bolts for tightness before each use. Use protective gloves when handling cutter blocks as edges are very sharp.

Cleaning
Clean machine after each use.
Use protective gloves when cleaning to protect hands from metal splinters.
Do not use air gun as this may cause dust and metal filings to enter vents.

1. Extend cutter rod and disconnect from power source.
2. Wipe or brush away all dust and metal filings. Pay particular attention to lower half of cutter rod.
3. Connect to power source and press pedal switch to complete cut cycle.

Oil Level Check
Check oil every 2 months or if loss of power is apparent in the rebar cutter.
Hydraulic oil is highly flammable; keep away from sparks and naked flame.
In case of ingestion or eye contact, consult a physician immediately.

1. Adjust the stopper and make 3-4 cuts, noting exactly the point at which the rebar is breaking.
2. Pinch the next bit of rebar, stopping just before it breaks. Unplug the machine from the power source.
3. Turn the unit over so the oil plug is uppermost (if the machine is hot allow it to cool down first).
4. Remove the oil plug and seal the washer (never remove when the machine is hot).
5. Check oil is level with the bottom of the plug hole. If the oil is too low, top up with approved ISO VG46 oil.
6. Remove air bubbles – gently tilt cutter lengthways and return to level position. Top up and tilt the cutter in the opposite direction. Repeat this process until all air has been extracted.
7. Replace the seal washer and oil plug.
8. Connect to power source and completely sever rebar.

Oil Change
Change oil at least once a year or sooner if it appears dirty.

1. Unplug the machine from the power source.
2. Turn the unit over so the oil plug is uppermost (if the machine is hot allow it to cool down first).
3. Remove the oil plug and seal the washer (never remove when the machine is hot).
4. Turn the cutter over and drain oil into a suitable receptacle. When oil ceases to drain, tilt the machine to the rear to allow oil trapped in the piston housing to drain out. When the housing is empty, tilt the unit in the opposite direction to empty the residue in the pump case.
5. Once all oil has been drained from the machine, turn the unit over so the oil plug is uppermost.
6. Slowly fill the machine with fresh oil and replace the seal washer and oil plug.
7. Connect the machine to the power source and follow the procedure for the Oil Level Check.

Note: Dispose of hydraulic oil under local regulations.
Bolt Tightness
All bolts should be checked for tightness weekly or after every 500 cuts (whichever comes first).

Carbon Brushes
Inspect carbon brushes monthly. Worn brushes will result in power loss and cause irreparable damage to the armature’s commutator. Check brushes immediately if a loss of power or electrical fault is experienced.

Replacing Carbon Brushes

1. Unplug the machine from the power source.
2. Locate the brush caps on both sides near the back of the motor housing.
3. Open the brush caps with a screwdriver and remove carbon brushes from the machine.
4. Inspect the carbon brushes and replace where worn or damaged.
5. Reinstall new carbon brushes and brush caps securely.

CONTACT

• RAPIDTOOL
• Taren Point, NSW 2229 AUSTRALIA
• www.rapidtool.com.au

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