FASCUT ®

Model FR-800-C Rebar Bender/Cutter

Model FR-800 Rebar Bender

INSTRUCTION MANUAL
Built in the U.S.A. – Since 1979

FASCUT® Industries, 7248 Inama Rd., Sauk City, WI 53583

Phone: (608) 643-6678
Fax: (608) 643-2682
Website: www.fascut.com
Email: info@fascut.com
 MODEL FR-800-C BENDER/CUTTER
MODEL FR-800 BENDER
INTRODUCTION
The FR-800 is a rotary table type bender. The FR-800-C is the same bender
with the addition of a cutter head. By following the enclosed instructions and
maintenance schedule, your FASCUT machine will provide you with years of
trouble free service.

WARNING: Do not attempt to operate until you have read thoroughly and
understand completely all instructions, rules, etc., contained in this manual.
Failure to comply can result in accidents involving fire, electric shock, or serious
personal injury. Maintain instruction manual and review frequently for continuing
safe operation and instructing possible third-party users.

DO NOT turn on machine before removing the shipping plug on the top of the oil
reservoir and replacing with supplied breather cap. To gain access, remove the
six screws that hold on the back panel.

ALWAYS wear safety glasses when operating. KEEP fingers away from cutting
blades and bending rollers.

FR-800 FR-800-C
Size (L x W x H) 32” x 18” x 29” 32” x 24” x 29”
Weight 290 pounds 380 pounds
Cut/Bend Capacity 1 bar - #8 (1”), #7 (7/8”), or #6 (3/4”)
2 bars - #5 (5/8”)
3 bars - #4 (1/2”)
4 bars - #3 (3/8”)
Voltage / Amps 110-120 volts @ 15 amps – 50/60 Hz, single phase
220-240 volts @ 7.5 amps – 50/60 Hz, single phase
Power Supply Two stage hydraulic pump driven by a one (1) HP
continuous duty electric motor.
Bend Dies 1-1/2”, 3”, 4-1/2”, and 6” diameter
Bend Time 2 sec/90° up to #5 bar, 7 sec/90° up to #8
Cut Time (FR-800-C) 2 to 4 seconds
 OPERATION
1. ALWAYS WEAR SAFETY GLASSES when operating.

2. ALWAYS KEEP FINGERS AWAY from cutting blades and bending rollers.

3. PLUG UNIT INTO a 110-120 Volt outlet on a circuit with no less than a 20
amp breaker. When using an extension cord, never use less than 12 gauge
wire. Runs of over 100 feet are not recommended. Excessive voltage drop
at the unit will cause the motor to burn out.

Or if 220 Volt

WIRE UNIT TO a 220-240 volt, 50/60 cycle, 1 phase power source. Unit will
draw approximately 8 amps. When using an extension cord, never use less
than 14-guage wire. Excessive voltage drop at the unit will cause the motor
to burn out.

4. GENERATOR MUST BE 5000 WATTS OR LARGER. Disable idle down

feature so generator engine is running at operating speed when turning on
rebar cutter.

5. TURN ON using the toggle switch. In cold weather operations, turn unit on
and allow to warm up for 5 to 10 minutes before using.

6. ALWAYS TURN OFF unit when not in use. DO NOT allow unit to idle for
long periods of time.

7. KEEP IN UPRIGHT POSITION to prevent loss of hydraulic oil from the oil
tank breather cap.

8. TO BEND a bar or bars, first select the proper bending spool by using the
following table:
1-1/2” #2 and #3 stirrup hooks
3” #4 and #5 stirrup hooks
#3 and #4 standard bends and hooks
4-1/2” #5 and #6 standard bends and hooks
6” #7 and #8 standard bends and hooks

The bending post has four different positions. It is held with an allen cap screw in
one of two threaded holes on the rotary table. The post can be rotated to one of
two possible positions per hole. Select the proper position depending on what
diameter bar you are bending and what spool diameter you are bending the bar
on. Place a bar into the bender and hold it straight (parallel) to the table. Loosen
the allen screw that holds the bending roller and move it forward so it touches
the bar. Adjust so the bar is straight (parallel) to the table when you are bending.
Move the bending angle adjustment on the side of the machine to the required
angle. Move this setting slightly to achieve the exact angle you require. Move
the two stops to lock the adjuster at this angle.

If you are making seismic stirrups, you can preset two bending angles by
positioning one stop for one of the angles and the other stop for the second
angle. When bending, simply slide the adjuster back and forth to either stop
depending on which angle you want to bend.

TO MAKE A BEND, HOLD THE BAR WITH YOUR HAND TO THE RIGHT AND
KEEP HAND AWAY FROM THE ROLLER. The bar is drawn TOWARDS the
roller when a bend is made. KEEP YOUR HANDS AWAY FROM THE
BENDING ROLLER. Hold the pedal down until the table stops and reverses
direction. The table automatically stops and reverses at your preset angle.
Release the pedal at any time to reverse direction. After a bend has been made
PULL on the bar to the RIGHT to keep it against the bending spool until the table
has returned to the start position.

NEVER HAVE ONE PERSON WORK THE FOOT PEDAL WHILE ANOTHER IS
HOLDING OR FEEDING REBAR INTO THE MACHINE.

OPERATION OF CUTTER
(on FR-800-C models)

1. ALWAYS wear safety glasses when operating.

2. KEEP FINGERS AWAY from cutting blades at all times.
3. TURN THE SELECTOR on the side of the machine from BEND to CUT.
4. POSITION bar or bars between cutting blades. Bar must rest on the bottom
of the cutter opening as shown. Adjust the rest on the right side so the bar is
held perpendicular to the cutting blades. Press the pedal until the cut is made
and then release the pedal. DO NOT cut very short pieces (3” or shorter) as
they could fly out and cause an accident.

HOW TO USE TYPE 801 CUTTING BLADE

Use the Type 801 cutting blade when cutting a lot of #3 or #4 bar. Your cutting
times will be faster because the cutter takes less time to advance and make
contact with the bar.

Replace the regular cutting blade for the Type 801 cutting blade in the
STATIONARY POCKET. As always, make certain the securing bolts are tight.
Adjust the bar support to keep rebar at a 90 degree angle to the cutting blades.
 MAINTENANCE
DRAIN AND REPLACE OIL at least once a year or 200 operating hours,
whichever comes first. Allow unit to run for five minutes before draining to warm
up the oil. Remove six screws that hold on the back panel. The drain plug is on
the end of the oil tank. After draining and replacing plug, fill through the breather
cap hole on top of the unit to within 1” of the top. (approx. 1-1/2 gallons) Use a
good quality hydraulic oil with an ISO VG-46 weight rating for general year round
use. Use heavier ISO VG-68 for continuous hot weather operation.

GREASE fitting on top of the shaft that holds the adjustable bending roller.

FOR FR-800-C (BENDER/CUTTER) ONLY:

GREASE fitting on the left side of the cutter head.

TIGHTEN blade securing bolts before each use period. Turn on the unit and
push the pedal to extend the cutter. Before releasing the pedal, turn off the unit.
Use the allen wrench on the machine to tighten the two bolts for each blade. If
unit is used with loose cutting blades, severe damage to the cutter and broken
blades will result.

CUTTING BLADES have 4 indexable cutting edges. When one set of edges is
worn out, simply remove blade securing bolts and rotate to the next good side.
Grind worn edges flat if they prevent proper seating of the blade in it’s new
position. Do not attempt to resharpen worn edges. DO NOT CONTINUE TO
CUT WITH WORN BLADES.
 STOP BAR ATTACHMENT OPTION

The stop bar attachment consists of a 1” square tube inserted into a holder
bolted to the top left side of the machine. The position of the tube can be locked
in place by tightening a thumb screw on the holder. Two paddle bar holders are
supplied that can be slid onto the tube from either the left or right of the holder.
Also, the paddle bar holders can be put onto the tube with their offset to the left
or right depending on the required stop dimensions.

Slide the paddle bars into their holders and position closer to or further away
from the centerline of the rotary table depending on the size of bar being bent
and the bending spool diameter being used. The proper setting allows the bar
being bent to slide off the paddle bar as soon as it begins to be bent.

For a rectangular stirrup, a second paddle bar can be set for the larger
dimension. The paddle bar closest to the rotary table can be slid out of the way
when the longer dimension is being bent.

WARNING: Make certain that the bending post will not hit a paddle bar when the
table rotates. Move the paddle bar further to the left, away from the rotary table
so there is clearance between the bending post and the paddle bar when the
table rotates. Use lines etched into the table to reference smaller dimensions.

The FR-800-C Bender/Cutter stop bar attachment has an additional paddle bar to
allow setting a reference stop for cutting lengths.
 Adjustment factor for Bending

For #3 bar bent on 1-1/2" diameter die - L minus 1-1/4" = M

For #4 bar bent on 3" diameter die - L minus 2-1/4" = M
For #6 bar bent on 4-1/2" diameter die - L minus 3-1/4" = M
For #8 bar bent on 6" diameter die - L minus 4-1/4" = M

Bending a Stirrup

Refer to the series of pictures showing a standard 5-bend stirrup being bent from
start to finish. In this example we are bending a 10" square stirrup with 5-1/4"
long tails out of #4 bar on the 3" diameter die.

Use the adjustment factor above to determine how to set the reference stop.
10"(L) minus 2-1/4" = 7-3/4"(M).

Add up the sides of the stirrup:

5-1/4"+10"+10"+10"+10"+5-1/4" = 50-1/2".

Cut a bar this long and make the stirrup. The bar will be too long because less
bar is needed to make a round corner than a square one. Measure how much
the bar is too long and deduct this from the original 50-1/2". Cut your bars to this
new length and the stirrup will now come together properly after making bend #5.
 Stirrup Bending Sequence
Bend #1 – Line up end of bar with mark on table and make 90 degree bend.
Bend #2 – Do the same on the other end of the bar.
Bend #3 – Move bent end over to the reference fence.
Bend #4 – Move bend #3 over to the reference fence. This time, lift up slightly
on the “hook” end. This will help the “hook” end travel over the other “hook” end
when making bend #5.
Bend #5 – Stirrup comes together.
 WIRING DIAGRAMS

Pressing the foot switch completes the circuit to energize the valve coil. The limit
switch is spring loaded and normally open. It is triggered by a cam on the rotary
disk shaft. Moving the angle adjuster from 0 deg. to 180 deg. positions the limit
switch closer to or farther away from the cam. This controls how much the rotary
disk must turn before it triggers the limit switch. When the limit switch is
triggered, it energizes the relay which will open the valve coil circuit, causing the
rotary disk to rotate back to the starting point.
 PARTS BREAKDOWN Nov. 1, 2007
Index # Description Part # Price/ea.
1 Rotary Disk w/central shaft 80335 232.00
2 Bending Die, 3” dia. 80346 55.00
Bending Die, 4-1/2” dia. 80347 65.00
Bending Die, 6” dia. 80348 75.00
3 Bending Post 80337 96.00
3a Bending Post Bolt 80338 8.40
4a Bending Roller 80321 60.00
4b Bending Roller Shaft 80322 32.00
4c Retaining Ring (2 req.) 80323 2.80
4d Grease fitting, straight 82547 1.24
4e Adjuster Plate 80324 39.00
4f Adjuster Plate Bolt 80325 9.95
5 On/Off switch – 110-v 76619 8.12
On/Off switch – 220-v 76620 9.60
Relay – 110-v 76951 15.95
Relay – 24-v for 220-v unit 76952 15.95
Relay Socket 76953 6.12
6 Foot pedal jack 72373 15.00
7 Bend angle adjuster w/knob & bracket 80620 13.75
 Limit Switch 74341 70.58
Limit cam 80621 17.80
8 Valve, hydraulic selector 80623 85.42
Valve, hydraulic selector handle only 80624 9.70
9 Foot Pedal Control 72365 129.00
Foot pedal cord w/plug 72369 18.79
10 Bar support (adjustable) 80715 21.00
11 Cutter Head Casting 80700 675.00
Cylinder to Cutter bolts/lock washers 80705 .79
Grease fitting, elbow 82548 1.94
Safety cover plate 80721 13.91
Safety Decal, cover plate 78643 .98
12 Cutting blade w/bolts & lockwashers (2 req.) 85666 37.50
Cutting blade type 801 w/bolts & lw 85667 59.00
Hydraulic Power unit (complete) 73405 980.00
Electric Motor – serial #18726 and up 75705 415.00
Electric Motor – serial #18725 and down 75706 517.00
Motor Starting Capacitor 77253 12.58
Motor Fan 75734 19.95
Motor Fan Shroud 75721 37.50
Motor drive coupling 75715 12.75
Hydraulic Pump 73424 394.00
Oil tank 76406 64.20
Oil tank o-ring 76421 9.00
Breather Cap 71062 9.00
Oil drain plug 76245 .79
Valve (directional) 78919 62.90
Valve (kick-down) 78989 78.63
Valve coil – 110-v 78937 47.60
Valve coil – 24-v for 220-v unit 78938 47.60
Frame 80612 390.00
Top Cover Plate 80613 59.00
Table Roller (2 req.) 80615 18.45
Bar rest 80710 9.50
Bar rest support 80616 13.27
Fan, cooling 80618 38.00
Fan, cooling power cord 80619 3.85
Allen wrench (1/4”) 80310 3.36
Allen wrench (3/4”) 80319 9.60
Hydraulic connecting tube w/nut & ferrule 80463 10.50
(indicate location)
Power cord w/plug (110-volts) 76745 12.28
Stop Bar Attachment (FR-800-C) 89729 118.00
Stop Bar Attachment (FR-800) 89727 118.00
Bender Rotary Actuator
 Bender Rotary Actuator
Nov. 1, 2007
Item Part Name Part # Cost Qty
No. each req’d
1 Housing 80510 775.00 1
2 Bearing 80522 28.95 2
3 Bearing Cap o-ring seal 80530 2.08 1
4 Bearing Cap 80513 49.00 1
5 Pinion 80520 148.00 1
6 Tie Rod nut 80515 .89 16
8 Tie Rod 80514 5.20 16
10 Pinion o-ring seal 80531 2.08 2
11 Relief Valve 80516 4.10 1
12 Cylinder Tube #18398 and up 80511 61.00 4
Cylinder Tube #18397 and down 80542 61.00
13 Piston back-up ring 80532 2.24 8
14 Piston o-ring seal 80533 1.60 4
15 Cylinder Tube o-ring seal 80534 .96 4
16 Piston Rack #18398 and up 80521 155.00 2
Piston Rack #18397 and down
not available. Must get part
#80521 and #80511
17 Cylinder Head 80512 47.00 4
23 Cylinder Head back-up ring 80535 1.92 4
24 Cylinder Head o-ring seal 80536 1.12 4
25 Bearing Cap set screw 80517 .32 1
26 Bearing Cap nylon pellet 80518 .16 1
Seal Kit, includes 1-#3, 2-#10, 80540 47.04
8-#13, 4-#14, 4-#15, 4-#23,
4-#24, 1-#25, 1-#26
Rotary Actuator – COMPLETE 80500 1,595.00
 Cutter Hydraulic Cylinder

Nov. 1, 2007
Description Part # Price/ea.
Hydraulic Cylinder (complete) 80430 550.00
Back body seal 80438 9.00
Piston Seal w/square loader ring 80436 34.90
Nylon Bearing 80440 4.95
Rod Seal 80442 15.50
Piston & rod assy. w/seal & loader 80434 219.00
Cylinder body w/back plate 80432 302.00
Key, ½” sq, #18380, #918 and up 80451 14.50
Key, ½” sq, #18379, #917 and down 80452 14.50
Spanner wrench, flat 80461 15.00
Spanner wrench, extended 80462 30.00
 TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
Motor will not 1. No power to unit. 1. Check supply cord, fuses,
start 2. Power cord or plug damaged. or circuit breaker.
3. On/off switch bad. 2. Replace power core
4. Motor wire connections loose. w/plug.
3. Replace on/off switch.
4. Tighten motor wire
connections.
Motor hums, 1. Extension cord too long or not 1. Extension cord must be
then blows heavy enough. min. 12 gauge wire and no
circuit breaker, 2. Starting capacitor bad. longer than 100 feet.
or motor is 3. Starting switch bad. 2. Replace starting
smoking 4. Generator too small. capacitor.
5. Generator running at idle 3. Replace starting switch.
before starting unit. 4. Use a 5 KW generator or
6. Motor windings burnt out. larger.
5. Turn off or disconnect idle
down feature.
6. Replace motor.
Motor runs, but 1. Relay has fallen out of its 1. Plug relay back into
nothing happens socket. socket.
when foot pedal 2. Relay socket is broken. 2. Replace relay socket.
is depressed. 3. Bend angle adjuster is moved 3. Move the bend angle
over to “0” degrees. adjuster away from “0”
4. Limit switch is bad. degrees.
5. Relay is bad. 4. Replace limit switch.
6. Foot pedal cord or plug is 5. Replace relay.
damaged. 6. Replace foot pedal cord
7. Jack is bad. w/plug.
8. Switch inside foot pedal is 7. Replace jack.
bad. 8. Replace inside switch.
9. Loose wire. 9. Check all wiring for loose
10. Valve coil is bad. connections.
11. Directional valve is bad. 10. Replace valve coil.
11. Replace directional valve.
Cutting blade 1. Cutting blade bolts are loose. 1. Retighten blade bolts
bolts breaking 2. Cutting blades are dull. regularly.
2. Turn blades to new cutting
edge or replace blades.
Cutting blades 1. Blades are dull. 1. Turn blades to a new edge
breaking 2. Blade bolts are loose. sooner.
3. Rebar is being dropped into 2. Check blade bolts for
the cutter. tightness more often.
4. You are cutting “no grade” 3. Place rebar into the cutter
steel with greater care.
5. Bar is being cut on the top 4. Only cut grade 40 or grade
corner of the cutting blade 60 rebar.
5. Bar must rest on the
bottom of the cutter
opening.
Oil is leaking 1. Hydraulic tubes and fittings 1. Check fittings for tightness.
are loose or damaged. Replace damaged fittings
2. Hydraulic cylinder body seals or tube.
or rod seal is leaking. 2. Install new body and/or rod
3. Oil is leaking from rotary seals in hydraulic cylinder.
actuator. 3. Install new seals and o-
rings in rotary actuator.

Bending or 1. Oil level is low. 1. Add oil to tank.

Cutting is slow 2. Oil is contaminated. 2. Drain and refill oil tank with
and lacks power 3. Hydraulic pump is worn. fresh ISO-46 hydraulic oil.
3. Replace hydraulic pump.
 FASCUT® Industries, Inc.

LIMITED WARRANTY

This product has been thoroughly inspected and tested before leaving the
factory. It is guaranteed against defective workmanship and materials for a
period of 1 year to the original owner. Should any trouble develop, return
defective part transportation prepaid to the factory. If inspection shows trouble is
caused by defective workmanship or material, all repairs will be made without
charge and returned, transportation prepaid. The guarantee does not apply
where: repairs or attempted repairs have been made by persons other than the
factory; repairs are due to normal wear; the tool has been abused or in an
accident; misuse is evident – caused by overloading the tool beyond its rated
capacity; use on improper voltage or current; use of the tool after partial failure or
use with improper accessories.

This warranty is in lieu of all other warranties, expressed or implied, and there
are no warranties on merchantability or fitness for a particular purpose. In no
event shall seller be liable for incidental, consequential or special damages. This
warrantee is void if Warrantee/Registration card is not filled out and returned.
This warranty gives you specific legal rights, and you may also have other rights,
which vary from state to state.

SERIAL NUMBER ______________________ DATE ____________________

FASCUT® Industries, Inc.

7248 Inama Rd.
Sauk City, WI 53583

Phone: (608) 643-6678

Fax: (608) 643-2682

Website: www.fascut.com