FASCUT ®

Model FS - 600 Rebar Cutter / 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: [email protected]
 INTRODUCTION
FASCUT® incorporates both a cutter and a bender into one compact rebar fabrication
machine. 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 and
may result in accidents involving fire, electric shock, or serious personal injury. Maintain this
instruction manual and review it frequently for continuing safe operation and instructing new
or possible third-party users.

DO NOT: TURN ON MACHINE BEFORE REMOVING THE SHIPPING PLUG ON THE TOP
OF THE OIL RESOVOIR AND REPLACING IT WITH THE SUPPLIED BREATHER CAP.
FAILURE TO DO THIS COULD RESULT IN DAMAGE TO THE MACHINE!

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

Model FS-600 Portable Bender/Cutter -- Specifications

Bend Capacity 1 bar - #6 (¾”) 19mm; 1 bar - #5 (⅝”) 16mm
Grade 60 (420 MPa) 1 bar - #4 (½”) 13mm; 2 bars - #3 (⅜ ”) 10mm
Bend Angle Control 0 - 130°; infinitely variable with accurate repeat
Bend Die Diameters 2 (½“) and 3 (¾ “) (64mm and 95mm)
Bending Method Three (3) point bending system
Bend Time Approx 3 seconds

Shear Capacity 1 bar - #6 (¾”) 19mm; 1 bar - #5 (⅝ ”) 16mm

Grade 60 (420 MPa) 2 bars - #4 (½”) 13mm; 3 bars - #3 (⅜ ”) 10mm
Shear Method Open Jaw Shear
Shear Time Approx 2 seconds

Dimensions 26” x 13” x 16”

(L x W x H) 66cm x 33cm x 41cm

Weight 180 pounds / 82kg; built in carrying handles

Power Supply Two stage hydraulic pump driven by a one (1) hp. continuous duty
electric motor

Voltage / Amps 110-120 volts @ 15 amps – 50/60 Hz, single phase

220-240 volts @ 7.5 amps – 50/60 Hz, single phase

1
 NORMAL OPERATION

1. ALWAYS WEAR SAFETY GLASSES when operating.

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

3. PLUG UNIT INTO a 110-120Volt outlet on a circuit with no less than a 20 amp
breaker. When using an extension cord, never use less than 12-guage wire.
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 CUT a bar or bars, position bar between

cutting blades. Bar must rest on the bottom
of the cutter opening as shown on the
diagram. Press the green button until cut is
made and then release.

DO NOT cut very short pieces as they could fly out and cause personal injury to
you or someone located close to you.

9. TO BEND a bar, rotate the adjustment knob to set the desired bend angle. Once
set, all bends will be identical. Position bar between the bending rollers and
bending die. Bar must be kept horizontal at all times.

BEND ONLY ONE BAR AT A TIME. Two ⅜” (#3) diameter bars or Three ¼” (#2)
diameter bars can be bent together.

DO NOT bend more than 1 - ½” (#4), 1 - ⅝” (#5) or 1 - ¾” (#6) diameter bar at a

time or injury to operator and/or damage to machine could result.
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 10. TO CHANGE THE BENDING RADIUS remove the bending die securing bolts with
Allen wrench provided on the machine and rotate to desired radius. Move bending
rollers to appropriate position by pulling drop pins up and out.

NOTE: Bending rollers must be moved to the outside hole positions to be able to
bend ⅝” (#5) or ¾” (#6) diameter bar. With the rollers in the inside hole positions,
only bars up thru ½” (#4) diameter will fit into the bender.

BENDER SET-UP FOR SMALL RADIUS BENDS

Bending rollers are moved to the inside hole

positions.

Bending die is secured in place with the SMALL radius

facing the bending rollers.

BENDER SET-UP FOR LARGE RADIUS BENDS

Bending rollers are moved to the outside hole

positions.

Bending die is secured in place with the LARGE radius

facing the bending rollers.

BENDER SET-UP FOR BENDING TIGHTER HOOKS

USING UP TO ½” (#4) DIA. BAR

Bending rollers are moved to the inside hole

positions.

Bending die is secured in place with the LARGE radius

facing the bending rollers.
Maximum ½” (#4) dia. bar with this set-up!

NOTE: The bending die must be fastened using the 2 securing hex bolts and
must be kept tight at all times or injury to operator and/or damage to machine could
result.

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 STIRRUP FABRICATION
Step 1: Determine dimensional size of stirrup to be fabricated.

Step 2: Determine the length of bar needed for specified stirrup using the following
formula.
Stirrup “Cut” Factor

For #3 (⅜”) or #4 (½”) Rebar – Use the following formula.

Length X (2) + Width X (2) + 3” = Cutting Length

Example: 12” square stirrup – 12” X 2 = 24” + 12” X 2 = 24” + 3” == 51”

For #5 (⅝”) or #6 (¾”) Rebar – Use the following formula.

Length X (2) + Width X (2) + 2” = Cutting Length

Example: 12” square stirrup – 12” X 2 = 24” + 12” X 2 = 24” + 2” == 50”

Step 3: Determine where to set Stop Bar in order to get the proper dimensional stirrup.
Measurement is made from the center of the “pear” shaped bending die, to the
Stop Bar bending fence.

Stirrup “Bend” Factor

If stirrup is square, adjust Stop Bar using the following formula.

Length/Width – Diameter of Bar = Stop Bar Position

Example: 12” square stirrup using #4 (½”) Rebar – 12” - ½” == 11 ½”

If stirrup is rectangular, adjust Stop Bar using the following formula.

Length (minus) Diameter of Bar = Stop Bar - “Right” Collar Setting

Width (minus) Diameter of Bar = Stop Bar - “Left” Collar Setting

Example: 12” X 18” Stirrup using #4 (½”) Rebar

12” -- ½” == 11 ½” Setting for “Left” Stop Collar

18” -- ½” == 17 ½” Setting for “Right” Stop Collar

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 STIRRUP & HOOK BENDING SEQUENCE

Bend #1
Position bar as shown;

Place end flush with the left side of the bending

fork.

This is done by eye.

Bend 90˚

Bend #2
Reposition bar as shown;

Lay bent “hook” flat on the stop bar reference

fence.

Bend 90˚

Bend #3
Reposition bar as shown;

Raise “hook” end of bar prior to bending.

(see Note below)

Bend 90˚

↑↑
Note: Raise “hook” end of bar by the amount equal to the diameter of the bar.

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Bend #4
Reposition bar as shown;

Raise “hook” end as bend is being made so hook

ends up above the remaining bar.

Note: This is made easier because of raising

“hook” end prior to bend #3.

Bend 90˚

Bend #5
Reposition bar as shown;

While bending lift bar up slightly to slide up and

over bending fork.

Bend 90˚

PRESTO

(1)

CUSTOM STIRRUP

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 OPTIONS
STOP BAR ATTACHMENT

The stop bar can be adjusted to give the

operator a 4’ reference fence for cutting or
bending uniformity. It is extremely useful in the
fabrication of stirrups. Not only are all bends
positioned properly, but all bends are in the
same plane. The adjustable collars allow the
operator to fabricate stirrups of different
shapes, such as rectangular.

The FS-600 has the adapters for attaching the

stop bar already built into the unit. No
modification is required. Just slide it in and you
are ready to go.

The stop bar attachment comes in 4 parts:

1) Thumb screw that is threaded into the left side adapter ring on the frame to
secure the stop bar in the desired position.
2) A 60” length of 1” square steel bar.
3) T - shaped fence bracket that bolts to the end of the steel bar.
4) Two adjustable reference stop collars.

ASSEMBLY

Bolt the “T” shaped fence bracket to the end of the steel bar using the hardware included with
the stop bar attachment. Next, slide one of the stop collars onto the bar with the thumb screw
facing the operator. Now insert the bar thru the holder rings that are located on the frame
from the LEFT side. Next, slide the other stop collar onto the bar with the thumb screw facing
the operator from the right side. Finally screw the remaining thumb screw into the LEFT
holder ring on the frame of the machine.

HOW TO USE

For normal operations, slide the stop bar left or right to the desired dimension and secure
with the thumb screw. Use the two stop collars when making rectangular shaped stirrups.
Push the bar to the right and set the left hand stop collar at the required dimension and
secure with the thumb screw. Now push the bar to the left and set the right hand stop collar
for the longer required dimension and secure with the thumb screw. Keep the thumb screw
on the machine frame loose for this operation. The bar can now be slid alternately back and
forth to each stop as the stirrup is being made.

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FOOT PEDAL CONTROL

The Foot Pedal comes fully assembled and pre-

wired. It can be plugged in at any time.

A jack is provided on the underside of the electric

box. Push the plug into the jack until it locks in
place. To remove, just push the release button on
the jack.

When the foot pedal is plugged in, both the push

button on the machine and the foot pedal will
control the machine.

Note: Extra caution must be observed when using the foot pedal to
keep fingers away from cutting blades and bending rollers.

Never: Have one person work the foot pedal while another is feeding
rebar into the machine.

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The on/off switch turns on power to both the electric motor and the valve coil control circuit. It
must be 1 HP rated.

Pressing the push button or foot pedal completes the circuit to energize the valve coil. The
limit switch is spring loaded and normally open. It is triggered by the slide casting when it
moves out. When the limit switch is closed, it triggers the relay which will open the valve coil
circuit, causing the slide casting to retract.

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 ROUTINE MAINTENANCE

1) DRAIN & REPLACE HYDRAULIC OIL at least once each year or 200 operating
hours, whichever comes first. Allow unit to run for five minutes before draining to
warm up the oil. Remove drain plug and drain oil. Remove breather cap and plug
hole with a ⅜” pipe plug. Tip unit on end and fill thru drain hole to within one (1)
inch of the top and replace plug. DO NOT OVERFILL. Use good quality hydraulic
oil with a rating of ISO-VG 46 for general year round use. Use heavier ISO VG-68
for continuous hot weather operation. The unit will take approximately 6 quarts of
oil to refill. Set unit upright again and remove the ⅜” pipe plug and re-install the
breather cap, hand tightening only.

Failure to re-install the breather cap could result in damage to the machine.

2) GREASE fitting on slide casting and lubricate bending rollers before EACH use
period. Re-bar scale will quickly dry up grease. Removal of this scale, and
lubricating the slide casting and rollers often will help to reduce wear.

Failure to remove excessive scale and lubricate machine regularly, could

result in increased wear and reduced life of the machine.

3) TIGHTEN blade securing hex bolts and bending die hex bolts with the supplied
Allen wrenches before each use period.

Failure to keep cutting blades or bending die securing hex bolts tight at all
times could result in injury to the operator and/or damage to the machine.

4) CUTTING BLADES have 8 indexable cutting edges. When one set of edges is
worn out, simply remove blade securing bolt and rotate to a new edge. If old edge
has mushroomed slightly, grind edge flat before installation to achieve proper
“seating” of the blade in its new position.

Do not attempt to re-sharpen worn edges. You will change the hardening
properties of the blade and reduce its overall useful life.

5) CLEANING machine with a pressure washer routinely will help keep oil and grease
from building up and will extend the overall life of the machine.

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 FASCUT™ Model FS-600 Rebar Fabricator
Parts List
Breakdown A
May 1, 2008
Index Description Part # Price/ea. Qty
# Req’d
1 Bend adj. knob 62154 7.52 1
2 Bend adj. mechanism 62158 38.98 1
3 Bend adj. mounting bolt 62423 .20 2
4 Bend adj. mounting star washer 62427 .10 2
5 Bending Die 63221 59.85 1
6 Bend die securing bolt 63351 2.52 2
7 Bending roller (1-3/8” dia.) 63444 19.80 2
8 Bending roller securing drop pin 63475 3.27 2
9 Casting, base 64531 445.00 1
10 Casting, slide 64533 230.00 1
11 Casting (LB mounting bolt w/nut) 71522 1.65 1
12 Casting (LF mounting bolt – dome head) 71525 1.20 1
13 Casting (RF mounting bolt) 71529 1.30 1
14 Casting (mounting bolt star washer) 71533 .15 3
16 Cutting blade w/bolt and washer (2 req’d) 65666 32.50 2
17 Cutting blade bolt and washer – base 65685 1.69 1
18 Cutting blade bolt and washer – slide 65695 1.69 1
19 Grease fitting 62547 1.24 1
20 Hydraulic Cylinder – complete 67425 456.00 1
Hydraulic cylinder front block 67567 176.00
Hydraulic cylinder back block 67568 132.00
Hydraulic cylinder tube 67566 89.00
21 Hyd. Cyl. Body seal kit 67523 18.00 1
22 Hyd. Cyl. Elbow fitting 73112 5.25 2
23 Hyd. Piston and rod assy. 67536 194.00 1
24 Hyd. Piston seal and loader ring 67672 32.50 1
25 Hyd. Nylon rod bearing 67785 3.95 1
26 Hyd. Rod seal and wiper 67822 15.97 1
27 Limit switch 74341 70.58 1
28 Limit switch mounting screw 74352 .10 2
29 Limit switch mounting lock washer 74354 .05 2
30 Limit switch trigger bolt w/nut 74356 1.25 1
31 Return spring 68386 9.21 1
32 Return spring slide casting bolt 77105 1.10 1
33 Safety cover plate w/decal 68642 7.29 1
34 Safety cover plate attach screw 68644 .15 2
35 Tie rod 69921 4.80 4
36 Tie rod nut 69923 .89 4

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13
 FASCUT™ Model FS-600 Rebar Fabricator
Parts List

Breakdown B
May 1, 2008
Index Description Part # Price/ea. Qty
# Req’d
1 Breather cap 71062 9.00 1
2 Cord grip 71814 3.85 3
3 Hyd. Pump only – serial #6506 and up 73424 394.00 1
(except for #6548 thru #6568)
4 Hyd. Pump elbow fitting 73662 5.25 2
5 Hyd. Pump mounting bolt 73844 2.25 4
6 Hyd. Pump oil seal o-ring 73519 .30 1
7 Hyd. Pump pressure seal o-ring 73546 .25 1
8 Hyd. Front return tube w/nut-ferrule 67923 10.50 1
9 Hyd. Rear pressure tube w/nut-ferrule 67947 10.50 1
10 Electric Motor – serial #8382 and up 75705 415.00 1
Electric Motor – serial #8381 and down to 75706 517.00
#6506 (except for #6548 thru #6568)
Electric Motor (Delta) – serial #6200 thru 75907 415.00
#6505 and #6548 thru #6568
11 Motor drive coupling 75715 12.75 1
Motor drive coupling (Delta) 75914 12.75
12 Motor fan shroud 75721 37.50 1
13 Motor fan 75734 19.95 1
14 Motor fan retaining ring 75735 .50 1
15 Motor case thru bolt 75797 2.25 4
16 Motor shaft bearing (2 req’d) 75872 8.12 2
17 Motor spring washer 75797 1.25 1
18 Motor starting switch 75889 16.97 1
19 Oil/quart – ISO-46 hydraulic oil 76046 3.90 6
20 Oil drain plug 76245 .79 1
21 Oil tank 76406 64.20 1
22 Oil tank o-ring 76421 9.00 1
23 Oil tank magnet 76256 4.15 1
24 Starting capacitor 77253 12.58 1
25 Valve, directional 78919 62.90 1
26 Valve coil, 110-v 78937 47.60 1
27 Valve coil, 24-v for 220-v unit 78938 47.60 1
28 Valve, kick-down 78989 78.63 1

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15
 FASCUT™ Model FS-600 Rebar Fabricator
Parts List

Breakdown C
May 1, 2008
Index Description Part # Price/ea. Qty
# Req’d
1 Allen wrench (5/16”) 61046 3.86 1
2 Allen wrench (3/8”) 61048 4.36 1
3 Cord grip 71814 3.85 3
4 Electric box mounting bolt 71932 .25 2
5 Electric box star washer 71938 .15 2
6 Electric box only – 110-v 66745 49.00 1
6 Electric box only – 220-v 66746 59.00 1
7 Electric box, wired w/limit switch – 110-v 66782 189.00 1
7 Electric box, wired w/limit switch – 220-v 66783 221.00 1
8 Foot pedal jack 72373 15.00 1
9 Frame 66855 159.00 1
10 Hyd. Power unit, complete 73405 980.00 1
11 PVC Conduit 74488 .98 1
12 Conduit fitting – straight 74492 1.49 1
13 Conduit fitting – elbow 74493 1.99 1
14 Motor connecting cord 75826 1.45 1
15 Motor mounting bolt 75788 .30 4
16 Motor mounting nut 75791 .30 4
17 On/Off switch – 110-v 76619 8.12 1
17 On/Off switch – 220-v 76620 9.60 1
18 On/Off switch boot 76633 2.97 1
19 Power cord w/plug – 110-v 76745 12.28 1
20 Push Button Control 76882 21.42 1
21 Relay – 110-v 76951 15.95 1
21 Relay – 24-v for 220-v unit 76952 15.95 1
22 Relay socket 76953 6.12 1
23 Stop bar thumb screw 77554 1.15 1
24 Terminal block 77837 4.85 1
Xxx Transformer, 24-v for 220-v unit (not 78101 21.72 1
shown)
Foot Pedal Control (complete) 72365 129.00
Foot pedal cord w/plug 72369 18.79
Stop bar attachment 69725 75.00

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TROUBLESHOOTING FS-600 Rebar Cutter/Bender
TROUBLE PROBABLE CAUSE REMEDY
Motor will not 1. No power to unit. 1. Check supply cord, fuses, or
start 2. Power cord or plug circuit breaker.
damaged. 2. Replace power core w/plug.
3. On/off switch bad. 3. Replace on/off switch.
4. Motor wire connections 4. Tighten motor wire connections.
loose.
Motor hums, 1. Extension cord too long 1. Extension cord must be min. 12
then blows or not heavy enough. gauge wire and no longer than
circuit breaker, 2. Starting capacitor bad. 100 feet.
or motor is 3. Starting switch bad. 2. Replace starting capacitor.
smoking 4. Generator too small. 3. Replace starting switch.
5. Generator running at idle 4. Use a 5 KW generator or larger.
before starting unit. 5. Turn off or disconnect idle down
6. Motor windings burnt out. feature.
6. Replace motor.
Motor runs, but 1. Relay has fallen out of its 1. Plug relay back into socket.
nothing happens socket. 2. Replace relay socket.
when push 2. Relay socket is broken. 3. Replace angle adjuster.
button is 3. Bend angle adjuster is 4. Readjust by loosening the jam
depressed. bent or damaged. nut behind the adjuster knob.
4. Bend angle adjuster is Rotate the knob 1 turn
always triggering the limit counterclockwise and then
switch. retighten the jam nut.
5. Limit switch is bad. 5. Replace limit switch.
6. Relay is bad. 6. Replace relay.
7. Push Button is bad. 7. Replace push button.
8. Loose wire. 8. Check all wiring for loose
9. Valve coil is bad. connections.
10. Directional valve is bad. 9. Replace valve coil.
10. Replace directional valve.

Foot Pedal does 1. Foot pedal cord or plug is 1. Replace foot pedal cord w/plug.
not work. (push damaged. 2. Replace jack.
button does) 2. Jack is bad. 3. Replace inside switch.
3. Switch inside foot pedal
is bad.
Slide casting 1. Slide casting needs 1. Apply WD-40 to slide casting to
does not return lubrication. loosen rebar scale and old
2. Something is jammed grease. Grease more often thru
behind slide casting. grease fitting.
3. Slice casting is bent. 2. Remove object jammed behind
4. Weak return spring. slide casting.
3. Replace slide casting or attempt
to straighten.
4. Replace return spring.

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Slide casting is 1. Steel being bent is taller than 1. Maximum bending capacity
bent gap between base casting is ¾”, #6 rebar or smaller,
and the plate between the ONE BAR AT A TIME.
bending rollers. 2. Support the ends of rebar
2. Tails of long bars being bent being bent with a table or
are dropping down, causing platform or extra worker
the bent bar to pry up on the holding onto end of bar.
slide casting. 3. Rest steel being bent flat on
3. A piece of material has been the base casting.
pinched between the
bending die and the plate
between the bending rollers.

Cutting blade 1. Cutting blade bolts are loose. 1. Retighten blade bolts
bolts breaking 2. Cutting blades are dull. regularly.
3. Blade socket is deformed. 2. Turn blades to new cutting
edge or replace blades.
3. Replace casting.

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.
Bending roller 1. Configuration of bending die 1. See instruction manual for
drop pin and rollers is incorrect for correct die and roller
breaking material being bent. positions.
2. Already bent steel is being 2. Only bend straight bars
placed back into the bender ONCE.
and bent a second time after 3. Do not bend steel harder
moving bending rollers to the than Grade 60 rebar.
inside hole positions.
3. Steel is harder than Grade
60 rebar.
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
seals in hydraulic cylinder.

Cutting is slow 1. Oil level is low. 1. Add oil to tank.

and lacks power 2. Oil is contaminated. 2. Drain and refill oil tank with
3. Hydraulic pump is worn. fresh ISO-46 hydraulic oil.
3. Replace hydraulic pump.

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 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

www.fascut.com
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