The portable, hand-held rebar bending and cutting system. OPERATOR S MANUAL Made in U.S.A.

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1 The portable, hand-held rebar bending and cutting system. OPERATOR S MANUAL Made in U.S.A.

2 Thank you for purchasing an EZE BEND SYSTEM. The OPERATOR S MANUAL provides information for all Power Heads, Hoses, and Pumps offered by EZE BEND, INCORPORATED. The OPERATOR S MANUAL is divided into four sections: I. Introduction and General Information II. Power Heads III. Hydraulic Hose Assemblies IV. Hydraulic Pumps DO NOT OPERATE THIS EQUIPMENT UNTIL YOU HAVE READ AND UNDERSTAND THIS OPERATOR S MANUAL. FAILURE TO OPERATE THE EQUIPMENT CORRECTLY COULD RESULT IN SERIOUS PERSONAL INJURY. I. INTRODUCTION and GENERAL INFORMATION WARRANTY The EZE BEND SYSTEM is designed for long-term, durable performance. With confidence, the manufacture offers a one-year warranty against defects in material and workmanship. This WARRANTY is expressly limited to the person(s) who purchased EZE BEND components for use in the ordinary course of the buyer s business. It does not cover any product or part that has been abused, worn out, altered, or used in a manner or for a purpose other than which it was intended. EZE BEND, INC., makes no other warranty of any kind, whatsoever. Liability shall be limited to repair and or replacement of EZE BEND SYSTEM components. MAINTENANCE There are few operator-serviceable components within the EZE BEND SYSTEM. The maintenance of external components is clearly outlined within the individual sections of this OPERATOR S MANUAL. DO NOT ATTEMPT TO SERVICE INTERNAL COMPONENTS. Any attempt to service internal components will void the warranty and may result in product failure or personal injury. SERVICE AND REPAIR The first step in identifying service or repair requirements is to isolate the problem. Use the process of elimination, if possible. For example, there are four points of electrical connections, one on the tool, one on the pump and then one on each end of the hose. Alternate the connections between the power heads, hoses, and pumps to isolate the exact location of the defect. Next, call EZE BEND at We may be able to offer suggestions to remedy your service requirements. It may also be possible to refer you to an approved service center within your locality.

3 SPEED A cut or bend with the EZE BEND SYSTEM is estimated to be equal to second for each numerical size of rebar. In other words, #4 rebar bends to 90-degrees in approximately 4 seconds or # 6 rebar bends to 90-degrees in approximately 6 seconds. Many factors can increase or decrease operating speed: Temperature Quality and specification of hydraulic oil Cleanliness of pumps screens, hydraulic oil, and couplers Age and condition of components Length of hydraulic hose Length and quality of electrical extension cord Power and capacity of hydraulic pump (Using the more powerful #8 Pump with #6 Power Heads increases operating speeds by approximately 00%. Rather than #4 rebar 90-degree bends requiring 4 seconds, they can be achieve in approximately seconds). DESIGN FEATURES These design features are inherent to all EZE BEND Power Heads.. Momentary Power Buttons - This SAFETY feature allows the operator to instantly stop and retract the tool s action by simply releasing the power button.. Hydraulic Quick Connectors - For easy attachment of the hydraulic connectors, place the Power Head face down on any surface that will provide resistance. Then, press the hydraulic hose connector into place. Once connected, rotate the connector s outer casing past the silver button to avoid inadvertent disconnects. To disconnect, realign the silver button and push in on the connector s outer casing. 3. Electrical Connectors - To connect, align and insert the inner portion of the connector. This may require rotation until it easily slips in to place. DO NOT FORCE. Next, thread the outside casing on until it clicks. To remove, simply unscrew and gently pull the connector away. 4. Safe electrical supply The standard 0-volt electrical supply is stepped down at the pump. Then, the EZE BEND Hose Assembly carries 4 SAFE volts to the Power Heads. At any time, the operator has only 4 volts in their hand!

PULL BENDERS #6 AND #8 The Pull Benders provide many creative job-site fabrication solutions. By pulling the rebar against stationary pins, rebar bends SAFELY away from the operator.

4 PULL BENDERS #6 AND #8 The Pull Benders provide many creative job-site fabrication solutions. By pulling the rebar against stationary pins, rebar bends SAFELY away from the operator. This bending action, coupled with an operating head that can pivot 360 degrees, makes the Pull Bender the perfect tool for bending cast-inplace rebar. Planning on the ease of bending cast-in-place rebar can simplify many projects. Alert operation is the key to safely using the Pull Bender. First, the rebar must be placed carefully within the cradle, lying flat against the cradle (#08) and in the middle of both rollers (#0). The rebar must extend beyond both roller pins by a minimum of inch. Pulling on only one pin will cause mechanical failure and may cause serious injury. To rotate the Pull Bender Head, loosen the 5/6 bolt in the center of the front block (part #07). Rotate the top and bottom plate assembly (#04 - #05) to the desired location. Avoid applying pressure to the 90-degree elbow (#9) during rotation process. When the Bender is new, you may need to alternately rotate the cradle (#08) and the top/bottom plates until desired angle is obtained. Be aware that the top and bottom plate assembly can move forward and out of position during rotation. Hold the top and bottom plate assembly tight against the Front Block (#03) during rotation. Then, retighten the bolt. If cradle returns slowly or not at all,. The 4 bolts securing the top and bottom plates may be over-tightened. Loosen all 4 bolts and retighten to equal torque.. The hydraulic connectors on either end of the hose, on the Power Head, or on the Pump may have incurred damage. Check for foreign materials in or on the connectors or scarring. Replace if necessary. 3. The cylinder may be damaged. This will require service from EZE BEND. Please note additional warnings listed in PRECAUTIONS above.

CUTTERS #6 AND #8 The Cutter Heads offer outstanding features, including 360-degree handle rotation, 4-sided Cutting Blocks, hand-operated Gauge Blocks, Shock Absorbers, and the lightest weight and

5 CUTTERS #6 AND #8 The Cutter Heads offer outstanding features, including 360-degree handle rotation, 4-sided Cutting Blocks, hand-operated Gauge Blocks, Shock Absorbers, and the lightest weight and smallest size in each of their classifications. The 360-degree rotation feature is simple to operate. Just loosen the _" socket head cap screw at the bottom of the handle plate (#003). Rotate to the desired angle and retighten. The 4-sided Cutting Blocks are secured with _" socket head cap screws. The Cutting Blocks operate under extreme pressure. Therefore, it is very important to check and retighten the Cutting Blocks DAILY. When a block becomes dull or chipped, remove, rotate, and reinstall. Again, secure very tight! Note: We recommend rotating both blocks to new cutting edges at the same time. The Gauge Block is spring loaded and easily rotated by one-hand. Rotate the Gauge Block to match the diameter of the rebar in use. Proper use will minimize shear, produce cleaner cuts and extend the life of the Cutting Blocks. To operate, simply pull out just enough to rotate, rotate, and then return to original location. Be sure the Gauge Block returns flush to the body. Leaving one edge elevated may cause breakage and injury. Note: It may seem easier to leave the Gauge Block wide open. However, you will find yourself replacing more Cutting Blocks, working with sharper and more dangerous rebar edges, and premature failure of the hydraulic cylinder. Shock Absorbers allow short cut rebar to safely drop, rather than dangerously fly away. is the key to safely using the Cutter. Always insure that rebar is carefully placed within the bottom of the housing (#00) and run straight across the face of both cutting blocks (#09). Please note additional warnings listed in PRECAUTIONS above.

6 Hydraulic Hose Assemblies There are two optional lengths for Hose Assemblies. The 5 ft. hose provides extended reach whereas the 0 ft. hose is best for production work EZE BEND encases the hydraulic hose and the electrical wire inside of a durable protection sleeve. The electrical and hydraulic connectors are identical on both ends and therefore, completely interchangeable. Always connect the hydraulic connection first, then the electrical. However, disconnect the electrical connection first, then the hydraulic. This order is easier to perform and eliminates unnecessary stress on the electrical components Wipe the hydraulic and electrical connectors clean prior to every connection. Never disconnect the hose while pump is activated. Although every attempt has been made to insure the SAFETY of the operator and the environment, CAUTION SHOULD BE USED IN THE PLACEMENT AND MANIPULATION OF THE HOSE. AVOID AUTOMOTIVE AND HEAVY MACHINERY TRAFFIC. WITH AS MUCH AS 0,000 P.S.I. IN USE AT ANY TIME, ACCIDENTAL RUPTURES COULD BE LETHAL. If your job demands constant twisting and turning of the Power Heads, the electrical wire may become taunt and twisted around the hydraulic hose. Monitor the hose assembly to avoid damage to the wire or the electrical connectors. To relieve stress in the wire, simply disconnect both wire connectors, straighten the electrical wire, and then reattach. At the end of each use, completely disconnect and remove the hose from the Power Head and the Pump. Then, stretch the hose. The stretching process requires two people. Grasp each end of the hose by the hydraulic connectors and gently pull the ends in opposite directions. The wire should straighten within the protective sleeve. Be sure to leave the same length of electrical wire extending from both ends of the hose assembly.

Hydraulic Pumps The EZE BEND SYSTEM employs Enerpac hydraulic pumps. Internationally recognized as the leader in hydraulic power systems, service centers are located throughout the United States.

7 Hydraulic Pumps The EZE BEND SYSTEM employs Enerpac hydraulic pumps. Internationally recognized as the leader in hydraulic power systems, service centers are located throughout the United States. Service centers can be located by accessing Enerpac s web site, Please read and retain the Enerpac operator s manual. Use only EZE BEND or Enerpac Hydraulic Oil. DO NOT install other oil products as they may cause system failure and void the warranty. Keep oil level full. Replace oil every 3-6 months. The.5 horsepower pump (7 lbs) is standard for use with the #6 Power Heads. The.7 horsepower pump (63 lbs.) is required for use with the #8 Power Heads. These pumps are designed to dump the hydraulic fluid immediately back into the tank. They do not hold. They also employ universal motor designs. As such, they draw low amperage (9.5 or 5) and operate sufficiently from most generators. For SAFETY, the power supply is stepped down at the pump, placing only 4-volts in the operator s hand. DO NOT ATTEMPT ANY ADJUSTMENTS ON THE HYDRAULIC PUMP, INCLUDING THE RELIEF VALVE. In extreme heat or extremely heavy and repetitive use, the pump may protect itself by shutting down. Unplug the pump and allow it to sit for 0 minutes. You may also move the pump in to some shade, place a fan directly on to the pump, or other suggestions that may keep it cool. The Enerpac Pump Manual for the 8-Pump (Enerpac ZU-4) describes many operating options. As many of these options are not necessary for the safe operation of the EZE BEND SYSTEM, they are not included on your pump. By excluding these features, you have realized a dramatic cost savings on your #8 system. Please note additional warnings listed in PRECAUTIONS above.

8 #6-CUTTER PARTS LIST CYLINDER ASSEMBLY BODY HOUSING HANDLE PLATE CYLINDER PISTON GAUGE BLOCK SHCS /4-0 X CYLINDER RETURN SPRING CYLINDER SEAL KIT CYLINDER HOUSING GAUGE BLOCK SPRING SHOULDER BOLT 3/8 X 3/4 CUTTING BLOCKS SHCS /4-0 X SET SCREW 5/6 X /4 NF SHOCK ABSORBER HANDLE ELECTRICAL CONNECTOR, FEMALE GRIP BUTTON ASSEMBLY HYDRAULIC CONNECTOR, FEMALE "EZE BEND" DECAL $ $ $0.00 $3.00 $60.00 $0.00 $3.00 $.50 $60.00/$0.00 $.00/$4.00 $.50

9 #8-CUTTER PARTS LIST USE THE 6-CUTTER DIAGRAM TO HELP DETERMINE PARTS FOR THE 8- CUTTER. REPLACE THE 000 SERIES PART NUMBERS WITH THE 400 SERIES NUMBERS AS SHOWN. August 5, 005 Supercedes all previously published lists CYLINDER ASSEMBLY BODY HOUSING HANDLE PLATE CYLINDER PISTON GAUGE BLOCK SHCS /4-0 X CYLINDER RETURN SPRING CYLINDER SEAL KIT CYLINDER HOUSING GAUGE BLOCK SPRING SHOULDER BOLT 3/8 X 3/4 CUTTING BLOCKS SHCS /4-0 X SET SCREW 5/6 X /4 NF SHOCK ABSORBER HANDLE ELECTRICAL CONNECTOR, FEM. GRIP BUTTON ASSEMBLY HYDRAULIC CONNECTOR, FEM. "EZE BEND" DECAL $ $ $35.00 $0.00 $3.00 $0.00 $75.00 $ $3.00 $.50 /$80.00 $.00/$4.00 $.50

10 #6-BENDER PARTS LIST August 5, 005 Supercedes all previously published lists SHCS /4-0 X ROLLERS BUSHINGS HANDLE ELECTRICAL CONNECTOR, FEMALE GRIP BUTTON ASSEMBLY HYDRAULIC 90 DEGREE ELBOW HYDRAULIC CONNECTOR, FEMALE "EZE BEND" DECAL CYLINDER ASSEMBLY HANDLE PLATE FRONT BLOCK TOP PLATE BOTTOM PLATE HHCS 5/6 8 X / CRADLE HHCS / 3 X / LOCK HEX NUT / X 3 CYLINDER PISTON CYLINDER HOUSING CYLINDER RETURN SPRING CYLINDER SEAL KIT $3.00 $35.00/$70.00 $30.00/$60.00 $40.00 $ $0.00 $95.00 $.50 $.00/$8.00 $. 75/$3.00 $30.00 $35.00 $75.00

11 #8-PULL BENDER PARTS LIST USE THE 6-PULL BENDER DIAGRAM TO HELP DETERMINE PARTS FOR THE 8-PULL BENDER. REPLACE THE 00 SERIES PART NUMBERS WITH THE 500 SERIES NUMBERS. August 5, 005 Supercedes all previously published lists SHCS /4-0 X ROLLERS BUSHINGS HANDLE ELECTRICAL CONNECTOR, FEM. GRIP BUTTON ASSEMBLY HYDRAULIC 90 DEGREE ELBOW HYDRAULIC CONNECTOR, FEMALE "EZE BEND" DECAL CYLINDER ASSEMBLY HANDLE PLATE FRONT BLOCK TOP PLATE BOTTOM PLATE HHCS 5/6 8 X / CRADLE HHCS 5/8 X 3 / LOCK HEX NUT / X 3 $3.00 $35.00/$70.00 $30.00/$60.00 $40.00 $ $35.00 $0.00 $75.00 $75.00 $.50 $70.00 $.50/0.00 $.75/$3.00

12 PUMPS AND HOSE ASSEMBLIES PARTS LIST August 5, 005 Supercedes all previously published lists HYDRAULIC PUMP PARTS EZE BEND, INCORPORATED HAS INSTALLED SPECIFIC ELECTRICAL AND HYDRAULIC CONNECTORS ON THE HYDRAULIC PUMPS. ALL OTHER PUMP COMPONENTS ARE ENERPAC ORIGINAL EQUIPMENT. 0-P HYDRAULIC PUMP ELECTRICAL CONNECTOR HYDRAULIC CONNECTOR, FEMALE $95.00 HOSE ASSEMBLY PARTS THE HOSE ASSEMBLY CONSISTS OF COMPONENTS THAT MAY BE DIFFICULT TO INSTALL. THE PROCESS OF ORIGINAL MANUFACTURING ALLOWS THESE COMPONENTS TO BE INCORPORATED FT. HYDRAULIC HOSE 5 FT. ELECTRICAL WIRE 5 FT. PROTECTION SLEEVE $0.00 $ FT. HYDRAULIC HOSE 0 FT. ELECTRICAL WIRE 0 FT. PROTECTION SLEEVE $ HYDRAULIC CONNECTOR, MALE, W/HEAT SHRINK ELECTRICAL CONNECTOR, MALE, W/HEAT SHRINK BAND-IT, LINE RETAINER $40.00/$80.00 $60.00/$0.00 $.00/$4.00

Operating, Servicing, and Safety Manual Model # Hydraulic Bender

Operating, Servicing, and Safety Manual Model # 900 90 Hydraulic Bender CAUTION: Read and Understand These Operating, Servicing, and Safety Instructions, Before Using This Machine. 1-800-467-2464 10 Cooperative