HIKOKI BENDOF DC-16MV User manual

DC-16MV
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Instruction manual
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OPERATING/SAFETY ORIGINAL INSTRUCTIONS
DC16MV
CORDLESS REBAR CUTTER
TO REDUCE THE RISK OF INJURY,YOU MUST READ AND
UNDERSTAND THESE INSTRUCTIONS

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CE DECLARATION OF CONFORMITY
We declare under our sole responsibility that these products are in conformity
with the following standards or standardized documents EN62841-1,
EN55014-1 and EN55014-2 in accordance with Council Directives 2006/42EC
and 2004/108/EC.
Model: DCC-1636HR/DC16MV
Beskrivning: Cordless Rebar Cutter
Noise Information
The measured values were determined according to EN62841-1.
Measured A-weighted sound pressure level: 87.6 dB(A)
Measured A-weighted sound power level: 76.6 dB(A)
Uncertainty KpA: 1.971 dB(A)
1st October, 2019
IKK Co., Ltd.
396-59 Ashitaka, Numazu City,
Shizuoka Pref. 410-0001 Japan

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WARNING!
TO AVOID SEVERE PERSONAL INJURY OR PROPERTY DAMAGE, READ
THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO USE THE
CUTTERS.
Ignorance of proper operating procedures can lead to accidents.
If in doubt about any procedure, contact your nearest authorized agent.
CONTENTS
Page
GENERAL SAFETY RULES................................................. 6
PARTS NAMES.................................................................... 9
SPECIFICATIONS.............................................................. 10
OPERATING INSTRUCTIONS............................................ 10
BASIC CUTTING INSTRUCTIONS..................................... 10
PRE-USE CHECKS............................................................ 10
CAUTION ON LI-ION BATTERY......................................... 11
BATTERY REMOVAL/INSTALLATION................................. 11
CHARGING........................................................................ 12
WARM-UP........................................................................... 15
STOPPER BOLT ADJUSTMENT......................................... 15
CUTTING........................................................................... 16
RELEASE VALVE................................................................ 16
POINTS OF ATTENTION.................................................... 16
MAINTENANCE.................................................................. 17
CUTTER BLOCKS............................................................... 17
CLEANING.......................................................................... 17
OIL-LEVEL CHECK (ADDING OIL)..................................... 17
OIL CHANGE...................................................................... 18
BOLT TIGHTNESS............................................................... 18
OVERHAUL......................................................................... 18
THESE TOOLS ARE FOR INDUSTRIAL USE ONLY.
*Specifications are subject to change without prior notice.

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GENERAL SAFETY RULES
WARNING: REARD AND UNDERSTAND ALL INSTRUCTIONS.
Failure 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 (cord-
less) power tool.
WORK AREA SAFETY
- Keep work area clean and well lit. Cluttered or dark areas invite accidents.
- Do not operate power tools in explosive atmospheres, such as in the pre-
sence of flammable liquids, gases or dust. Power tools create sparks which
may ignite the dust or fumes.
- Keep children and bystanders away while operating a power tool. Distra-
ctions can cause you to lose control.
ELECTRICAL SAFETY
- Power tools 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,
radiators, ranges and refrigerators. There is an 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 tools will increase the risk of electric shock.
- Do not abuse the cord. Never use the cord for carrying, pulling or unplug-
ging 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
for outdoor use. Use of a cord suitable for outdoor use reduces the risk of
electric shock.
- Do not use AC only rated tools with a DC power supply.
PERSONAL SAFETY
- Stay alert, watch what you are doing and use common sense when opera-
ting a power tool. Do not use a power tool while you are tired or under the
influence of drugs, alcohol or medication. A moment of inattention while
operating power tools may result in serious personal injury.
- Use safety equipment. Always wear eye protection. Safety equipment such
as protection goggles, dust mask, non-skid safety shoes, hard hat, or hea-
ring protection used for appropriate conditions will reduce personal injuries.
-Avoid accidental starting. Ensure the switch is in the off-position before
plugging in. Carrying power tools with your finger on the switch or plug-
ging in power tools that have the switch on invites accidents.

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- Remove any adjusting key or wrench before turning the power tool on. A
wrench or a key left attached to a rotating part of the power tool may result
in personal injury.
- Do not overreach. Keep proper footing and balance at all times. This ena-
bles better control of the power tool in unexpected situations.
- Dress properly. Do not wear loose clothing or jewelry. Keep your hair,
clothing and gloves away from moving parts. Loose clothes, jewelry or
long hair can be caught in moving parts.
- If devices are provided for the connection of dust extraction and collec-
tion facilities, ensure these are connected and properly used. Use of these
devices can reduce dust-related hazards.
- Keep handles dry, clean and free from oil and grease. Slippery hands can
not safely control the power tool.
POWER TOOL USE AND CARE
- Do not force the power tool. Use the correct power tools for your applica-
tion. The correct power tool will do the job better and safer at the rate for
which it was designed.
- Do not use the power tool if the switch does not turn on and off. Any power
tool that cannot be controlled with the switch is dangerous and must be
repaired.
- Disconnect the plug from the power source and/or the battery pack from the
power tool before making any adjustments, changing accessories, or sto-
ring power tools. Such preventive safety measures reduce the risk of star-
ting the power tool accidentally.
- Do not cover the power tool’s air vents nor operate the tool on dirt. Use a
plywood base under the tool to keep armature and fan clean. If the vents are
covered, the motor will overheat and may burn out.
- Store idle power tools out of the reach of children and do not allow persons
unfamiliar with the power tool or these instructions to operate the power tool.
Power tools are dangerous in the hands of untrained users.
- Maintain power tools. Check for misalignment or binding of moving parts,
breakage of parts and any other condition that may affect the power tool’s
operation. If damaged, have the power tool repaired before use. Many acci-
dents are caused by poorly maintained power tools.
- Keep cutting tools sharp and clean. Properly maintained cutting tools with
sharp cutting edges are less likely to bind and are easier to control.
- Use the power tool, accessories and tool bits etc., in accordance with these
instructions and in the manner intended for the particular type of power tool,
taking into account the working conditions and the work to be performed.
Use of the power tool for operations different from those intended could
result in a hazardous situation.

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BATTERY TOOL USE AND CARE
- Recharge only with the charger specified by the manufacture. A charger
that is suitable for one type of battery pack may create a risk of fire when
used with another battery pack.
- Use power tools only with specifically designated battery packs. Use of any
other battery packs may create a risk of injury and fire.
- When battery pack is not in use, keep it away from other metal objects, like
paperclips, coins, keys, nails, screws or other small metal objects, that can
make a connection from one terminal to another. Shorting the battery termi-
nals together may cause burns or a fire.
- Under abusive conditions, liquid may be ejected from the battery; avoid
contact. If contact accidentally occurs, flush with water. If liquid contacts
eyes, additionally seek medical help. Liquid ejected from the battery may
cause irritation or burns.
- Do not use a battery pack or tool that is damaged or modified. Damaged or
modified batteries may exhibit unpredictable behavior resulting in fire,
explosion or risk of injury.
- Do not expose a battery pack or tool to fire or excessive temperature. Expo-
sure to fire or temperature above 130°C may cause explosion.
- Follow all charging instructions and do not charge the battery pack or tool
outside the temperature range specified in the instructions. Charging impr-
operly or at temperatures outside the specified range may damage the bat-
tery and increase the risk of fire.
SERVICE
- Have your power tool serviced by a qualified repair person using only iden-
tical replacement parts. This will ensure that the safety of the power tool is
maintained.
- Never service damaged battery packs. Service of battery packs should
only be performed by the manufacturer or authorized service providers.
SPECIFIC SAFETY RULES
- Hold power tool by insulated gripping surfaces when performing an
operation where the cutting tool may contact hidden wiring or its own cord.
Contact with a “live” wire will make exposed metal parts of the tool “live” and
shock the operator.
- Use clamps or other practical ways to secure and support the workpiece to
a stable platform. Holding the work by hand or against your body is unstable
and may lead to loss of control.
- Keep hands away from the cutting area and moving parts.
- Do not use dull or damaged blades. Damaged part(s) can break easily or
could cause injury.
- Maintain labels and nameplates.

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PARTS NAMES
360° Rotatable between pump, case and motor
1. Housing 2. Cutter blocks 3. Trigger switch
4. Oil-plug 5. Handle mouth 6. Motor
7. Pump case 8. Release valve 9. Battery
10. Charger 11. Handle (detachable)
10 9
6
3
8
4
7
2
1
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SPECIFICATIONS
Model DC16MV
Cutting capacity Up to16mm (5/8”) diameter
Cutting speed ≥ 2.4 sec. (16mm)
Max. Rebar hardness Tensile strength 560N/mm2
Power Supply Rechargeable battery
Voltage DC36V
Dimensions (LxWxH) 340x92x264 mm (without handle)
Weight 5,8 kg (including battery)
Battery & Charger (HiKOKI)
Battery (Li-ion Multi Volt) BSL36A18 : DC36V-2.5Ah / 18V-5.0Ah
Charger UC18YSL3
Charging Time Approx. 32 min.
OPERATING INSTRUCTIONS
BASIC CUTTING INSTRUCTIONS
Important: Always read, understand and obey the safety instructions included
with your new Cordless Rebar Cutters before operating. Use Rebar Cutters on
concrete reinforcing bars only. These tools are not to be used in cutting other
kinds of metal or materials. Do not cut ungraded rebar.
WARNING: There is always a chance that the cut end may shoot out, especi-
ally if less than 30 cm in length. Exceeding designated material specifications
will greatly increase this risk and will also damage the tool. Do not attempt to
cut rebar harder, thicker or thinner than specified for the specific tool.
DO NOT CUT SHORT PIECES: Be especially careful when cutting off short
lengths (30 cm or less) as the cut end tends to fly out.
PRE-USE CHECKS
1. WARNING: Do not expose the tool to rain or wet conditions. Water entering
a power tools will increase the risk of electric shock.
2. WARNING: Wear safety goggles, safety glasses with side shields or a face
shield when using these tools.
3. Check that the power source is appropriate to the tool.
CARE: If voltage is too high, the motor will burn out. If voltage is too low,
insufficient power will be generated. Use rechargeable battery 18V.

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4. WARNING: Avoid accidental starting. Ensure the switch is in the off-
position before battery attached.
5. Note that battery must be charged before initial use (see p.12 CHARGING).
6. Check and keep work area clean and enough work space.
7. Check condition of cutter blocks and tightness of cutter block bolts.
CHECK FOR CRACKS OR DAMAGE, LOOSEN BOLTS
8. 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 bolts and rotate both blocks so that two
new edges come into use. Replace and tighten bolts (Each block has four
cutting edges). When all four cutting edges have been used or if either
block is cracked or otherwise damaged, replace both blocks.
CAUTION: A loose or cracked block may result in injury to operator.
CAUTION ON LITHIUM-ION BATTERY
To extend the lifetime, lithium-ion battery equips with the protection to stop the
output. In the case of 1 to 3 described below, when using the tools, even if you
are pulling switch, the motor may stop. This is not the trouble but the result of
protection function.
1. When the battery power remaining runs out, the motor stops. In such case,
charge it up immediately.
2. If the tool is overloaded, the motor may stop. In this case, release the
switch of the tool and eliminate causes of overloading. After that, you can
use it again.
3. If the battery is overheated under overloaded work, the battery power may
stop. In this case, stop using the battery and let the battery cool. After that,
you can use it again.
4. Never short-circuit the battery.
Furthermore, please heed the following warning and caution.
BATTERY REMOVAL/INSTALLATION
1. Battery removal
Hold the handle tightly and push the battery latches to remove the battery.
2. Battery installation
Insert the battery while observing its polarities.

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CHARGING (Charger: UC18YSL3)
Before using the tool, charge the battery as follows.
1. Connect the charger’s power cord to a receptacle. When the power cord
is connected, the charger’s pilot lamp will blink in red (At 1-second inter-
vals).
2. Firmly insert the battery into the charger.
3. When inserting a battery in the charger, the charge indicator lamp will blink
in blue.
When the battery becomes fully recharged, the charge indicator lamp will
light up in green.
(1) Charge indicator lamp indication
The indications of the charge indicator lamp will be as shown in table
below, according to the condition of the charger or the rechargeable bat-
tery.

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Indications of the charge indicator lamp
Charge
indica-
tor lamp
(RED/
BLUE/
GREEN/
PUR-
PLE)
Before
charging
Blinks
(RED)
Lights for 0,5 seconds. Does not
light for 0,5 sec. (Off for 0,5 sec.)
Plugged
into power
source
While
charging
Blinks
(BLUE)
Lights for 0,5 seconds. Does not
light for 1 sec. (Off for 1 sec.)
Battery
capacity at
less than
50%
Blinks
(BLUE)
Lights for 1 second. Does not
light for 0,5 sec. (Off for 0,5 sec.)
Battery
capacity at
less than
80%
Lights
(BLUE)
Lights continuously Battery
capacity at
more than
80%
Charging
complete
Lights
(GREEN)
Lights continuously
(Continuous buzzer sound:
about 6 seconds)
Overheat
standby
Blinks
(RED)
Lights for 0,3 seconds. Does not
light for 0,3 sec. (Off for 0,3 sec.)
Battery
overheated.
Unable to
charge.
(Charging
will com-
mence when
battery
cools.)
Charging
impossible
Flickers
(PURPLE)
Lights for 0,1 seconds. Does not
light for 0,1 sec. (Off for 0,1 sec.)
(Intermittent buzzer sound:
about 2 seconds)
Malfunction
in the bat-
tery or the
charger
(2) Regarding the temperatures of the rechargeable battery.
The temperatures for rechargeable batteries are between 0°C ~ 50°C,
and batteries that have become hot should be cooled for a while before
being recharged.
(3) Recharging time (At 20°C)

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Approx. 32 minutes (BSL36A18), but the charging time may vary according
to the ambient temperature.
4. Disconnect the charger’s power cord from the receptacle.
5. Hold the charger firmly and pull out the battery.
NOTE: After operation, pull out batteries from the charger first, and then
keep the batteries properly.
6. About remaining battery indicator
When pressing the remaining battery indicator switch to light the indica-
tor lamp, the indicator will shut off approximately 3 seconds. It is best to use
the remaining battery indicator as a guide since there are slight differences
such as ambient temperature and the condition of the battery.
State of lamp Battery Remaining Power
Lights:
The battery remaining power
is over 75%.
Lights:
The battery remaining power
is 50-75%.
Lights:
The battery remaining power
is 25-50%.
Lights:
The battery remaining power
is less than 25%.
Blinks:
The battery remaining power
is nearly empty. Recharge the
battery soonest possible.
Blinks:
Output suspended due to
high temperature. Remove
the battery from the tool and
allow it to fully cool down.
Blinks:
Output suspended due to
failure or malfunction. The
problem may be the battery,
please contact your dealer.

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7. How to use the LED light
While the switch is pulled, the LED light will automatically light up the tip
portion of the tool. The LED light will automatically turn off 10 seconds after
the switch is released. The LED light also functions as a warning signal that
lights up during use.
WARM-UP
If in cold weather, you should warm up the tool for 30-60 seconds so that the
hydraulic oil reaches the proper viscosity. Pull trigger-switch (ON) to extend
piston then release the switch (OFF) when it has reached its full stroke. Repeat
5-7 times without rebar.
STOPPER BOLT ADJUSTMENT
The adjustable stopper functions to maintain the rebar in the correct position
during cutting and must be properly set for each size of rebar before making a
cut. Screw in the stopper to provide sufficient clearance for the rebar. Keeping
rebar at right angles (90 degrees) to front cutter block, screw out the stopper
until it is just touching the rebar. Once set, the stopper needs no further
adjustment while cutting rebar of the same diameter, but must be reset for a
different size rebar.
Safeguard
Function
LED Light Display Corrective Action
Overburden
Protection
On 0,1 second/off 0,1 second If the operating with the shift
knob set on HIGH, adjust to
LOW and continue operation.
Remove the cause of the over-
burdening.
Reactive Force
Control
Remove the cause of the over-
burdening. When operating
the tool, firmly hold the tool to
make sure it doesn’t jerk.
Temperature
Protection
On 0,5 second/off 0,5 second Allow the tool and battery
thoroughly cool.

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WARNING: Failure to correctly set the
stopper will result in excessive wear of
cutter blocks and may cause cut end
to fly out.
CUTTING
1. Insert rebar between stopper bolt and front cutter block, making sure
that it is properly seated in U-shaped support. Keeping rebar at right angles
(90 degrees) to front cutter block.
2. WARNING: Flying ends are a hazard to all personnel in the vicinity. Erect
safety screens.
3. Pull trigger-switch and keep depressed while piston advances and
rebar is cut (If the switch is released at an intermediate point, the piston
will stop).
4. When cut is completed, release the switch. The piston retracts
automatically (Note that the switch cannot be re-activated until the piston
has fully retracted).
RELEASE VALVE
In the event that piston should fail to return
automatically for any reason (e.g. the piston
has become jammed by some reasons), use
4 mm hexagon key provided to slightly loosen
release valve. Make sure to tighten the release
valve before making the next cut.
POINTS OF ATTENTION
1. Be especially careful when cutting off short lengths (30cm or less) as the
cut end tends to fly out.
WARNING: Flying ends are a hazard to all personnel in the vicinity. Erect
safety screens.
2. Do not cover air vents.
CARE: If vents are covered, motor will overheat and may burn out.
3. If hydraulic oil exceeds 70 degrees C (158 degrees F) in temperature,
power will drop. Allow the tool to cool before resuming operation. Be
particularly careful in summer when the aluminum pump case heats up
quicker.
4. If a drop in power is observed and motor is unusually hot, check battery.
5. If piston should ever fail to retract completely, push rear cutter block
backwards to manually retract piston or check under piston to remove any
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. Once
piston has been retracted, pull trigger-switch long enough to partially
Release value

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advance the piston. Disconnect battery. Check piston and housing for
accumulated dirt and iron filings that may be jamming the piston (See p.17
CLEANING). If, after cleaning, the piston still does not automatically retract
when fully extended, the piston itself may be damaged. Return the tool to
an authorized repair center.
6. Check that power source is appropriate to the tool.
CARE: If voltage is too high, the motor will burn out. If voltage is too low,
insufficient power will be generated. Use rechargeable battery 36V.
MAINTENANCE
WARNING: DISCONNECT BATTERY before performing any maintenance.
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 bolts and rotate both blocks
so that two new edges come into use. Replace and
tighten bolts (Each block has four cutting edges). When
all four cutting edges have been used or if either block
is cracked or otherwise damaged, replace both blocks.
CAUTION: A loose or cracked block may result in injury to operator.
CLEANING
Clean your tool every day, preferably immediately 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. Wipe or brush away all dirt and metal
filings.
OIL-LEVEL CHECK (ADDING OIL)
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 in a drop in pressure and loss of cutting power.
CAUTION: Hydraulic oil is highly flammable. Keep away from sparks and
naked flame. Do not smoke. Hydraulic oil may cause inflammation of the eyes
and skin. If ingested, it could cause diarrhea and vomiting. In case of eye
contact, rinse in clean water for at least 15 minutes and consult a physician. 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 the tool if it is cold.

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2. If piston is still moving, pinch a piece of rebar, stopping just before it
breaks off (It is a 1/2 movement of piston).
3. Disconnect battery and place the tool so that the oil-plug is uppermost.
4. Remove oil-plug and seal washer (packing).
CAUTION: Never remove oil-plug when the tool is hot or oil will spurt out.
5. Check that oil is level with bottom of plug hole (i.e. that pump case is full
to the brim). If oil level is too low, top up with fresh hydraulic oil with anti
foam and anti-abrasion properties (ISO viscosity grade VG32, e.g. Tellus
32 (Shell), DTE-24 (Mobil) or Uni-Power VG32 (Esso).
6. After topping up, extract air from the system. Gently tilt the tool lengthwise
and return it to a level position. Top up again and tilt in the opposite
direction. Repeat this process until all air has been extracted.
CARE: Tool cannot function properly if oil contains air bubbles.
7. Replace seal washer (packing) and oil-plug. The operation is now complete.
OIL CHANGE
The hydraulic oil should be changed at least once a year, sooner if it appears
dirty.
NOTE: Hydraulic oil should be warm before draining.
1. Disconnect battery. Remove oil-plug and seal washer (packing). Turn the
tool over and drain oil into a suitable receptacle. When oil ceases to
drain out, tilt the tool to rear so that oil trapped in piston housing can run out.
When housing is empty, tilt the tool in the opposite direction to empty the
residue in pump case.
2. With drain-hole uppermost, slowly fill the tool with fresh oil. Replace plug
and lightly tighten. Connect battery and advance piston two or three times.
Disconnect battery and remove oil-plug. Top up oil level and replace oil-
plug.
3. Finally, follow procedure for OIL-LEVEL CHECK (Steps 2-6)
NOTE: Dispose of hydraulic oil in accordance with local regulations. Do not
pour into the sea, a river, a lake of drains.
BOLT TIGHTENESS
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. Always make sure that the bolts holding both cutter blocks are also
tight.
OVERHAUL
Return the tool to an authorized distributor for overhaul at least once every two
years, sooner if subject to heavy use.