BN Products DBD Series User manual

DBD-25X Bender ManualB | Page 1
Tool Manual
DBD-Series 0-180 degree Rebar Benders
BN Products-USA, LLC.
3450 Sabin Brown Road
Wickenburg, AZ 85390
[phone] • [phone]
FAX: [phone]
[e-mail] • www.bnrebartools.com
DBD-25X
PORTABLE REBAR BENDER
Updated: October 12, 2017

DBD-25X Bender ManualB | Page 2
NOTE: When using electric tools, basic safety
precautions should always be followed to
reduce the risk of electric shock and personal
injury, including the followings items:
READ ALL INSTRUCTIONS AND SAVE
THEM FOR FURTURE REFERENCE
1. Keep hands away. From all moving parts and rollers
while operating.
2. Dress properly. Loose clothing or jewelry can get
caught in moving parts. Wear sturdy boots with non-
skid soles. Steel toed boots and safety glasses are recom-
mended.
3. Keep children and bystanders away. Distractions can
cause you to lose control.
4. Do not overreach. Keep proper footing and balance at
all times. is enables better control of the power tool in
unexpected situations.
5. Stay alert. Watch what you are doing and use common
sense when operating a power tool. Do not use a power
tool while you are tired or under the inuence of drugs
or alcohol. A moment of inattention while operating
power tools may result in serious personal injury.
6. Do not exceed the maximum number of bars that can
be bent at one time. Please refer to specications.
7. When positioning the bar between rollers, make sure to
lay it at on the machine surface. Failure to do so may
cause the rebar to y out.
8. Do not expose tool to rain or use in damp locations..
Do not use tool in presence of ammable liquids or
gases. Keep work area well lit. If the tool is used out-
doors, keep it covered when not in use and protect it
from rain or water.
9. Do not try to bend materials harder than “Grade 60
or 600N/mm2” as they will either crack and y out or
cause machine failure.
10. Disconnect tool from receptacle when not in use. Dis-
connect when servicing or changing rollers to prevent
accidents.
11. Keep tool clean at all times for best and safest perfor-
mance. Follow instructions for lubricating and chang-
ing parts. Keep hands dry and free of oil or grease.
Inspect switches, tool cords periodically and have them
repaired or replaced by an authorized service center
if damaged. Check moving parts for alignment and
binding as well as for breakage and improper mounting.
Damaged parts should be repaired or replaced by an
authorized service facility unless otherwise indicated in
this instruction book.
DBD-25X Portable Rebar Bender
1. Moving bending roller
2. Center roller
3. Adjustable stopper
4. Main switch
5. Pilot lamp
6. Operation button On/O
7. Angle setter (lever type) 2-stops
8. Angle stopper (two)
9. Emergency stop button
10. Plug-in for foot switch
11. Roller set
12. Foot Operated Switch

DBD-25X Bender ManualB | Page 3
SPECIFICATIONS
Model DBD-25X
Max. Bending Capacity 7/8” (#7) (22 mm) Grade 60 Rebar
Bending Angle 0-180°
Bending Speed 6 seconds for 180° bend
Electric Power Supply 115 Volts, 50/60Hz, 12 amps
Dimensions L x W x H
(mm)
16.4” x 18” x 16.2”
(420) x (462) x (415)
Weight (Kg) 190 lbs. (86 kg)
DBD-25X Rebar Bender Roller Selection Chart
Recommended Bending Roller Selection Chart for DBD-25X Bender on Standard Hook Details
Combination of Center Roller and Moving Roller according to the bar size:
Bar Diameter Size
Max. Grade 60
Center Roller
#
Center Roller
Outside Diameter
CRSI Recommended
Inside Bend Diameter
Moving
Roller
No. of bars that can
be bent at one time
7/8” (22mm) #7 No. 5 4.75” (120mm) 5.25” (134mm) No. 1 1 -Piece
3/4” (19mm) #6 No. 5 4.75” (120mm) 4.50” (115mm) No. 1 2 -Pieces
5/8” (16mm) #5 No. 4 3.75” (96mm) 3.75” (96mm) No. 3** 2 -Pieces
1/2” (13mm) #4 No. 3 3.12” (79mm) 3.00” (76mm) No. 5 3 -Pieces
3/8” (10mm) #3 No. 1 1.95” (50mm) 2.25” (57mm) No. 6 4 -Pieces
** Use a second No. 4 Roller on moving roller to produce a complete 180° Bend.
Recommended Bending Roller Selection Chart for DBD-25X Bender on Stirrup Hooks
Combination of Center Roller and Moving Roller according to the bar size:
Bar Diameter Size
Max. Grade 60
Center Roller # Center Roller Out-
side Diameter
CRSI Recommended
Inside Bend Diameter
Moving
Roller
No. of bars that can
be bent at one time
5/8” (16mm) #5 No. 1 1.95” (50mm) 2.50” (51mm) No. 6 2 -Pieces
1/2” (13mm) #4 No. 1 1.95” (50mm) 2.00” (51mm) No. 6 3 -Pieces
3/8” (10mm) #3 ** 1.63” (42mm) 1.50” (38mm) No. 6 4 -Pieces
** Use roller sha only with no roller.
Bending Roller Sizes for DBD-25X Bender Only
Part Number -Roller Number Outside Diameter
#1BR5140 -No. 1 1.95” (50mm)
#1BR5142 -No. 2 2.73” (70mm)
#1BR 5143 -No. 3 3.12” (79mm)
#1BR51441 -No. 4 3.75” (96mm)
#1BR51451 -No. 5 4.75” (120mm)
#1BR5146 -No. 6 6.13” (156mm)

DBD-25X Bender ManualB | Page 4
WARNING:
ALWAYS UNPLUG THIS TOOL
BEFORE ATTACHING OR
REMOVING ROLLERS OR
ACCESSORIES.
1. Select and set the correct rollers for the bars to be
bent. See the table above.
2. Plug the electrical power cord into an appropriate
outlet.
3. Lay the bar on the machine surface between the
center roller and bending roller. Adjust the stopper
so that the bar is parallel to the front edge of the
machine.
4. Turn the main switch on and check that the pilot
lamp has lit up.
5. Set the angle and make a test bend. If the bent
angle is not exact, adjust the angle setter slightly
to the right or le. Lock in the angle stoppers to
duplicate the same angle each time.
6. Push the operation button or foot switch. e mov-
ing bending roller will automatically return to the
start position once the bend has been completed.
7. If it is necessary to stop the machine in an emer-
gency, push the emergency stop button or release
your foot from the foot operated switch. e
bending roller will return to the start position
automatically.
BENDING ANGLES
CAN BE PRESET
1. Set the angle setter to 135° then tighten the right
angle stopper to lock the 135° position.
2. Set the angle setter to 90° then tighten the le angle
stopper to lock the 90° position.
3. Set the angle setter to 135°. Push the operation but-
ton to make your rst bend.
4. Slide the rebar to the desired length and set the
angle setter to 90°. Push the operation button to
complete your second bend.
For stirrups, cut your rebar to the desired length before
bending. en make both bends for your turndowns.
Finally make your (3) 90° bends to connect your ends
together. See below.
WARNING: Never touch any moving parts or roll-
ers while the rebar bender is being operated.

DBD-25X Bender ManualB | Page 5
INSPECTION AND MAINTENANCE
WARNING: ALWAYS UNPLUG TOOL BEFORE PERFORMING MAINTENANCE.
DO NOT USE PARTS OR ACCESSORIES THAT ARE NOT
GENUINE DIAMOND BRAND from BN Products-USA
1. At least once a month remove the bottom plate and grease all the visible gears and pinions. At the
same time, check the carbon brushes for wear or damage. Replace with new brushes if they are
worn out.
2. Check that there are no loose nuts and bolts before starting the operation.
3. Aer operation is completed, be sure to remove metal dust, dirt, oil, etc… adhering to the ma-
chine surface.
4. In order to empty the metal dust from the bender, (remove side cover DBD-25X and DBD-32X
models) then tilt the machine to one side allowing the debris to fall out of the catch pan. Be sure
to blow out any remaining dirt and dust with compressed air prior to using the tool again (wear
safety goggles to block blowing debris).
1C1961A Carbon Brush

DBD-25X Bender ManualB | Page 6
No. Part No. Part Name Qty
1 1BR5001 GEAR CASE M 1
2 1BR5002 GEAR CASE C 1
3 1BR5206 GEAR CASE PACKING 1
4 7CB06045 CAP BOLT M6X45 2
5 7SW006 SPRING WASHER M6 2
6 7B08050 BOLT M8X50 3
7 7SW008 SPRING WASHER M8 4
8 7PW008 PLATE WASHER M8 1
9 7B08025 BOLT M8X25 1
10 7N008 NUT M8 1
11 7B10100 BOLT M10X100 4
12 7PW010 PLATE WASHER M10 4
13 7SW010 SPRING WASHER M10 4
14 7N010 NUT M10 4
15 7B12020 BOLT M12X20 1
16 7WF12 SEAL WASHER WF12 1
No. Part No. Part Name Qty
17 1BR5023 HELICAL GEAR 1
18 1BR5025 PINION NO.1 1
19 1BR5024 HELICAL GEAR KEY 2
20 1BR5009 NEEDLE BEARING TA1212 1
21 1BR5003 BEARING 6202V, 6202ZZ 4
22 1BR5026 GEAR NO.1 1
23 1BR5027 PINION NO.2 1
24 1BR5028 GEAR NO.2 1
25 1BR5029 PINION NO.3 1
26 1BR5030 PINION KEY 7X7X20 1
27 1BR5004 BALL BEARING 6204 2
28 1BR5006 BALL BEARING 6005 1
29 1BR5015 OIL SEAL SC22-32-7 1
30 1BR5008 BALL BEARING 6009Z 1
31 1BR5016 OIL SEAL SC45-62-9 1
32 1BR5010 NEEDLE BEARING
TA223020
1

DBD-25X Bender ManualB | Page 7
No. Part No. Part Name Qty
33 1BR5011 CIRCLIP AR-30 1
34 1BR5038 7TMF1342 CLUTCH ASS’Y 1
35 1BR5043 SHIM 1
36 1BR5038D CLUTCH ARMATURE
FLANGE
1
37 1BR5007 BEARING 6007ZZ 1
38 1BR5031 BEARING NUT 1
39 1BR5032 BEARING WASHER 1
40 1BR5033 GEAR NO.3 1
41 1BR5035 SHAFT 1
42 1BR5034 GEAR NO.3 KEY 1
43 1BR5036 PINION NO.4 1
44 1BR5037 PINION KEY 1
45 1BR5017 OIL SEAL SC30-45-8 1
46 1BR5047 FLANGE UNIT UCFL205 1
47 7B14028 BOLT M14X28 2
48 7SW014 SPRING WASHER M14 2
49 1BR5012C ARMATURE 1
50 1BR6200ZZ BALL BEARING 6200ZZ 1
51 1BR5012B STATOR COIL 1
52 1BR5012D MOTOR HOUSING 1
53 1BR5012H BRUSH CAP 2
54 1BR5012A CARBON BRUSH SET 1
55 1BR5012E CARBON BRUSH HOLDER 2
56 1BR5048 MOTOR COVER 1
57 7B08015 BOLT M8X15 WITH
WASHER
1
58 7CB06050 CAP BOLT M6X50 2
59 7CB06070 CAP BOLT M6X70 2
60 7SW006 SPRING WASHER M6 4
61 1BR5044 CLUTCH COVER 2
62 7PB06008 PAN HEAD BOLT M6X8
W/WASHER
4
63 1BR50501A FRAME 1
64 1BR50511 BASE 1
65 7CB10020 CAP BOLT M10X20 6
66 1BR5133 DAMPER 1
67 7SW010 SPRING WASHER M10 1
68 7N010 NUT M10 1
69 1BR5063 ADJUSTABLE STOPPER 1
70 1BR5064 ADJUSTABLE NUT 1
No. Part No. Part Name Qty
71 1BR5065 ADJUSTABLE HANDLE 1
72 1BR5066 SPRING PIN Φ5X8 2
73 1BR5055 SIDE COVER 2
74 7PB06008 PAN HEAD BOLT M6X8 8
75 7SW006 SPRING WASHER M6 8
76 7PW006 PLATE WASHER M6 8
77 1BR7120 DUST COVER 1
78 1BR7121 DUST COVER STAY 4
79 7SB06050 FLAT HEAD BOLT M6X50 4
80 7SW006 SPRING WASHER M6 4
81 7N006 NUT M6 4
82 1BR5068 MAIN SHAFT 1
83 1BR5069 SWIVEL ARM 1
84 1BR5070 BALL BEARING 6208Z 2
85 1BR5071 BALL BEARING 6207Z 1
86 1BR5072 SNAP RING C-80 1
87 1BR5073 SPACER 1
88 1BR50741 ROLLER SHAFT 1
89 1BR5075 SPRING PIN Φ8X60 1
90 1BR50791 MAIN SHAFT CLAMP 1
91 7CB10020 CAP BOLT M10X20 2
92 7CB10025 CAP BOLT M10X25 2
93 7SW010 SPRING WASHER M10 4
94 7SS10025 SET SCREW M10X25 1
95 7N010 NUT M10 1
96 1BR5084 SWIVEL GEAR 1
97 7CB10035 CAP BOLT M10X35 8
98 7SW010 SPRING WASHER M10 8
99 7SP08030 SPRING PIN Φ8x30 1
100 1BR5087 LIMIT SWITCH CAM 1
101 7SS06010 SET SCREW M6X10 1
102 1BR51324 ANGLE SET PINION 1
103 1BR52261 ANGLE SETTER 1
104 1BR50941 ANGLE STAND 1
105 7B308015 BOLT M8X15 WITH
WASHERS
2
106 1BR5098 DISK SPRING M10 2
107 1BR5099 LOCK NUT SET 1
108 1BR5101 SWITCH CAM 1
109 7B308015 BOLT M8X15 WITH
WASHERS
1

DBD-25X Bender ManualB | Page 8
No. Part No. Part Name Qty
110 1BR5107 WIRE CLAMP 1
111 7CB10020 CAP BOLT M10X20 1
112 7SW010 SPRING WASHER M10 1
113 1BR51101 JIB 1
114 7B14070 BOLT M14X70 1
115 7PW014 PLATE WASHER M14 2
116 7UN014 SELF LOCK NUT M14 1
117 1BR5116 WIRE ROPE 1
118 1BR5117 WIRE CLIP WITH NUT 1
119 1BR5118 SPRING HANGER 1
120 1BR5119 RETURN SPRING 4
121 1BR5135 CENTER COVER 1
122 1BR5134 CENTER PLATE 1
123 7SB06015 FLAT HEAD BOLT M6X15 1
124 1BR507811 ROLLER STOPPER 1
125 1BRSS10 SNAP PIN 1
126 1BR5050 SWITCH PANEL 1
127 1BR7070A ANGLE STOPPER ( R ) 1
128 1BR7071 ANGLE STOPPER ( L ) 1
129 7CB06018 CAP BOLT M6X18 2
130 7DS006 DISK SPRING M6 2
131 7PW006 PLATE WASHER M6 2
132 7PB306015 PAN HEAD BOLT W/
WASHERS
5
133 1BR5140 ROLLER NO.1 Φ50MM 1
1BR5142 ROLLER NO.2 Φ70MM 1
1BR5143 ROLLER NO.3 Φ79MM 1
1BR51441 ROLLER NO.4 Φ96MM 1
No. Part No. Part Name Qty
1BR51451 ROLLER NO.5 Φ120MM 1
1BR5146 ROLLER NO.6 Φ156MM 1
134 76208Z BALL BEARING 6208Z 6
135 7HSL08 BEARING FOR ROLLER
NO.3
1
136 7BR60 SNAP RING BR60 FOR
NO.3
1
137 1BR5076 ROLLER CLAMP 2
138 1BR5080 CLAMP BOLT 2
139 1BR5129 1BR5129 CONTROL BOX
ASSEMBLY
1
1BR5406 MAGNET CONDUCTOR 1
1BR5129C DIODE 1
1BR51291K THYRISTER 1
1BR5129F FUSE HOLDER 1
1BR5129G FUSE 1
1BR5129H TRANSFORMER 1
140 1BR5126 PILOT LAMP 1
141 1BR5127 OPERATION SWITCH 1
1BR5231 EMERGENCY BUTTON 1
142 3CD0151 MAIN SWITCH 1
143 1BR5128 SOCKET FOR FOOT
SWITCH
1
144 1BR5124 LIMIT SWITCH AZ7141 2
145 7PB204030 PAN HEAD BOLT W/
WASHER
4
146 1BR5012G CORD ARMER 1
147 1BR5012F CORD SET 1
1BR5231 EMERGENCY STOP
BUTTON (NOT SHOWN)
1
1BR3100400 HANDLE (NOT SHOWN) 2