BN Products DBR-25WH User manual

Page 1
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
DBR – 25WH
REBAR STRAIGHTENER
HANDLING INSTRUCTIONS
READ THESE INSTRUCTIONS CAREFULLY BEFORE
ATTEMPTING TO USE REBAR STRAIGHTENER
Not following proper operating procedures can lead to accidents.
If in doubt of any procedure, contact your local authorized agent.
The DBR-25WH is a portable heavy-duty electric/hydraulic rebar bender
and straightener. It helps save valuable man-hours by cleanly and e󰀩-
ciently bending or straightening bent rebar. It functions as a simple 90-de-
gree portable electric rebar bender. The interchangeable bending hook
covers rebar diameters from #4 to #8 grade 60. Maximum pressure for
bending and straightening ranges from 8.5 to 11 tons. It’s portable and
versatile enough to bend or straighten rebar in-place with its push/pull hy-
draulic capabilities. It will bend a 90-degree angle in only (4) seconds.
The bending head also rotates 360 degrees. Ships complete in a plastic
carrying case with hydraulic oil, a tool kit and two additional bending dies.
This tool solves bending applications other tools can’t even attempt.
DBR-25WH_Product_Manual-2018

Page 2
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
GENERAL SAFTEY PRECAUTIONS
Application: Use DBR-25WH on concrete re-enforcing
bars only.
RESTRICT USE TO DESIGNATE MATERIALS
There is always a chance that the end of material may
break and shoot out, especially if the material is harder
than those specied. Exceeding designated material
specications greatly increase this risk and will also
damage the tool. Do not attempt to use the tool for
rebar harder, thicker, or thinner than those specied.
USE EYE PROTECTION
Wear safety goggles, safety glasses with side shields or a
face shield when using the rebar straightener.
KEEP HANDS AWAY
Do not touch rebar, housing, hook, rollers, and/or the
piston while rebar straightener is being operated.
GUARD AGAINST ELECTRIC SHOCK
To avoid possible electric shock, do not handle the DBR-
25WH with wet hands, or use in the rain or other damp
places. Be aware of all power lines, electric circuit and
other hazards that may be contacted, especially those
that are below the surface or otherwise hidden from
view.
UNPLUG TOOL
Disconnect the tool from outlet when not in use and be-
fore cleaning, adjusting, or servicing. Do not disconnect
plug from outlet by pulling on the cord. Always check
that the switch lock is OFF before plugging your tool in.
BEWARE OF YOUR ENVIRONMENT
Do not use rebar straightener in the presence of amma-
ble materials (e.g., paint, thinner, petroleum products,
and adhesives.) Do not use rebar straightener in a pos-
sibly explosive environment, (e.g., fumes, gas, or dust)
or in areas that are poorly ventilated.
KEEP WORK AREA TIDY AND WELL LIT
Make sure that work area is properly lighted and clear of
obstructions. Operator should at all times have an unob-
structed view of their rebar straightener, rebar, and the
surrounding area.
WEAR PROPER APPAREL
Do not wear loose clothes, dangling objects, or jewelry.
Restrain long hair. The use of a safety helmet and rubber
soled boots are strongly recommended. If safety gloves
are worn, be especially careful that gloves do not get
caught in the moving parts.
KEEP VISITORS AWAY
Keep all visitors at a safe distance from the work area for
their own protection and to prevent distraction of the
operator.
Max Rebar Diameter 25 mm
Straightening Max yield point 345N/mm2
Bending Max yield point 295N/mm2
Rebar Diameter Straightening Capacity Bending Capacity
Push Pull Push Pull
13 mm up to 125° up to 121° up to 94° up to 92°
16 mm 128 124 90 90
20 mm 130 126 90 90
25 mm 132 124 90 90
Max pressure 11 Tons 8.5 tons 11 tons 8.5 tons
Output 1.5 HP
Weight 22.5 Kg
Dimension 660x270x200mm (LxWxH)

Page 3
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
MAINTAIN REBAR STRAIGHTENER WITH CARE
Inspect rebar straightener before each use. Faulty or
loose bending hook could possibly result in personal
injury. Keep handle dry, clean and free from oil and/or
grease. Keep housing and piston free of dirt and iron l-
ings. Check that no screws or bolts are loose or missing.
Follow all instructions for maintenance. Inspect switch,
cord, plug and any extension cable at regular intervals.
STORE CAREFULLY
When not in use, store rebar straightener and its acces-
sories in a dry place where they cannot be accessed by
anyone but the operators.
PARTS AND SPECIFICATIONS (Figure 1)
1. Handle
2. Switch
3. Mode control lever
4. Oil plug
5. Front handle
6. Hook
7. Roller
8. Housing
9. Motor
OPERATING INSTRUCTIONS
Check the oil level.
Check that the power source is appropriate to the rebar
straightener.
CARE- If voltage is too high, the motor will burn out, if
voltage is too low, insucient power will be generated.
NEVER USE DC CURRENT OR AC HIGHER THAN
110V
Check that the power supply is properly earthed.
CAUTION- Failure to properly earth the power supply
may result in a shock to the operator.
Check that the cord is undamaged and that the plug is
not loose.
CAUTION- Cut or abraded covering could result in a
short and electric shock to the operator.
If an extension cord is to be used, make sure that it is
undamaged and that it is the proper thickness for the
length. See table below.
100/115V 230V
Cable
Length
Cable Size
(AWG)
Nominal
Diameter
Up to 10m (33 ft.) 16 1.0mm2
Up to 15m (50 st.) 14 1.25mm2
Up to 30m (100ft.) 10 1.5mm2
Before plugging the tool in, make sure that the switch
lock is o.
CAUTION- If switch lock is ON; the rebar straightener
will start as soon as it is plugged in. To disengage lock,
pull the trigger switch, the lock button will pop out.
WARM UP
In cold weather, warm up the unit for 30-60 seconds
so that the hydraulic oil will reach the proper viscosity.
Pull the trigger switch to extend the piston and release
when it has reached its full stroke. Repeat this action 3-5
times.
POINTS OF ATTENTION
1. Do not cover air vents.
2. CARE- If vents are covered, the motor will overheat
and may burn out.

Page 4
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
3. If hydraulic oil exceeds 70*C, (158*F) the power will
drop. Allow the unit to cool before resuming opera-
tion. (Be particularly careful in summer, when the
aluminum pumpcase heats up quicker.
4. If a drop in power is observed and motor is unusu-
ally hot, check the carbon brushes.
OPERATION
The DBR-25WH is primarily intended to straighten
deformed rebar. It can, or course, also be used to bend
straight rebar.
To enable the unit to be used in conned spaces, there are
twooperating modes: Push& Pull.The modeisselected by
movingthemodecontrollevertotheappropriateposition.
“A” for push (piston advances) and “B” for pull (pis-
ton retracts) In either mode, simply press the switch to
move the piston.
NB: The movement of the piston is limited by a safety
valve. To prevent overheating, release the trigger switch
when the piston has reached its travel limit.
TO PUSH
Advance or retract the piston so that the hook is in a
suitable starting position. Set the mode control lever to
“A” and t the rebar as shown at the left. Pull the trigger
switch until the rebar is at the desired angle.
TO PULL
Set the hook in the correct starting position , make sure
that the mode control lever is in the “B” position and t
the rebar as illustrated. Pull the trigger switch until the
desired angle is attained.
NB: It is important that the rebar be properly tted in
the hook and against the rollers.
INTERIOR ANGLE
Since the piston stroke is limited, interior straightening
/ bending angle will vary according to rebar diameter
and operating mode. Refer to the table below.
CLEANING
Clean rebar straightener everyday, preferably immedi-
ately after use.
CAUTION- Wear gloves to protect hands from metal
splinters. Do not use air guns – Blasting with air guns
can cause metal lings and/or dust to get into eyes and
respiratory system.
1. Disconnect unit.
2. Wipe or brush away all dirt and metal lings. Pay
particular attention to the lower half of the piston,
where dirt is more easily accumulated.
3. Once the piston has been retracted, pull the trigger
switch long enough to partially unplug unit. Check
the piston for accumulated dirt and iron lings that
may be jamming the piston.
OIL LEVEL CHECK
As rebar straightener is hydraulically operated, the oil
level must be checked at frequent intervals, preferably
everyday. Failure to maintain the oil at proper levels will
result in a drop in pressure and loss of the benders hy-
draulic power.

Page 5
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
CAUTION- Hydraulic oil is highly ammable. Keep
away from sparks and naked ame. DO NOT SMOKE
WHEN NEAR OIL/BENDER.
CAUTION- Hydraulic oil may cause inammation of
the eyes and skin. If ingested, it will cause diarrhea and
vomiting.
In case of eye contact, rinse in clean water for at least 15
minutes and consult a physician immediately, as blind-
ness can occur.
In case of skin contact, wash thoroughly with soap and
water.
In case of ingestion, consult a physician immediately.
DO NOT DELIBERATELY INDUCE VOMITING.
OIL MAINTENANCE CON’T.
1. Oil should be warm, but not hot. Warm up the unit
if cold.
2. Unplug unit from the power source.
3. Remove oil plug and the seal washer (packing)
4. CAUTION- Never remove oil plug when unit is hot,
as the oil may spurt over.
5. Check that oil is level with the bottom of the plug
hole (i.e. the pump case is full to the brim) If oil level
is too low, top up with 20- weight hydraulic oil with
anti-foam and anti- abrasion properties (ISO viscos-
ity grade VG46, e.g., Shell Tellus 46, Mobil Oil DTE-
25, or Esso Uni Power SQ46)
6. After topping up, extract air from the system. Gently
tilt the unit and return it to the level position. Top
up again and tilt in the opposite direction. Repeat
this action until all air has been removed.
7. CARE- Rebar straightener cannot function properly
if oil contains air bubbles.
8. Replace seal washer and plug. Extend to its full
stroke, and remove oil plug and seal washer. Then
repeat the procedure of above
9. Replace the oil plug and seal washer.
OIL CHANGE
The hydraulic oil should be changed at least once a year,
sooner if it appears to be dirty.
1. Unplug the unit from the power source. Remove the
oil plug and packing. Turn the unit over and drain
oil into an appropriate receptacle.
2. With drain hole uppermost, slowly ll the unit with
fresh oil. Replace plug and lightly tighten. Connect
the unit to power source and advance piston two
or three times. Unplug the unit and remove the oil
plug. Top up the oil level and replace plug.
3. Finally, follow procedure for oil level check.
Please dispose of any hydraulic oil in accordance with
local regulations. Do not pour into sea, a river, lake or
drains.
BOLT TIGHTNESS
Once a week, or after every 30 times use, check the tight-
ness of all bolts, especially those securing the housing to
the cylinder.
CARBON BRUSHES
Inspect the two carbon brushes at least every two
months. (Normal brush life is around 200 hours.
CARE- Warn carbon brushes will result in power loss,
cause the motor to run hot and irreparably damaging
the armature’s commutator.
1. Disconnect unit.
2. Unscrew both brush caps and pull out the carbon
brushes.
3. Replace the brushes if less than 6MM in length.
OVERHAUL
Return the unit to an authorized agent for overhaul at
least once every two years, sooner if subject to heavy us-
age.
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone]
Fax: [phone]• [e-mail]
WWW.bnrebartools.com
Maximum Bending Diameter 1” #8 Rebar (25mm) Grade 60
Bending Angle Up to 94 degrees (1/2”) - up to
90 degrees ( 1”)
Voltage/ Amperage 115V 50/60Hz / 12 amps
Tool Weight 57.3 lbs (26 kg)
Dimensions L x W x H 25.75” (660mm) x 10.5”
(270mm) x 7.8” (200mm)

Page 6
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
DBR-25WH Portable #8 Rebar Bender
NO Part No. Part Name Qty
18 1C1922 VALVE END SPRING 1
19 7ORP14 O RING P14 1
20 1DBR83 BACK-UP RING 1
21 7SB08015 DISC SCREW M8X15 3
22 7BRP55 BACK-UP RING P55 2
23 7ORP55 O RING P55 1
24 1DBR20B HOSE BAND Ø120 2
25 1DBR66 COVER A 1
26 1DBR67 COVER B 1
27 1DBR68 PIPE COVER (1DBR682) 1
28 1DBR20A HOSE BAND Ø100 2
29 1DBR79 BAND PACKING 2
30 1DBR64 AIR BAG 1
31 7ORG70 O RING G70 2
32 7BRG70E BACK-UP RING G70 2
33 1DBR55 PIPE CYLINDER 1
34 1DBR54 STOPPER 1
35 7CB06030 CAP BOLT M6X30 2
NO Part No. Part Name Qty
1 1DBR205790 HOUSING 1
2 1DBR72 ROLLER 2
3 1BL5402000 ROLLER CLAMP (1DBR73) 2
4 7B812025 HEX. BOLT M12X15 2
5 7SW012 SPRING WASHER
M12(7SW0012)
2
6 1DBR80 HOOK 1
7 1DBR711 PACKING 2
8 1DBR309550 HOLDING WIRE 2
9 7MB3025DU DRY BUSH 1
10 7BRP30 BACK-UP RING P30 1
11 7ORP30 O RING P30 1
12 1DBR309540 HOUSING GUIDE 1
13 7PT1/8 PLUG PT1/8 4
14 3DS2359 ELBOW NIPPLE 1
15 1DBR562 PISTON 1
16 1DBR581 VALVE COVER 1
17 1DBR57 END VALVE 2

Page 7
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
NO Part No. Part Name Qty
36 1DBR511WH CYLINDER 1
37 1DBR63 TUBE 4X2.5 1
38 3P1044 MAGNET FILTER 3
39 1C1971 RAM 3
40 1C1972 RAM RETURN SPRING 3
41 1C1973 DELIVERY VALVE 3
42 1C1331 DELIVERY VALVE SPRING 3
43 1C13352 SPRING GUIDE 3
44 1C13292 PUMP HEAD SEAL 3
45 7698 BALL BEARING 698 1
46 1C1325 BEARING GUIDE 2
47 712NQ2410A NEEDLE BEARING (1C13401) 1
48 7SRH027 SNAP RING H27 1
49 1DBR751 VALVE CASE (1DBR75) 1
50 3DS2360 CONNECTOR 1
51 1DBR62 OIL PIPE 1
52 1DBR77 GUIDE BOLT 1
53 7WF06 SEAL WASHER (3DS2026) 2
54 7CB06006 CAP BOLT M6X6 1
55 7SB3/16 STEEL BALL 3/16 1
56 3DA102K STOPPER SPRING 1
57 7CB06040 CAP BOLT M6X40 4
58 7SW006 SPRING WASHER M6
(7SW0006)
4
59 3DS23322 ROTARY VALVE 1
60 7ORP18 O RING P18 2
61 1DBR531 VALVE LEVER 1
62 7SP420 SPRING PIN Ø4X20 1
63 7SB5/32 STEEL BALL 5/32 1
64 1DBR821 VAVLE SET 1
65 7BSH4 DISK SPRING 24
66 1DBR84 GUIDE BOLT 1
67 7SS12012 SET SCREW M12X12 1
68 1C1951B PUMP CASE PACKING 1
69 3DS1939B PUMP CASE 1
70 7B10015 OIL PLUG M10X15 1
71 7WF10 SEAL WASHER WF10 1
NO Part No. Part Name Qty
72 1DBR420610 SEAL COVER 1
73 7TCV19358 OIL SEAL TCV-19-35-8 1
74 76004VV BALL BEARING 6004VV 1
75 7AR308740 ARMATURE WITH CAM (100v) 1
75 7HTK360788CB ARMATURE WITH CAM (115v) 1
75 7HTK360788EB ARMATURE WITH CAM (230v) 1
76 7HTK310546B DUST SEAL 1
77 760002RU BALL BEARING 60002RU 1
78 7HTK340318B STATOR COIL (100v) 1
78 7HTK340319CB STATOR COIL (115v) 1
78 7HTK340319EB STATOR COIL (230v) 1
79 7P205055 PAN HEAD BOLT M5X55 2
80 7HTK971050B MOTOR HOUSING (1C1961K) 1
81 7HTK971055B SIDE COVER (7971055) 1
82 7P204008 PAN HEAD BOLT M4X8 2
83 7HTK971091B TAIL COVER (1C1961S) 1
84 7P205010 PAN HEAD BOLT M5X10 2
85 7SS05008 SET SCREW M5X8 2
86 7HTK971001B BRUSH HOLDER (1C1961J) 2
87 7HTK999043B CARBON BRUSH SET
(1C1961A)
1
88 7HTK935829B BRUSH CAP (1C1961H) 2
89 7CB06090 CAP BOLT M6X90 4
90 1C2618 MAIN HANDLE 1
91 1C1946 SWITCH COVER 1
92 7HTK971390B SWITCH (100 - 230v) 1
93 7HTK308283B CONDENSER (100 - 230v) 1
94 7CB06018 CAP BOLT M6X18 4
95 7HTK958049B CORD ARMER (1BR5012G) 1
96 7P204015 PAN HEAD BOLT M4X15
(7PB04015)
2
97 7P204008 PAN HEAD BOLT M4X8
(7PB04008)
2
98 7COD-
1253C050J
CORD SET (100v) 1
98 7HTK500399ZB CORD SET (115v) 1
98 7HTK311433B CORD SET (230v) 1
99 1DBR2945 O RING P7 4
100 7PT1/8 PLUG PT1/8 2
101 1DBR419520 ARMATURE BUSH (with No.75) 1

Page 8
BN Products-USA, LLC.
3450 Sabin Brown Road • Wickenburg, AZ 85390
[phone] • [phone] • [e-mail]
BD25WH Bending Die Set
#15 Bend Die #20 Bend Die 1DBR80A Bend Hook (Standard)
M16 x D7 Female Threads on one end M16 x D7 Female Threads on one end M16 x D7 Female Threads on both ends
Marked: 1/2” & 15 Marked with: 3/4” & 20 3 inches wide
With this bending die push/bend
forward only
With this bending die push/bend
forward only
With this bending hook push/bend forward
& pull/bend backwards or straighten rebar
4.5” Bend Radius 6” Bend Radius 3.75” Bend Radius
ACI Approved Bend for #6 Rebar (19mm) ACI Approved Bend for #8 Rebar (25 mm) ACI Approved Bend for #5 Rebar (16 mm)
DBR-25WH Dies and Hook Bending Radiuses
Standard with DBR-25WH Bender/Straightener
Special order 1DBR80 bend die available upon
request. It measure 1 3/4” wide
Notes: For In-place bending applications the bend-
ing head pictured to the left needs to be raised at
least 1.5” o the surface of the concrete in order
to make a complete 90 degree bend. The minimum
height above the concrete surface in which a bend
can be made is 6” or 152.5 mm.