The Bernardo D5 manual rack and pinion press (renamed DP 5 in technical material) features a gray cast iron structure, effective force of 1,560 kg / 15,298 N with an 800 mm adjustable lever and 60 kg manual force, a usable workpiece height of 445 mm, a column axis distance of 215 mm, a 50×50×645 mm spindle, and a Ø 257 mm rotating plate with multiple openings (19, 28, 38, 68 mm). It is suitable for inserting/extracting bearings, bushings, gears, straightening, and broaching. Weight 160 kg. Manufactured in Austria, distributed in Italy by Krollit as an official Bernardo distributor since 2007.
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Effective force (with 800 mm lever): 1,560 kg / 15,298 N
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Max workpiece height: 445 mm
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Column axis distance: 215 mm
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Rotating plate: Ø 257 mm with 4 openings
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Spindle: 50 × 50 × 645 mm
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Structure: Gray cast iron
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Weight: approx. 160 kg
Who uses the D5 and for what
The Bernardo D5 (also called DP 5) is the top-of-the-range manual rack and pinion press in the DP family, sized for heavy-duty workshop applications. The gray cast iron structure (vs steel of smaller DP 1/2/3 models) provides maximum stability and resistance under high loads. With a usable workpiece height of 445 mm and an 800 mm adjustable lever, it handles operations that smaller manual presses cannot: straightening medium shafts, inserting/extracting large bearings, assembling gears, broaching. The effective force of 1,560 kg is achieved with a manual effort of 60 kg on the lever, a lever ratio of over 25:1. The Ø 257 mm rotating plate with 4 openings (19, 28, 38, 68 mm) allows different components to pass through without changing equipment. In Krollit's customer laboratories, it is chosen by mechanical workshops, maintenance departments, railway workshops for small maintenance, transmission manufacturers, and disassembly laboratories.
Its place in the Bernardo range
In the DP range of Bernardo manual rack and pinion presses, the D5 is the top model in terms of size and capacity. Below it: DP 1 (force 1,140 kg, height 135 mm, weight 11 kg) for small components; DP 2 (force 1,285 kg, height 190 mm, weight 30 kg) intermediate; DP 3 (force 1,181 kg, height 300 mm, weight 40 kg) for taller pieces. The D5 stands out for its gray cast iron structure (vs steel of other DPs) and significantly larger dimensions (160 kg vs 11-40 kg). For applications requiring pieces up to 445 mm high or stable forces over 1.2 tons, the D5 is the only choice in the manual range. Above manual presses, Bernardo offers HCP hydraulic presses starting from 30 tons, sized for industrial needs.
Krollit logistics and support
Bernardo shipping in 5-9 business days (7 days to Southern Italy). At 160 kg, it requires a pallet jack or two people with care for handling and installation. It must be fixed to a robust workbench using the mounting holes. Original Bernardo spare parts available from stock with shipping in 3-5 business days. Customer support available in Italian.
Who the D5 is for
| Profile |
Compatibility |
Reason |
| Passionate hobbyist |
Adequate |
Tool sized for professional use. For occasional hobby use, smaller models (DP 2 or DP 3) might be more practical and less expensive. |
| Mechanical workshop / maintenance department |
Recommended |
For inserting/extracting large bearings, assembling gears, straightening medium shafts. The cast iron structure provides superior stability compared to other DPs. |
| Transmission department / mechanical manufacturer |
Recommended |
Usable workpiece height of 445 mm handles components that smaller manual presses cannot accommodate. The Ø 257 mm rotating plate with multiple openings speeds up operation changes. |
Not suitable for: applications requiring force greater than 1.5 tons (consider HCP hydraulic presses); high-volume serial production (the press is manual, not automatic); pieces over 445 mm in height; use on a construction site without a stable support bench.
Working capacity
| Specification |
Value |
| Max workpiece height |
445 mm |
| Column axis distance |
215 mm |
| Manual force (on the lever) |
60 kg / 588 N |
| Effective force on the workpiece |
1,560 kg / 15,298 N |
| Lever length |
800 mm |
Spindle and rotating plate
| Specification |
Value |
| Spindle dimensions |
50 × 50 × 645 mm |
| Rotating plate diameter |
257 mm |
| Rotating plate openings |
1 × Ø 19 mm / 1 × Ø 28 mm / 1 × Ø 38 mm / 1 × Ø 68 mm |
Dimensions and weight
| Specification |
Value |
| Machine dimensions (L × W × H) |
370 × 550 × 810 mm |
| Net weight |
approx. 160 kg |
| Structure material |
Gray cast iron |
Compliance
| Specification |
Value |
| Marking |
CE |
Standard equipment
- Bernardo D5 manual press (gray cast iron machine body)
- Ø 257 mm rotating plate with multiple openings
- 800 mm long adjustable lever
Frequently Asked Questions
Why is the D5 made of gray cast iron while the DP 1/2/3 are made of steel?
Gray cast iron has superior vibration damping capabilities compared to steel and greater stability under static loads. On smaller DP models (1/2/3), the advantage of cast iron is not noticeable, but on the D5 with forces up to 1.5 tons, cast iron improves working precision.
The choice of material depends on the scale. The cast steel of the DP 1/2/3 is correctly sized for their capacities (forces up to 1.3 t and heights up to 300 mm). For the D5 with greater forces and dimensions, cast iron provides thermal mass and rigidity that reduce micro-vibrations during precision operations such as shaft straightening.
Can I really apply 1.5 tons with 60 kg of effort?
Yes, that's the principle of the lever: with an 800 mm lever and the internal mechanical ratio of the rack, a manual effort of 60 kg is multiplied by over 25 on the rack. The effective force on the workpiece is 1,560 kg.
The lever-force ratio is a design characteristic of the press: a longer lever = greater force multiplication. The D5 with an 800 mm lever has the highest ratio in the DP range (26:1 ratio vs 19:1 for the DP 1 with a 350 mm lever). This allows a single operator to exert forces that would otherwise be impossible manually.
Does it need to be fixed to the workbench or can it be used freestanding?
It must be fixed to a robust workbench using the mounting holes in the base. The force exerted by the lever requires stability: without fastening, the machine will lift during pressing.
The workbench must be sized to withstand lateral and lifting forces during pressing operations. A light or unstable workbench makes the D5 inaccurate and potentially dangerous. The machine's 160 kg weight helps stability but does not replace mechanical fastening to the workbench. Standard fastening bolts are sufficient.
Can I do broaching with the D5?
Yes, it is one of the stated applications. The effective force of 1,560 kg allows broaching on small-medium components in standard steels. For broaching large components or hard steels, consider hydraulic presses.
Broaching requires constant and progressive force during the stroke: the D5's rack is designed to generate uniform force. For repetitive broaching in production, manual cycling can be limiting; for serial production, consider hydraulic presses with automated cycles.
What is the practical difference with the DP 3?
The D5 has an effective force of 1,560 kg vs 1,181 kg, a workpiece height of 445 mm vs 300 mm, a cast iron structure vs steel, and a weight of 160 kg vs 40 kg. It is sized for more demanding applications.
The DP 3 is already a good capacity manual press for most workshops. The D5 is justified for specific applications requiring pieces up to 445 mm high or stable forces over 1.2 tons, such as straightening medium-large shafts or industrial-sized bearings. For general use, the DP 3 is sufficient with lower cost and footprint.
