KAKA Industrial FB-4 User manual

Operation Manual FB-4
KAKA Industrial®
— 1 —
Unpacking
The METAL BENDER is shipped from the
manufacturer in a carefully packed Carton
box. Thoroughly inspect the product upon
opening the package.
After unpacking the unit, carefully inspect
for any damage that may have occurred
during transit. Check for loose, missing, or
damaged parts. Shipping damage claims
must be led with the carrier and are the
responsibility of the user.
Specications
The KAKA 4" METAL BENDER is a
high quality, industrial style tool capable
of generating a powerful 2-1/2 tons of
pressing force to create 90° or lesser
repeatable bends in mild steel and
aluminum up to 4” wide.
● For cold forming of steel and metals
including setup plate for table clamping.
● Stamp a stencil for round roll bending
available.
Stock No. ................................173204
Model........................................FB-4
Maximum Jaw Travel..............................2-1/2”
Minimum Bend Radius..............................1/4”
Maximum Bend Angle.................................90°
Average Maximum Expected Material Bending
Mild steel:
0.75"x0.67"(19x17 mm),
1.97"x0.43"(50x11 mm),
3.98"x0.31"(101x8 mm).
Packing size......17"x8"x7" (44x21x18 cm)
N.W./G.W. ..........18/22 lbs (8.5/10 kg)
NOTE: Material thicknesses shown are
for mild steel only. High carbon steel and
stainless steel thickness will be less while
aluminum thickness will be higher.
- 3/4” wide, max. = 3/8” thick
- 2” wide, max. = 1/4” thick
- 4” wide, max. = 3/16” thick
Important
• This tool has leveraged rotating
components that generate greatly amplied
crushing and bending forces which can
quickly cause severe injury!
Keep ngers and hands away from moving
parts when operating.
• Handling sharp metal can cause serious
cuts. Wear thick, well tting work gloves to
prevent cuts from handling sharp metal.
WARNING
Tremendous external torque loads are placed
on this Metal Bender during operation. This tool
cannot be operated without adequate support or
severe personal injury or property damage can
occur if it should suddenly be become dislodged
or moves while in use. Before beginning ANY
work with this tool, it is absolutely necessary that
it be securely bolted to a heavy, sturdy, anchored
workbench.
SAVE THESE INSTRUCTIONS
Thank you for purchasing our FB-4
METAL BENDER. Before attempting to
operate your new tool please read these
instructions thoroughly. You will need
these instructions for the safety warnings,
precautions, assembly, operation,
maintenance procedures, parts list and
diagrams. Keep your invoice number
with these instructions. Write the invoice
number on the inside of front cover. Keep
the instructions and invoice in a safe, dry
place for future reference.

Operation Manual FB-4
Model FB-4
— 2 —
children. Inspect the tools prior to storage
and before reuse.
12. Maintain product labels and
nameplates. These carry important safety
information.
WARNING
The warnings, cautions, and instructions
discussed in this instruction manual cannot cover
all possible conditions or situations that could
occur. It must be understood by the operator that
common sense and caution are factors which
cannot be built into this product, but must be
used by the operator.
KNOW HOW TO USE TOOL
1. Use right tool for job. Do not force tool
or attachment to do a job for which it was
not designed.
2. Keep hands out of path of bending dies
and clear from dies.
3. Exceeding capacity may be dangerous
to operator and damage may occur to
machine.
4.Be sure there is sufcient working room
around the tool to allow for safe handling of
various lengths of metal.
5. Bolt machine to sturdy stand that is
bolted to oor to prevent sliding or tipping
of machine.
6.Strenuous physical force may need to
be applied to the Metal Bender during
use. Failure to ensure proper footing
can quickly result in a fall which could
inflict serious personal injury or property
damage. Always work in a clean,
uncluttered environment.
CAUTION
Pieces of mill scale, rust and other debris may
be ejected from the workpiece during operation.
Wear approved eye and skin protection at all
times while operating.
General Safety Information
CAUTION
Always follow proper operating procedures as
defined in this manual even if you are familiar
with use of this or similar tools.
Remember that being careless for even a fraction
of a second can result in severe personal injury.
WARNING
For your own safety, read all of the instructions
and precautions before operating tool.
SAFETY RULES
1. Wear proper apparel. Do not wear loose
clothing, gloves, neckties, rings, bracelets
or other jewelry which may get caught in
moving parts of machine.
2. Wear protective hair covering to contain
long hair.
3. Wear safety shoes with non-slip soles.
4. Wear safety glasses complying with
United States ANSI Z87.1.
Everyday glasses have only impact
resistant lenses. They are NOT safety
glasses.
5. Be alert and think clearly. Never operate
tools when tired, intoxicated or when
taking medications that cause drowsiness.
6. Keep work area clean. Cluttered work
areas invite accidents.
7. Work area should be properly lit.
8. Keep visitors at a safe distance from
work area.
9. Keep children out of workplace. Make
workshop childproof. Use padlocks to
prevent any unintentional use of tools.
10. Assemble only according to these
instructions. Improper assembly can
create hazards.
11.When tools are not in use, store them
in a dry, secure place out of the reach of

Operation Manual FB-4
KAKA Industrial®
— 3 —
NOTE
Excessive resistance while operating could
indicate a defect with the workpiece material or
broken or damaged Metal Bender components.
To avoid injury, stop work immediately and
inspect workpiece material for nicks, dents,
welds, excessive scale or remaining coatings.
Clean or repair as necessary or discard and
begin with a new piece. Also inspect Metal
Bender components for looseness or damage.
Assembly
CAUTION
PINCH HAZARD!
The KAKA Metal Bender consists of moderately
heavy metal components which can present a
hand/finger pinch hazard and cause potentially
serious injuries if dropped on feet. Avoid pinching
hands while handling parts during assembly and
wear thick, welltting work gloves to prevent cuts
from handling sharp metal. The use of safety
shoes is strongly recommended.
1. Set the Metal Bender on a clean, level
work surface.
WARNING
INJURY HAZARD!
Tremendous external torque loads are placed on
this Metal Bender during operation.
This tool cannot be operated without adequate
support or severe personal injury or property
damage can occur if it should suddenly be
become dislodged or moves while in use. Before
beginning ANY work with this tool, it is absolutely
necessary that it be securely bolted to a heavy,
sturdy, anchored workbench.
2. With the (4) 5/16” (8mm) holes in the
baseplate as a guide, Mark the locations
and centers with a pencil.
3. Drill 5/16” (8mm) mounting holes in
work surface.
NOTE: A minimum thickness of 3/16”(4.76mm)
steel or 1/2”(12.7mm) of a wood-based surface is
strongly recommended.
4. Use (4) 5/16” (8mm) bolts (Not
Included) washers and nuts to secure
baseplate to work surface.
5. Attach Handle #2 to Drive Stem (FIG 1).
6. Thread Acorn Nut #1 onto Drive Stem
and tighten securely with a 30mm wrench
(FIG 1).
7. Thread the Stop Rod Locknut #19 onto
the Stop Rod #20.
8. Thread the Stop Rod #20 with Locknut
#19 into threaded hole in left side of the
Metal bender (FIG 2).
9. Tighten Locknut #19.
10. Slip Workpiece Stop #23 over Stop
Rod #20, place Stop Clamping Screw
#21 through hole then thread on Stop
Clamping Wingnut #22.
The KAKA Metal Bender is now ready
to use.

Operation Manual FB-4
Model FB-4
— 4 —
Operation
WARNING
Tremendous external torque loads are placed
on this KAKA Metal Bender during operation.
This tool cannot be operated without adequate
support or severe personal injury or property
damage can occur if it should suddenly be
become dislodged or moves while in use. Before
beginning ANY work with this tool, it is absolutely
necessary that it be securely bolted to a properly
anchored heavy, sturdy, anchored workbench.
CAUTION
The KAKA Metal Bender exerts tremendous
bending and crushing forces in operation which
can present a hand/finger pinch hazard and
cause potentially serious injuries. Avoid moving
parts while operating and wear thick, well-
tting work gloves to prevent cuts from handling
sharp metal. The use of safety shoes is strongly
recommended.
CAUTION
The KAKA Metal Bender was specifically
designed to be operated by one person only.
Never have one person operate the Handle while
one handles the material workpiece or serious
injury could occur.
NOTICE
Workpiece material should be clean of any rust,
burrs, nicks, welds or coatings before attempting
to bend or interference and binding may occur.
NOTICE
Apply a minimal amount of a light lubricant
to material and die surfaces to ease bending
process. Do not over lubricate.
1. Position the workpiece between the
jaws then rotate the Handle #2 in a
Clockwise direction while holding the
workpiece in place with the opposite
hand. As the moving Jaw begins to exert
pressure on the workpiece, remove your
hand from the workpiece and continue to
rotate Handle #2 bending the workpiece
as you go.
NOTE: The 8mm Shear Pin in the joint of the
Drive Bar and Upper link is designed to fail
under excess pressure. If replacing, use a softer
material 8mm pin or mild steel bolt (FIG 3).
2. As the desired bend is achieved, stop
Clockwise rotation and reverse rotational
direction of the Handle to release the
completed workpiece.
FOR PRODUCING REPEATABLE BENDS
1. To record the depth and angle of bend:
Using the gauge located along the slot on
top of the tool body, record the dimension
aligned at the rear edge of the Drive Bar
(FIG 3).

Operation Manual FB-4
KAKA Industrial®
— 5 —
NOTICE
There will be a certain amount of “springback”
meaning that you must rotate past your gauge
target then allow it to “spring back” to the final
desired bend angle. This varies widely according
to the particular material and thickness being
worked. Chromoly and high carbon steel will
generally have more “springback” than milder
steels and aluminum. This is one reason that
some “trial and error” must be performed to
explore the properties of the material before
working on a nal project piece.
2. To record the location of bend: Set the
position of the Workpiece Stop Gauge #22
so that the point where the bend is to occur
on the workpiece is determined by where
the edge of the workpiece contacts the Stop
Gauge (FIG 4).
Maintenance
NOTE: Maintenance should be performed before
each use.
1.Clean dirt and debris from threaded
drive screw.
2. Check tightness of all hardware.
3. Check operation for binding. Lubricate
moving parts and drive screw periodically
with medium bodied chassis grease.
4. Apply a thin film of light oil or rust-
preventive to all bare steel areas.
5. Store in a clean, dust-free, dry,
dampness free area preferably covered
with plastic sheeting.
NOTE: The 8mm Shear Pin in the joint of the
Drive Bar and Upper link is designed to fail
under excess pressure. If replacing, use a softer
material 8mm pin or mild steel bolt (FIG 4).

Operation Manual FB-4
Model FB-4
— 6 —
Drawing
Parts List
Ref.No. Description QTY. Ref.No. Description QTY.
1Capping Nut 1 14 Lower Plate 1
2Handle 1 15 Pin 1
3Snap Ring 1 16 Upper Plate 1
4 Bearing 1 17 Screw M8x16mm 5
5Outer Bushing 1 18 Washer 1
6Inner Bushing 1 19 Nut M8 1
7 Lead Screw Assembly 1 20 Rod 1
8End Cover 1 21 Screw M6x25mm 1
9 Body 1 22 Piece Part Stop 1
10 Bending Die 1 23 Knob 1
11 Pressing Die 1 24 Base 1
12 Shaft Pin 1 25 Scale 1
13 Spacer 1 26 Screw M5x10mm 4

Operation Manual FB-4
KAKA Industrial®
— 7 —
SERVICE RECORD
KAKA Industrial ®
Date Maintenance performed Repair components require
NOTES

Stock No: 173204
Edition 1 4/2019
Copyright © 2019 KAKA
If you have any questions about the use of this product, please contact the
nearest one to you as below:
KAKA INDUSTRIAL LLC
Mail:
[email protected]
Add: 4200 Steve Reynolds
Blvd Ste 6 Norcross,
GA 30093
U.S.A.
KAKA INDUSTRIAL LTD
Mail:
[email protected]
Add: 3143 Underhill Avenue
Burnaby,
B.C V5A3C8
Canada
KANG INDUSTRIAL PTY LTD
Mail:
[email protected]
Add: 3 Wayne Court
Dandenong,
VIC 3175
Australia