KAKA Industrial 171003 User manual

Operation Manual 3-IN-1/30
KAKA Industrial®
- 1 -
Specifications
Stock No. ...................171003
Effective Width............760mm (30 inches)
Maximum
Shearing Thickness…..1mm (20 gauge)
Bending Thickness……1mm (20 gauge)
Bending Angle...............90°
Rolling thickness………1mm (20 gauge)
Roll Diameter………….39mm (1-1/2
inches)
Packing dimensions…. 990x440x680mm
(39x17x27 inches)
Net weight....................127KGS (280 lbs.)
Unpacking
The SHEAR / BRAKE / ROLL 3-IN-1/30 is
shipped from the manufacture in a
carefully packed ply-wood case.
Carefully open crate and unbolt brake
from shipping pallet and remove from
crate using heavy duty lifting equipment
such as an overhead crane.
Thoroughly inspect the product upon
opening the package. After unpacking the
unit, carefully inspect for any damage that
may have occurred during transit.
If damage has occurred, shipping
damage claims must be filed with the
carrier and are the responsibility of the
user.
Check for completeness. Immediately
report missing parts to dealer.
Warning
The warnings, cautions and instructions
discussed in this instructions 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 supplied by
the operator.
SAVE THESE INSTRUCTIONS
Thank you for purchasing 30-inch
Shear/Brake/Roll machine. 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

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 2 -
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.
SAFETY RULES
1. Know your machine. Read this manual
carefully. Learn the machine’s
applications and limitations, as well as
specific potential hazards peculiar to it.
2. Keep work area clean and well lit.
Cluttered or dark work areas invite
accidents.
3. Keep Children away. All children
should be kept away from the work area.
Never let a child handle a tool without
strict adult supervision.
4. Do not operate this tool if under the
influence of alcohol or drugs. Read
warning labels on prescriptions to
determine if your judgment or reflexes are
impaired while taking drugs. If there is
any doubt, do not attempt to operate.
5. Use safety equipment. Eye protection
should be worn always when operating
this machine. Use ANSI approved safety
glasses. Everyday eyeglasses only have
impact resistant lenses. They are NOT
safety glasses. Dust mask, non-skid
safety shoes, hard hat, or hearing
protection should be used in appropriate
conditions.
6. Wear proper apparel. Loose clothing,
gloves, neckties, rings, bracelets, or other
jewelry may present a potential hazard
when operating this machine. Please
keep all apparel clear of the machine.
7. Don’t overreach. Keep proper footing
and balance always when operating this
product.
8. Check for damage. Check your tool
regularly. If part of the tool is damaged it
should be carefully inspected to make
sure that it can perform its’ intended
function correctly. If in doubt, the part
should be repaired. Refer all servicing to
a qualified technician. Consult your
dealer for advice.
9. Maintain tools with care. Keep tools
sharp and clean. Properly maintained
tools, with sharp cutting edges, are less
likely to bind and are easier to control.
10. When you move, install, clean or
adjust the machine, keep away from the
shears.
11. Put down the protective cover when
you don’t use the sliding roll of the
machine.
12. Keep your hands away from the die
when you are working on it.

Operation Manual 3-IN-1/30
KAKA Industrial®
- 3 -
Set-Up and Assembly
Floor Diagrams
Figure 1 –hole centers for Shear, Brake
and Roll
Assembly
Tools required for setup and assembly:
5, 6, 8mm hex keys (“Allen wrenches”)
19mm open end wrench
1. Finish removing crate from around
machine.
2. Remove bolts holding machine to
pallet.
3. Carefully clean all rust protected
surfaces with a mild solvent or kerosene
and a soft rag. Do not use lacquer thinner,
paint thinner, or gasoline, as these may
damage painted surfaces.
4. Coat all machined surfaces with a very
light film of oil to inhibit rust.
5. Carefully move machine to a work
bench or stand. Machine location must
allow free access on all sides.
6. Bolt machine to stand or workbench.
The stand or workbench must be bolted
to the floor.
(NOTE: An optional stand is available for
this machine; see Section 8. Contact
KAKA distributor to order.)
7. Remove one handle (A, Figure 2) from
each operating handle assembly, using
8mm hex key.
Figure 2
8. Loosen lock bolt (C, Figure 2).
9. Slide bar (B) into hub and tighten lock
bolt (C) to secure.
10. Re-install handle (A).
11. Install both guide rods into either the
upper or lower set of threaded holes
(Figures 3/4) and tighten the setting by
rotating hex nut against the cast base of
the machine with 19mm wrench.
12. Install guide plate as shown in
Figures 3 or 4. Secure it to rods using the
T-handles.

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 4 -
Figure 3 (Brake position)
Figure 4 (Shear position)
NOTE: For brake operation, install guide
rods into upper set of holes (Figure 3); for
shear operation, install in lower set of
holes (Figure 4).
Press Brake set-up
Do not bend material
larger than 30 ” 20-gauge mild steel.
Failure to comply may cause serious
injury and/or damage to the machine.
To set up for bending:
1. Place a strip of wood (F, Figure 5) on
bottom die, the full length of die.
2. Close brake until the wood contacts
upper dies(E).
3. Loosen screws (D) using 6mm hex key.
Figure 5
4. Select upper dies (E) for desired job
and remove the others by sliding them
out the left end.（Included die set sizes 1”,
2”, 3”, 6”, 8” and 10”）
5. Move operating handle until the wood
pushes up the dies so that they seat
uniformly in upper beam.
6. Securely re-tighten all screws (Figure
3), then release and remove wood strip.
7. If making repeated bends or using a
long workpiece, position guide rods and
plate for brake operation, as shown in
Figure 3.
8. Scribe a line on workpiece for bend
location. (Be sure to accommodate bend

Operation Manual 3-IN-1/30
KAKA Industrial®
- 5 -
allowance based upon thickness of
material. This can be done either through
trial and error, or by consulting a
machinist’s handbook.)
9. Rest workpiece on v-block (lower die)
so that the scribed line is aligned with the
tips of upper die(s).
10. Hold workpiece steady and use
operating handle to make bend.
To adjust brake beam (G, Figure 6) for
90°bends at bottom of stroke:
1. Slightly loosen locking screws (H)
using 8mm hex key.
2. Turn brake beam adjusting screws (G)
with 19mm wrench, until test bends
reflect 90° bend at both ends of brake.
3. Re-tighten screws (H).
Figure 6
For special repetitive bends, the brake
beam may be adjusted to over-bend the
desired angle since the metal will have
some degree of “spring back”.
Shear set-up
Do not shear material
larger than 30 ” 20 gauge mild steel.
Failure to comply may cause serious
injury and/or damage to the machine.
1. Install guide rods and plate in shear
position (Figure 4) and adjust to desired
length of workpiece cut.
2. Place workpiece against guide block at
right edge of table (K, Figure 7). The end
of workpiece should be against guide
plate.
3. Operate handle to begin shearing cut.
Shearing action progresses from right to
left.
NOTE: 1. To prevent distortion when
notching, “snap”the handle to facilitate
piercing.
2. Do not reach behind the machine to
catch the cut-off piece. A large cut-off
piece should be allowed to drop onto a
special table designed to catch pieces
that are bigger than the workbench.
3. Large pieces being cut may require a
front table to support the piece.

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 6 -
4. All metal cut on this machine will have
a sharp edge. File or sand the sharp edge
before handling to avoid injury.
Figure 7
Lower Blade Adjustment
Upper and lower shear blades have been
factory aligned and should not require
immediate adjustment. Should
re-alignment be needed in the future,
proceed as follows:
1. Place a heavy sheet of paper in the
cutting position, along entire length of bed,
and make a cut.
2. If the shear does not cut the paper,
loosen screw (L, Figure 7) at each end of
table, with 8mm hex key.
3. Rotate adjustment screws (M, Figure 8)
to shift table and change the gap between
blades. Do not allow the blades to
overlap.
4. If the shear cuts the paper on the ends,
but not the center, slightly turn screw (N,
Figure 9) clockwise until paper is cut the
entire length.
Figure 8
5.If the shear cuts the paper in the center,
but not the ends, turn screw (N)
counterclockwise until paper is cut the
entire length.
Figure 9
Blade Rotation/Replacement
Exercise caution when
working with or near the blades. Use
work gloves when handling them.

Operation Manual 3-IN-1/30
KAKA Industrial®
- 7 -
The shearing blades are reversible and
interchangeable; when the edges dull,
rotate them to the new edge, as follows:
1. Remove hold-down by loosening
screws (O, Figure 10), using 6mm hex
key.
2. Raise upper blade to highest position.
3. Remove seven screws (P, Figure 10)
and carefully remove blade.
4. Rotate or replace blade and re-install
screws (P).
5. Re install hold-down. When blade is in
highest position, the gap between the
hold-down and the table should be within
1/4. Adjust to this position by turning the
two screws (O, Figure 10) as needed.
When the blade starts its downward travel,
the hold-down should immediately hold
workpiece in place.
Figure 10
Slip Roll set-up
Do not roll material larger
than 30 ” 20-gauge mild steel. The slip
roll guard must cover the rolls except
when material is being fed into the
rolls. Failure to comply may cause
serious injury and/or damage to the
machine.
Material Size Considerations
To determine approximate length of
material needed for a desired size tube,
use the following formula :
C=πD
Where Cis the circumference, πequals
3.1417 and Dis the diameter.
For example: To find the length of
material needed (C) to form a tube 4" in
diameter, multiply 3.1417 by 4". Result:
12.5667" is the circumference of
approximate length of material needed.
Cut several pieces of material to this
length for a forming test run. Material may
have to be lengthened or shortened
depending upon results of test run.
TIP: If it doesn’t interfere with the
proposed final shape or design, a slight
bend made with the press brake on the
leading edge will simplify the initial rolling

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 8 -
process, by allowing the leading edge to
slip more easily over the idle roll.
Beware of pinch point –
the intersection of upper and lower
rolls. Failure to comply may cause
serious injury to fingers and/or hands.
1. Make sure rolls and workpiece are
clean and free of debris to prevent pitting
of sheet metal.
2. Back off idle roll completely by rotating
idle roll screws (Q, Figure 11)
counter-clockwise.
3.Loosen bolt (R, Figure 11) to increase
space between upper and lower press
rolls.
Figure 11
4. Insert material between upper and
lower rolls, and tighten bolt (R, Figure 11)
to lower the upper roll, until material fits
snugly. The upper roll must have
sufficient pressure on work piece to feed
properly.
5. Rotate both idle roll screws (Q, Figure
11) to adjust idle roll’s proximity to the two
main rollers. Raise both ends an equal
amount.
6. Run workpiece through the machine
using the handles. If workpiece is large,
make sure it receives proper support as it
exits the machine.
7. Make further passes of workpiece,
raising the idle roll incrementally before
each pass, until desired radius is
achieved.
No exact formula can be followed when
making roll adjustments because material
“spring-back ”varies with the kind of
material being formed. Only by test
forming several pieces can correct
adjustments be obtained. Also, keep in
mind that it is much easier to re-pass
material to make a smaller radius than to
attempt to increase a radius that was
made too small.
The idle roll must be adjusted exactly
parallel or the material will spiral during
the rolling process. Measure each end of
the opening with calipers if greater
precision is required.

Operation Manual 3-IN-1/30
KAKA Industrial®
- 9 -
Deliberately setting the rolls non-parallel
can be used to make cone shapes.
To remove cylindrical shaped
workpieces:
1. Loosen bolt (R, Figure 12)
Figure 12
2.Carefully grasp upper roll and swing out
the end.
Grasp upper roll firmly,
to prevent it falling out of machine.
3.Slip workpiece off end of roll.
4.Re install upper roll, and tighten bolt (R,
Figure 12).
Flat Rolling
Softer metals (copper, aluminum, etc.)
can be processed through the slip roll
machine to straighten, flatten, or reduce
their thickness. Simply adjust the upper
press roll for thickness, lower idle roll all
the way down, and feed workpiece
through (Figure 13).
NOTE: The idle roll will not descend
completely out of the path of the
workpiece; thus, there may be a slight
bend in the workpiece. By flipping the
workpiece over and re-feeding it, this
bend can be minimized.
Figure 13
Forming a Radius
1. Adjust upper press roll as needed.
2. Insert workpiece from front.
3. Operate handle; when the material
reaches the point where the radius is to
begin (a, Figure 14), stop the machine
and raise the idle roll an equal amount on
each end to achieve desired bend.

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 10 -
Figure 14
4. Restart rolls and continue until bend is
completed (b, Figure 14). Support
workpiece as it exits machine.
5. Make further passes if needed, along
with incremental idle roll adjustments.
Forming a Tube
1. Adjust upper press roll as needed for
workpiece thickness.
2. Feed workpiece into machine. As it
nears the end (a, Figure 15), stop and
reverse direction (b, Figure 15).
3. Make further passes if needed, along
with incremental idle roll adjustments.
Figure 15
Bending Wire
There are three wire grooves at the end
of the press rollers to accommodate a
5/32”, 11/64” and a 7/32” wire.
Use the smallest groove into which the
wire will comfortably fit. Bend the wire
using the same principles as described
for forming a radius. To make a complete
loop of wire, use the instructions for
forming a tube.
Maintenance/Lubrication
Use caution when doing
maintenance work around the shear
blades.
1.Apply #2 lithium tube grease once a
month to the grease nipples on both ends
of frame (A, Figure 16).
2.Keep the slip rolls clean and rust-free,
and frequently apply a light coat of oil to
them.
3.Lightly brush multi-purpose grease onto
the gears at the end of the rollers (B,
Figure 16). Turn operating handle to
distribute the grease.
4.Keep other exposed areas clean and
lightly coated with oil, such as the shear
blades, table and upper dies. (Remove

Operation Manual 3-IN-1/30
KAKA Industrial®
- 11 -
upper dies from bar for more effective
cleaning).
Figure 16
Optional Accessories
Part No. Description
A Optional Stand
B Optional Stand
C Optional Stand
Stand type A
Stand type B
Stand type C

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 12 -
Trouble
Probable Cause
Remedy
SHEAR
Material won’t cut.
Incorrect blade gap.
Adjust gap to accommodate
thicker
material.
Machine capacity exceeded.
Use materials within capacity.
Cuts not square.
Unequal blade gap.
Make blade gap equal.
Not contacting table guides.
Maintain consistent guides
contact.
Blade is bowed.
Remove bow.
Insufficient hold-down
pressure.
Adjust hold down.
Poor cut quality.
Dull blade(s).
Replace or sharpen.
Incorrect blade gap.
Adjust gap as needed.
Loose gibes.
Adjust backlash out of gibes.
BRAKE
Workpiece not
bending, or
bending difficult.
Workpiece too thick.
Use materials within capacity.
Improper bend allowance.
Adjust brake beam for proper
bend size.
Bend radius not
consistent across
material.
Machine capacity exceeded.
Use materials within capacity.
Brake beam improperly set for
bending
allowance.
Adjust brake beam for
consistent bend.
SLIP ROLL
Cones are made
when
trying to roll
cylinders.
Rolls not parallel.
Adjust idle (rear) roll until
parallel to upper
press roll.
Workpiece not
bending.
Machine capacity exceeded.
Use materials within capacity.
Idle roll not engaging.
Inspect and make corrections as
needed.

Operation Manual 3-IN-1/30
KAKA Industrial®
- 13 -
PARTS LIST
PART
NO.
DESCRIPTION
Q'TY
PART
NO.
DESCRIPTION
Q'TY
1
Left frame
1
18
Handle
1
2
Work bench
1
19
Threaded rod
2
3
Cross beam
1
20
Positioning plate
2
4
Crank arm
2
21
Limited block
1
5
Right frame
1
22
Support Plate
1
6
Rear frame
1
23
Blade
2
7
Cover
2
24
Back pressing roll
1
8
Press plate bracket
2
25
Lead screw
2
9
Spring
2
26
Nut M10
2
10
Press plate
1
27
Adjusting screw
2
11
Moving cutter plate
1
28
Grease fitting
2
12-1
Upper braking Die 10"
1
29
Press cover
2
12-2
Upper braking Die 8"
1
30
Gear
2
12-3
Upper braking Die 6"
1
31
Lower roll
1
12-4
Upper braking Die 3"
1
32
Upper roll
1
12-5
Upper braking Die 2"
1
33
Protecting cover
1
12-6
Upper braking Die 1"
1
34
Pin (φ3X18)
2
13
Die clamping plate
1
35
Eccentric mounting
2
14
Bolt M10X60
2
36
Handle
2
15
Arm rolling wheel
2
37
Roller Adjustment Knob
2
16
Guide
1
38
Flat Key
2
17
Adjustable nut
2
39
Screw M6X16
4

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 14 -
PART
NO.
DESCRIPTION
Q'TY
PART
NO.
DESCRIPTION
Q'TY
40
Screw M6X12
2
53
Screw M8X25
9
41
Bolt M6X40
2
54
Screw M10X25
4
42
Pin (φ4X10)
2
55
Washer
2
43
Handle
4
56
Screw M8X80
2
44
Screw M6X10
2
57
Screw M10X25
2
45
Screw M10X45
2
58
Screw M6X12
2
46
Washer
4
59
Screw M6X12
14
47
Bolt M12X60
1
60
Bushing
4
48
Bolt M10X25
2
61
Nut M10
2
49
Washer
2
62
Stand type A (Optional)
1
50
Nut M12
3
63
Stand type B (Optional)
1
51
Bolt M12X40
2
64
Stand type C (Optional)
1
52
Screw M10X35
2

Operation Manual 3-IN-1/30
KAKA Industrial®
- 15 -
Diagram:

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 16 -
NOTES

Operation Manual 3-IN-1/30
KAKA Industrial®
- 17 -
NOTES

Operation Manual 3-IN-1/30
Model 3-IN-1/30
- 18 -
SERVICE RECORD
KAKA®Industrial
Date Maintenance performed Repair components require

Operation Manual 3-IN-1/30
KAKA Industrial®
- 19 -
SERVICE RECORD
KAKA®Industrial
Date Maintenance performed Repair components require

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
Stock No: 171003
Edition 2 01/2019
Copyright ©2019 KAKA