KAKA Industrial W-2416Z User manual

Operation Manual W-2416Z
KAKA Industrial®
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SPECIFICATIONS
Stock No. .....................................173121
Model.........................................W-2416Z
Bend Length.........................24” (610mm)
Bend Thickness(mild stee*l).....................
........................................16ga. (1.52mm)
Bend Thickness(stainless steel**)............
......................................20ga. (0.912mm)
Bend Angle........................0-135 degrees
Box Depth............................1.18” (30mm)
Minimum Reverse Bend....0.625” (16mm)
Floor Stand...........................................No
Shipping Dimensions.........34” x 14” x 18”
(864 x 356 x 457mm)
Shipping Weight...............185 lbs. (85 kg)
(Based on a material tensile strength of
*64000 PSI – mild steel **100000 PSI –
stainless steel )
DESCRIPTION
The W-2416Z Pan Brake is hand
operated and capable of bending up to
16ga. (1.52mm) mild steel and 20ga.
(.912mm) stainless x 24”(610mm) long.
The machine has 5 removable fingers and
a 1.18”(30mm) box depth allowing it to
fabricate pans, boxes, channels, angles,
and other shapes. Adjustable
counterweights allow the operator to
balance the bending leaf to correspond to
material thickness.
Note
The photos illustrations using in this
manual are representative only and may
not depict the actual color, labeling or
accessories and may be intended to
illustrate technique only.
Note
The specifications and dimensions
presented here are subject to change
without prior notice due to improvements
of our products.
SAVE THESE INSTRUCTIONS
(Refer to them often and use them to
instruct others.)
PROTECT EYES
Wear safety glasses or suitable eye

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protection when working on or around
machinery.
BEWARE OF CRUSH HAZARD
Closing upper beam and brake bed will
result in loss of fingers or limbs if placed
in machine. NEVER place your hand or
any part of your body in this machine.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can
cause impairment or loss of hearing.
Wear suitable hearing protective devices
such as ear muffs or earplugs to protect
against objectionable or uncomfortable
loud noises.
BEWARE OF CRUSH HAZARD
NEVER place your hands, fingers, or any
part of your body in the die area of this
machine.
KEEP CLEAR OF MOVING OBJECTS
Always be aware of the position of the
clamp handle and the counterweight.
They are heavy and can swing back
suddenly causing serious body or head
injuries.
SAFETY PRECAUTIONS
Metal working can be dangerous if safe
and proper operating procedures are not
followed. As with all machinery, there are
certain hazards involved with the
operation of the product. Using the
machine with respect and caution will
considerably lessen the possibility of
personal injury. However, if normal safety
precautions are overlooked or ignored,
personal injury to the operator may result.
Safety equipment such as guards,
hold-downs, safety glasses, dust masks
and hearing protection can reduce your
potential for injury. But even the best
guard won’t make up for poor judgment,
carelessness or inattention. Always use
common sense and exercise caution in
the workshop. If a procedure feels
dangerous, don’t try it.
REMEMBER: Your personal safety is
your responsibility.
WARNING
FAILURE TO FOLLOW THESE RULES
MAY RESULT IN SERIOUS PERSONAL
INJURY
1. Only trained and qualified personnel
can operate this machine.

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KAKA Industrial®
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2. Make sure guards are in place and in
proper working order before operating
machinery.
3. Remove any adjusting tools. Before
operating the machine, make sure any
adjusting tools have been removed.
4. Keep work area clean. Cluttered areas
invite injuries.
5. Overloading machine. By overloading
the machine you may cause injury from
flying parts. DO NOT exceed the
specified machine capacities.
6. Machine usage. DO NOT use the
brake as a press or crushing tool.
7. Dressing material edges. Before
bending sheet metal, always chamfer and
deburr all sharp edges.
8. Do not force tool. Your machine will do
a better and safer job if used as intended.
DO NOT use inappropriate attachments
in an attempt to exceed the machines
rated capacity.
9. Use the right tool for the job. DO NOT
attempt to force a small tool or
attachment to do the work of a large
industrial tool. DO NOT use a tool for a
purpose for which it was not intended.
10. Dress appropriate. DO NOT wear
loose fitting clothing or jewelry as they
can be caught in moving machine parts.
Protective clothing and steel toe shoes
are recommended when using machinery.
Wear a restrictive hair covering to contain
long hair.
11. Use eye and ear protection. Always
wear ISO approved impact safety
goggles. Wear a full- face shield if you are
producing metal filings.
12. Do not overreach. Maintain proper
footing and balance at all times. DO NOT
reach over or across a running machine.
13. Stay alert. Watch what you are doing
and use common sense. DO NOT
operate any tool or machine when you
are tired.
14. Check for damaged parts. Before
using any tool or machine, carefully check
any part that appears damaged. Check
for alignment and binding of moving parts
that may affect proper machine operation.
15. Observe work area conditions. DO
NOT use machines or power tools in
damp or wet locations. Do not expose to
rain. Keep work area well lighted. DO
NOT use electrically powered tools in the
presence of flammable gases or liquids.
16. Blade adjustments and maintenance.
Always keep blades sharp and properly
adjusted for optimum performance.
17. Keep children away. Children must

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never be allowed in the work area. DO
NOT let them handle machines, tools, or
extension cords.
18. Store idle equipment. When not in
use, tools must be stored in a dry location
to inhibit rust. Always lock up tools and
keep them out of reach of children.
19. DO NOT operate machine if under the
influence of alcohol or drugs. Read
warning labels on prescriptions. If there is
any doubt, DO NOT operate the machine.
20. Keep visitors a safe distance from the
work area.
CLEANING
Your machine may be shipped with a
rustproof waxy oil coating and grease on
the exposed unpainted metal surfaces. To
remove this protective coating, use a
degreaser or solvent cleaner. For a more
thorough cleaning, some parts will
occasionally have to be removed. DO
NOT USE acetone or brake cleaner as
they may damage painted surfaces.
Follow manufacturer’s label instructions
when using any type of cleaning product.
After cleaning, wipe unpainted metal
surfaces with a light coating of quality oil
or grease for protection.
WARNING
DO NOT USE gasoline or other petroleum
products to clean the machine. They have
low flash points and can explode or cause
fire.
CAUTION
When using cleaning solvents work in a
well-ventilated area. Many cleaning
solvents are toxic if inhaled.
TRANSPORTING AND LIFTING
CAUTION
Lifting and carrying operations should be
carried out by skilled workers, such as a
truck operator, crane operator, etc. If a
crane is used to lift the machine, attach
the lifting chain carefully, making sure the
machine is well balanced. Choose a
location that will keep the machine free
from vibration and dust from other
machinery. Keep in mind that having a

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KAKA Industrial®
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large clearance area around the
machine is important for safe and
efficient working conditions.
Follow these guidelines when lifting:
●Always lift and carry the machine with
the lifting holes provided at the top of the
machine.
●Use lift equipment such as straps,
chains, capable of lifting 1.5 to 2 times the
weight of the machine.
●Take proper precautions for handling
and lifting.
●Check if the load is properly balanced
by lifting it an inch or two.
●Lift the machine, avoiding sudden
accelerations or quick changes of
direction.
●Locate the machine where it is to be
installed, and lower slowly until it touches
the floor.
●The lift truck must be able to lift at least
1.5 –2 times the machines gross weight.
●Make sure the machine is balanced.
While transporting, avoid rough or jerky
motion, and maintain a safe clearance
zone around the transport area.
●Use a fork lift with sufficient lifting
capacity and forks that are long enough
to reach the complete width of the
machine.
●Remove the securing bolts that attach
the machine to the pallet.
●Approaching the machine from the side,
lift the machine on the frame taking care
that there are no cables or pipes in the
area of the forks.
●Move the machine to the required
position and lower gently to the floor.
●Level the machine so that all the
supporting feet are taking the weight of
the machine and no rocking is taking
place.
INSTALLATION
IMPORTANT:
Consider the following when looking for a
suitable location to place the machine:
●Overall weight of the machine.
●Weight of material being processed.
●Sizes of material to be processed
through the machine.

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●Space needed for auxiliary stands,
work tables, or other machinery.
●Clearance from walls and other
obstacles.
●Maintain an adequate working area
around the machine for safety.
●Have the work area well illuminated
with proper lighting.
●Keep the floor free of oil and make sure
it is not slippery.
●Remove scrap and waste materials
regularly, and make sure the work area is
free from obstructing objects.
●If long lengths of material are to be fed
into the machine, make sure that they will
not extend into any aisles.
Before beginning assembly, take note of
the following precautions and suggestions.
●LEVELING: The machine should be
sited on a level, concrete floor. Provisions
for securing it should be in position prior
to placing the machine. The accuracy of
any machine depends on the precise
placement of it to the mounting surface.
●FLOOR: This tool distributes a large
amount of weight over a small area. Make
certain that the floor is capable of
supporting the weight of the machine,
work stock, and the operator. The floor
should also be a level surface. If the unit
wobbles or rocks once in place, be sure
to eliminate by using shims.
●WORKING CLEARANCES: Take into
consideration the size of the material to
be processed. Make sure that you allow
enough space for you to operate the
machine freely.
Anchoring the Machine
●Position the machine on a firm and
level concrete floor.
●Maintain a safe operating distance
around the machine.
●Anchor the machine to the floor, as
shown in the diagram, using bolts and
expansion plugs or sunken tie rods that
connect through holes in the base of the
stand.
Adjusting the Setback
Setback is the distance from the front
edge of the finger to the front edge of the
clamp block as shown in (fig. 6). This

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distance is determined by the gauge
(thickness) of the piece part and inside
radius of the bend. The setback is
typically 1-1/2 - 2 times the material
thickness.
1.To adjust, make sure all the fingers are
properly aligned to each other and the
hold down assembly is not locked in the
down position.
2.Loosen the setscrews at the back of the
hold down assembly as indicated by the
“*”in (fig. 7). Insert a tool, such as an
allen wrench, into one of the spooked
holes of the eccentric hub and rotate it,
which moves the hold down assembly
either forward or back. When the fingers
are at the correct setback distance and
parallel to the clamp block edge, tighten
the setscrews “*”.
Adjusting the Clamping Pressure
The clamping pressure may have to be
adjusted as the thickness of the piece
part changes. A suitable pressure should
have a medium resistance when pulling
back on the hold down handle. At the end
of the stroke there should be a definite
locking of the piece part under the hold
down assembly.
1. Loosen the turnbuckle jam nuts on
both sides of the hold down assembly.
Rotate the two turnbuckles until the
desired tension is reached.
2. Retighten all four jam nuts.

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OPERATION
When performing basic bending
operations it is important that the fingers
of the brake are parallel with the edge of
the clamping block. Also make sure you
have the proper setback and clamping
pressure set for the thickness material
being bent.
CAUTION
Always wear proper eye protection with
side shields, safety footwear, and leather
gloves to protect from burrs and sharp
edges.
Keep hands and fingers clear of the
clamping beam. Stand off to the side of
the machine to avoid getting hit with the
bending apron as it comes up to bend.
When handling large heavy sheets make
sure they are properly supported.
Bending Sheet Metal
1. Lift and rotate the clamping handle (cw)
clockwise to raise the clamping assembly.
2. Insert the piece part between the
clamp block and the brake fingers.
3. Align the fingers of the hold down
assembly to the scribed bend line of the
piece part and clamp in place by pulling
the clamp handle back.
Note: DO NOT force the clamping handle.
The holding pressure only needs to be
tight enough to hold the sheet metal from
moving when bending.
4. Pull up on the bending leaf handles
until the piece part has reached the
desired bend angle.
5. Lower the bending leaf, raise the hold
down assembly, and remove the bent
piece part.
6. If you are doing box and pan bending,
choose fingers that closely match the
dimensions of the finished piece.
BENDING ALLOWANCE
In order to bend sheet metal accurately,
you will need to consider the total length
of each bend. This is referred to as bend
allowance. Subtract the bend allowance
from the sum of the outside dimensions of
the piece part to obtain the actual overall
length or width of the piece. Because of
differences in sheet metal hardness, and
whether the bend is made with the grain
or against it, exact allowances must
sometimes be made by trial and error.
However bend allowances for general

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use can be obtained from metal working
books or from the Internet.
UNDERSTANDING SPRINGBACK
Springback, also known as elastic
recovery, is the result of the metal
wanting to return to its original shape
after undergoing compression and stretch.
After the bending leaf is removed from
the metal and the load is released, the
piece part relaxes, forcing the bent
portion of the metal to return slightly to its
original shape. The key to obtaining the
correct bend angle is to over bend the
metal a little and allow it to spring back to
the desired angle. All metals exhibit a
certain amount of spring back.
MATERIAL SELECTION
CAUTION
It must be determined by the customer
that materials being processed through
the machine are NOT potentially
hazardous to operator or personnel
working nearby.
When selecting materials keep these
instructions in mind:
●Material must be clean and dry.
(without oil)
●Material should have a smooth
surface so it processes easily.
●Dimensional properties of material
must be consistent and not exceed the
machine capacity values.
●Chemical structure of material must
be consistent.
●Buy certificated steel from the same
vendor when possible.
LUBRICATION AND MAINTENANCE
WARNING
Maintenance should be performed
on a regular basis by qualified
personnel.
Always follow proper safety precautions
when working on or around any
machinery.
●Check daily for any unsafe conditions
and fix immediately.
●Check that all nuts and bolts are
properly tightened.
●On a weekly basis clean the machine
and the area around it.

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●Lubricate threaded components and
sliding devices.
●Apply rust inhibitive lubricant to all
non-painted surfaces.
Oil Ports
Using an oil can with a good quality #30W
oil, apply 5-6 drops into each of the ports
on both ends of the machine. Repeat
weekly or more often depending on
usage. Wipe off any excess oil.
Note: Proper maintenance can increase
the life expectancy of your machine.