KAKA Industrial W-3616Z User manual

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W-3616Z Pan Box Brake
Operator Manual
KAKA INDUSTRIAL LLC

5
SAVE THESE INSTRUCTIONS.
Refer to them often and use them to instruct others.
PROTECT EYES
Wear safety glasses or suitable eye 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.
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 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.

TECHNICAL SPECIFICATIONS
Bend Length 36” (915mm)
Bend Material Thickness 16ga. (1.52mm) mild steel*
20ga. (0.912mm) stainless steel**
Bend Angle 0 – 135 degrees
Box Depth 1.18” (30mm)
Minimum Reverse Bend .625” (16mm)
Floor Stand No
Shipping Dimensions (L x W x H) 47”x16’’x22’’
Shipping Weight 271 lbs.
Based on a material tensile strength of *64000 PSI – mild steel
**100000 PSI – stainless steel
DESCRIPTION
The W-3616Z Pan Brake is hand operated and capable of bending up to 16ga. (1.52mm) mild
steel and 20ga. (.912mm) stainless x36” (915mm) long. The machine has 6 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 product

10
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.
GAS

11
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 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.

12
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.
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.
.31"
(7.87mm)
.50"
(12.7mm)

*
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
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
Bending
Wing
Setback
Distance
Clamp
Block
figure 6
Finger
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
figure 7
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.
figure 8

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 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.
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.

PARTS IDENTIFICATION DRAWING

PARTS IDENTIFICATION LIST
Item Description Qty.
1Leaf weldment 1
2Shaft 1
3Body 1
4Hold down assembly 1
5Eccentric shaft 2
6Connecting block 2
7Washer M6 4
8Hex bolt M6 x 11 4
9Hex nut M10 2
10 Threaded stud 2
11 Hex nut M10 2
12 Bushing 2
13 Right eccentric shaft 1
14 Handle rod 1
15 Handle 1
16 Pin shaft 2
17 Cotter pin 2
18 Set screw M6 x 8 4
19 Flat key 2
20 Bushing 4
21 Small shaft 2
22 Left eccentric shaft 1
23 T-nut 8
24 Bending die (set) 1
25 Soc. screw M8 x 22 8
26 Flat washer M8 8
27 Hex bolt M10 x 15 2
28 Counterweight 1

TROUBLESHOOTING
FAULT PROBABLE CAUSE REMEDY
INACCURATE BENDS
Fingers are not aligned
Setback distance is not equal
from one side to the other
Clamping assembly is not
holding piece part securely.
Follow proper finger alignment
procedure.
Accurately measure distance
and set accordingly.
Re-adjust the clamping
pressure.
BENDING LEAF HARD
TO LIFT AND BEND.
Exceeding the bending limits of
the brake.
Counterweight is not on leaf.
Do not bend material thicker
than the machine was designed
for.
Attach the counterweight to
lessen force needed to lift
bending leaf.