KAKA Industrial W-4816Z User manual

Operation Manual W-4816Z
KAKA Industrial®
— 1 —
Unpacking
The Pan & Box Brake is shipped
from the manufacturer in a carefully
packed ply-wood case. 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.
Immediately report missing parts to
dealer.
If damage has occurred, shipping
damage claims must be led with the
carrier and are the responsibility of
the user.
Specications
The Model W-4816Z Pan & Box
Brake is hand operated and capable
of bending up to 16 ga. (1.52mm) mild
steel and 20 ga. (.912mm) stainless
x 48” (1219mm) long allowing it to
fabricate pans, channels, angles,
and other shapes. Adjustable
counterweights allow the operator
to balance the bending leaf to
correspond to material thickness. An
adjustable stop gauge is included to
allow the operator to perform repeat
bends.
Item No. ................................173123
Model..............................W-4816Z
Bending Length.........48" (1220 mm)
Bending Thickness......16Ga (1.5 mm)
Bending Angle........................0-135°
Packing size......62"x18"x26" (158x45x65 cm)
N.W/G.W. ........365/405 lbs (166/184 kg)
SAVE THESE INSTRUCTIONS
Thank you for purchasing our
W-4816Z Pan and Box Brake. 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.
General Safety Information
CAUTION
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.

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Operation Manual W-4816Z
Model W-4816Z
intended. DO NOT use inappropriate
attachments in an attempt to exceed
the machines rated capacity.
3.Overloading machine. By
overloading the machine you may
cause injury from flying parts. DO
NOT exceed the specified machine
capacities.
4. Machine usage. DO NOT use the
brake as a press or crushing tool.
5. Dressing material edges. Before
bending sheet metal, always chamfer
and deburr all sharp edges.
6.Blade adjustments and
maintenance. Always keep blades
sharp and properly adjusted for
optimum performance.
7.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.
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 supplied by the operator.
2. Wear protective hair covering to
contain long hair.
3. Wear safety shoes with non-slip
soles.
4. Wear safety glasses. 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 children. Inspect the tools
prior to storage and before reuse.
12. Maintain product labels and
nameplates. These carry important
safety information.
KNOW HOW TO USE TOOL
1.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.
2.Do not force tool. Your machine will
do a better and safer job if used as

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Operation Manual W-4816Z
KAKA Industrial®
Important:
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 ash points
and can explode or cause re.
CAUTION
When using cleaning solvents
work in a well-ventilated area.
Many cleaning solvents are toxic if
inhaled.
Assembly
IMPORTANT:
Consider the following when looking
for a suitable location to place the
machine:
1. Overall weight of the machine.
2. Weight of material being processed.
3. Sizes of material to be processed
through the machine.
4. Space needed for auxiliary stands,
work tables, or other machinery.
5. Clearance from walls and other
obstacles.
6. Maintain an adequate working area
around the machine for safety.
7. Have the work area well illuminated
with proper lighting.
8. Keep the oor free of oil and make
sure it is not slippery.
9. Remove scrap and waste materials
regularly, and make sure the work
area is free from obstructing objects.
10. 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.
1. Is the machine is bolted to the
pallet? Before attempting any of the
assembly procedures remove all of
the loose parts and hardware and
unbolt the machine from the pallet.
2. 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.

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Operation Manual W-4816Z
Model W-4816Z
3. 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.
4. 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
1. Position the machine on a rm and
level concrete oor.
2. Maintain a safe operating distance
around the machine.
3. Anchor the machine to the oor, as
shown in the diagram, using bolts and
expansion plugs or sunken tie rods
that connect through holes in the base
of the stand.(Pic.1)
Attaching the Counterweight
1.Have a helper hold the
counterweight.
2. Back off the two hex bolts and
slide the counterweight rod into the
receiver pipe.
3. When the rod is flush with the
bottom of the receiver, tighten the hex
bolts.(Pic.2)
NOTE
DO NOT use the counterweight
handle to raise the bending leaf.
You may damage the hinges or the
bending leaf.
Attaching the Stop Rod
1. Remove the nut and washer and
slide the stop rod into the stop block
(A) the install the washer and nut
back onto the rod.
2. Remove the cotter pin and push the
short end of the stop rod into the tab
(B) on the bending leaf and secure
with the cotter pin. (Pic.3)

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Operation Manual W-4816Z
KAKA Industrial®
Adjusting the Stop Rod
The stop rod is used for repeat
bending when you want the bending
leaf to stop at the same
position each time.
1. Loosen the stop nut and washer
and make your bend, stopping at the
top of the bend.
2. Tighten the nut and washer up to
the stop block.
3. The bending angle can now be
repeated until reset by the operator.
Adjusting the Setback
Setback is the distance from the front
edge of the nger to the front edge of
the clamp block as shown in picture.
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. (Pic.4)
1. To adjust, make sure all the ngers
are properly aligned to each other and
the hold down assembly is not locked
in the down position.
2. Loosen the setscrews (C) at the
back of the hold down assembly (Pic.
5).
3. Insert a tool, such as an allen
wrench, into one of the spoke holes of
the eccentric hub and rotate it, which
moves the hold down assembly either
forward or back.
4. When the ngers are at the correct
setback distance and parallel to
the clamp block edge, tighten the
setscrews (C).

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Operation Manual W-4816Z
Model W-4816Z
Adjusting the Clamping
Pressure
CAUTION
1. Excessive clamping pressure can
“pre load” and permanently distort
the brake.
2. DO NOT bend material heavier
than the rated capacity, even in
shorter lengths.
3. Use material with square-sheared
edges. (a rolled edge will cause
bowing).
4. Bending a round object will warp
or nick the clamp edge.
5. Adjust the clamp pressure
accordingly for different metal
gauges.
6. Do not use a pipe extension
on the clamp bars to get more
leverage.
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(s). At the end of
the stroke there should be a definite
locking of the piece part under the
clamping leaf.
To adjust the pressure, move the nuts
on the threaded link shaft either up
or down.
1. To adjust the clamping pressure,
tighten both sides of the clamping leaf
with a piece part in the brake.
a. If the clamping pressure seems
light and the piece part is loose in the
clamp, move the adjusting nuts UP.
b. If the clamping pressure seems
hard and you can’t lock the handles,
move the adjusting nuts DOWN.
c. Once the pressure feels right, no
further adjustments are necessary
for this thickness piece part. (When
changing thickness it may become
necessary to adjust again.)
2. Remove the piece part from under
the clamping leaf, lock down the leaf
with the handles, and loosen pressure
on the top nut.
3. Unlock the clamping leaf and turn
the bottom nut ½ turn in the desired
direction.
4. Lock the clamping leaf, re-tighten
the top nut, and repeat Step 1 above
until the desired pressure is reached.

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Operation Manual W-4816Z
KAKA Industrial®
Clamp Alignment (end to
end)
Make a 90° test bend about 2”
(50.8mm) in from each end of the
machine. Stack the bent strips on top
of each other and check that they are
bent to the same degree.
If a strip is over bent, increase the
setback distance on that side. If a strip
is under bent, decrease the setback
distance on that side. Again, move the
setback adjustment past the desired
set back point, and then forward to
remove the slack.
Bending Wing Alignment
Bending accuracy is dependent on
the top surface of the bending leaf
and the attached bending wing being
ush with the top face of the clamping
block when the bending leaf is in the
lowered position. If it appears that
an adjustment is necessary, contact
service team local, or manufacture.
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.
CAUTION
Keep hands and ngers 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.
CAUTION
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 ngers.
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

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Operation Manual W-4816Z
Model W-4816Z
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 nished 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
When selecting materials keep these
instructions in mind:
1. Material must be clean and dry.
(without oil)
2. Material should have a smooth
surface so it processes easily.
3. Dimensional properties of material
must be consistent and not exceed
the machine capacity values.
4. Chemical structure of material
must be consistent.
5. Buy certificated steel from the
same vendor when possible.
LUBRICATION AND
MAINTENANCE
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.

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Operation Manual W-4816Z
KAKA Industrial®
WARNING
Maintenance should be performed
on a regular basis by qualified
personnel.
Always follow proper safety
precautions when working on or
around any machinery.
1.Check daily for any unsafe
conditions and x immediately.
2. Check that all nuts and bolts are
properly tightened.
3. On a weekly basis clean the
machine and the area around it.
4. Lubricate threaded components
and sliding devices.
5. 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.
ASSEMBLY AND SETUP
STAND (Optional)
Assemble stand as picture shown below
using supplied bag of hardware.

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Operation Manual W-4816Z
Model W-4816Z
TROUBLESHOOTING
FAULT PROBABLE CAUSE REMEDY
INACCURATE BENDS
1. Fingers are not aligned
2. Setback distance is not equal
from one side to the other
3. Clamping assembly is not
holding piece part securely.
Follow proper nger alignment
procedure.
Accurately measure distance and
set accordingly.
Re-adjust the clamping pressure.
BENDING LEAF HARD
TO LIFT AND BEND.
1. Exceeding the bending limits
of the brake.
2. 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.

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Operation Manual W-4816Z
KAKA Industrial®

— 12 —
Operation Manual W-4816Z
Model W-4816Z
Parts List
Ref. Description QTY. Ref.No. Description QTY.
1 Nut M18 2 21 Clamp Plate 34mm 5
2 Left Eccentric Handle 1 22 Frame 1
3 Big Washer 2 23 Case 4
4 Left Connecting Rod 1 24 Shaft Ring Φ18 4
5 Washer 2 25 Shaft 2
6Spacer Bush 226 Shaft 2
7Cotter Pin φ4X25 4 27 Cotter Pin φ5X25 2
8Pin φ16X70 2 28 Hex. Bolt M10X35 1
9 Eccentric Shaft 2 29 Flat Gasket Φ10 1
10 Set Screw M8X8 4 30 Counterweight 1
11 Upper Die Framework 131 Counterweight Rod 1
12 Right Eccentric Handle 1 32 Set Screw M12X20 2
13 Right Connecting Rod 1 33 Bending Leaf 1
14 M12 4 34 Hex. Bolt M8X16 7
15 M10X25 18 35 Φ8 7
16 Brake Dies 4" 5 36 Limit Angle plate 1
17 Brake Dies 3" 6 37 Handle Grip 2
18 Brake Dies 2" 5 38 Φ18 2
19 Clamp Plate 63mm 5 39 Φ16 2
20 Clamp Plate 45mm 6

— 13 —
Operation Manual W-4816Z
KAKA Industrial®
Date Maintenance performed Repair components require
SERVICE RECORD

— 14 —
Operation Manual W-4816Z
Model W-4816Z
Date Maintenance performed Repair components require
SERVICE RECORD
NOTES

— 15 —
Operation Manual W-4816Z
KAKA Industrial®
Date Maintenance performed Repair components require
SERVICE RECORD
NOTES

— 16 —
Operation Manual W-4816Z
KAKA Industrial®
Item No: 173123
Edition 1 12/2020
Note: This manual is only for your reference. Owing to the continuous
improvement of the machine, changes may be made at any time without
obligation on notice.