KAKA Industrial PR-3 - User Manual

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Operation Manual PR-3

KAKA Industrial

- 1 -

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.

Specifications

Stock No. ......................................176001

Dia. of Roller.......................32mm(1

⁄

Round Steel Capacity.............6.5mm(

⁄

Flat Steel Capacity........25x4mm(1x0.16")

Handle length....................320mm(12

⁄

Packing dimensions......360x200x210mm

(14.2x7.9x8.3")

Net Weight.........................6kg (13.2 lbs.)

Unpacking

The ROLL BENDER PR-3 is shipped

from the manufacture 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.

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.

SAVE THESE INSTRUCTIONS

Thank you for purchasing PR-3 ROLL

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.

SAFETY RULES

1. Kno w you r mac hi ne . Re ad th is

manual carefully. Learn the machine’s

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Summary

General Warnings and Precautions

Safety Rules

Know Your Machine

Understand the machine's functions, applications, and potential hazards.

Work Area Safety

Maintain a clean, well-lit work area and keep children away.

Safe Operation Practices

Do not operate under influence, use safety equipment, wear proper apparel, avoid overreaching.

Machine Integrity and Care

Check for damage, keep hands away from moving parts, stay alert, use correct parts.

Equipment Storage and Use

Store idle equipment properly and use the correct tool for the job.

Assembly Instructions

Connector and Drive Shaft Assembly

Assemble connector onto drive shaft and secure with taper pin.

Handle Attachment

Attach the handle to the connector and drive shaft assembly.

Mounting Procedure

Workbench Setup

Position the unit on the workbench, mark, drill, and secure with bolts.

Operating the Roller Bender

Ring Size Adjustment

Adjust the wheel position using the knob for desired ring sizes.

Bending Process

Insert stock, clamp, and rotate handle to form rings.

Ring Removal

Loosen clamping action by turning the knob counterclockwise.

Maintenance and Care

Cleaning and Lubrication

Clean with solvent and lubricate key drive shafts and adjustable shaft.

Storage

Store the tool in a dry area out of reach of children.

The KAKA Industrial PR-3 is a manual roll bender designed for shaping various metal stocks into rings. This robust tool is ideal for small to medium-scale metalworking applications, offering precision and control for a variety of ring sizes.

Function Description

The primary function of the PR-3 roll bender is to bend round steel, flat steel, and other suitable metal stocks into circular shapes, or rings. It operates manually, requiring the user to rotate a handle to drive the bending process. The machine utilizes a three-roller system: an upper drive wheel, a lower drive wheel, and an adjustable wheel. The stock is fed between these rollers, and by adjusting the position of the adjustable wheel, the radius of the bend can be controlled, allowing for the creation of rings of different diameters. The handle is rotated counter-clockwise to process the ring, and a knob is used to clamp and loosen the stock between the wheels.

Important Technical Specifications

Stock No.: 176001
Dia. of Roller: 32mm (1 1/4")
Round Steel Capacity: 6.5mm (1/4")
Flat Steel Capacity: 25x4mm (1x0.16")
Handle Length: 320mm (12 5/8")
Packing Dimensions: 360x200x210mm (14.2x7.9x8.3")
Net Weight: 6kg (13.2 lbs.)

Usage Features

The PR-3 roll bender is designed for ease of assembly and operation, with several features that enhance its usability:

Mounting: The unit must be securely mounted to a workbench before use. This involves marking and drilling holes through the base of the unit into the workbench, then securing it with bolts, lock washers, washers, and nuts (sold separately). Proper mounting ensures stability and safe operation.
Assembly: The assembly process involves sliding the connector onto the drive shaft II, then inserting the handle into the connector and drive shaft II, and finally attaching the connector to the drive shaft II using a taper pin. Clear diagrams are provided to guide the user through this process.
Adjustable Ring Size: The machine features an adjustable wheel that can be moved up or down by turning a knob. This allows for precise control over the ring diameter:
- 1" rings: Adjustable wheel in its uppermost position.
- 2" rings: Adjustable wheel in the middle position.
- Larger rings: Adjustable wheel in the lowest position.
Clamping Mechanism: A knob is used to clamp the stock between the wheels, ensuring a secure grip during the bending process. Turning the knob clockwise clamps the stock, while turning it counter-clockwise loosens it for removal of completed rings.
Manual Operation: The handle provides a direct and tactile way to control the bending, giving the operator full command over the process.
Safety Guidelines: The manual emphasizes critical safety rules, including keeping the work area clean and well-lit, keeping children away, avoiding operation under the influence of alcohol or drugs, using safety equipment (eye protection, dust mask, non-skid safety shoes, hard hat, hearing protection), wearing proper apparel (avoiding loose clothing, jewelry), maintaining proper footing and balance, regularly checking for damage, keeping hands away from moving parts, staying alert, using only identical replacement parts and intended accessories, storing idle equipment safely, and not forcing the machine.

Maintenance Features

Proper maintenance is crucial for the longevity and optimal performance of the PR-3 roll bender:

Cleaning: After each use, the machine should be cleaned with a non-toxic solvent to remove any residue or debris.
Lubrication: There are three key lubrication points on the machine: the DRIVE SHAFT I (#12), DRIVE SHAFT II (#11), and the ADJUSTABLE SHAFT (#18). These points should be greased using the ZERK FITTINGS (#21) to ensure smooth operation and prevent wear.
Storage: When not in use, the tool should be stored in a dry location to inhibit rust. It should also be stored in an area out of reach of children to prevent unauthorized access and potential accidents.
Damage Inspection: Users are advised to regularly check the tool for damage. If any part is damaged, it should be carefully inspected to ensure it can still perform its intended function correctly. In case of doubt, the part should be repaired by a qualified technician or the dealer should be consulted for advice.
Parts List and Diagram: The manual includes a comprehensive parts list and an exploded diagram, which are invaluable for identifying specific components for maintenance, repair, or replacement. This allows users to order the correct parts and understand the machine's internal structure.

The KAKA Industrial PR-3 roll bender is a reliable and user-friendly tool for metal ring fabrication, provided that proper assembly, operation, and maintenance procedures are followed.