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Knudson KR Series General Operating And Maintenance Instructions

Gutter forming machines
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KR-SERIES (KR-56A, KR-50A, KR-60A)
Gutter Forming Machines
GENERAL OPERATING AND MAINTENANCE INSTRUCTIONS
Knudson Mfg., Inc.
th
10401 W. 120
Ave.
Broomfield, CO 80021
USA
(303) 469-2101 (tel)
(303) 469-7994 (fax)
9/27/2005
VERSION 4.0
Version: 4.0
Date: 12/02
1

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  • Page 1 KR-SERIES (KR-56A, KR-50A, KR-60A) Gutter Forming Machines GENERAL OPERATING AND MAINTENANCE INSTRUCTIONS Knudson Mfg., Inc. 10401 W. 120 Ave. Broomfield, CO 80021 (303) 469-2101 (tel) Version: 4.0 (303) 469-7994 (fax) Date: 12/02 9/27/2005 VERSION 4.0...
  • Page 2 Change Record Page: Document: KR-SERIES Manual Date Change Authorization 12/02 Updated with solidworks models 9/27/2005 VERSION 4.0...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. PROFILE SPECIFICATIONS..................4 2. MACHINE SPECIFICATIONS ..................14 3. TERMINOLOGY ......................18 4. REQUIRED TOOLS AND EQUIPMENT..............20 5. INSTALLATION ......................21 6. SETUP AND OPERATION ..................25 7. ADJUSTMENT AND TROUBLESHOOTING............34 8. CHANGEOVER PROCEDURES ................44 9. MACHINE MAINTENANCE..................48 10. TRANSPORT AND MOVING .................50 9/27/2005 VERSION 4.0...

  • Page 4: Profile Specifications

    1. PROFILE SPECIFICATIONS 1.1. PROFILE SPECIFICATIONS 1.1.1. Profiles Refer to the enclosed profile drawings at the end of this Section: 5-in K-Style OG Gutter with Straight Back (KR-50A, KR-56A) 5-in K-Style OG Gutter with Free Float Hook (KR-50A, KR-56A) 5-in K-Style OG Gutter with 1-in Flange (KR-50A, KR-56A) 6-in K-Style OG Gutter Straight Back (KR-60A, KR-56A)
  • Page 5 9/27/2005 VERSION 4.0...
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  • Page 12 2. SAFETY FEATURES 2.1. GENERAL SAFETY RULES Read and understand entire Operator’s Manual prior to use of this machine. The operator should stay alert and use common sense when operating this and any machine. The operator should not use machine while tired or under the influence of drugs or alcohol. Proper dress is recommended.
  • Page 13 2.2.1. Safety Features Item Name Part Number Emergency Stop Button ELES-0B63 Top Front Cover 0050704 Top Rear Cover 0050703 Motor Cover, Top 0050702 Motor Cover, Side 0050705 Die Cover 0052326 Caution Sticker STKR-IBOP Four safety covers, combined with the design of the machine itself, completely encase the drive mechanisms of this machine.

  • Page 14: Machine Specifications

    3. MACHINE SPECIFICATIONS 3.1. MACHINE SPECIFICATIONS – MECHANICAL SYSTEMS 3.1.1. Basic Machine Specifications Length = 136-1/2-in (3467mm) (with Rack Shear) Width = 26-in (660mm) Height = 24-in (610mm) * Weight (base machine) = 1685-lbs (766-kg) Height (Including Uprights) = 35-in (889mm) Height (Including Spool) = 51-in (1295mm) *Note: Refer to the data sheet at the end of this Section for all weight specifications.
  • Page 15 3.1.7. Airborne Noise Emissions Equivalent continuous A-weighted sound pressure level = less than 70 dB (A) 3.2. STANDARD MACHINE SPECIFICATIONS – ELECTRICAL/CONTROL SYSTEMS 3.2.1. Electrical Power System 3.2.1.1. Standard Package Line Voltage = 100-115 Volts AC / 200-230 Volts AC (+/- 10%) Line Current = 15 Amps Line Frequency = 60 / 50 Hz (+/- 1%) Line Phase = 1φ...
  • Page 16 3.3.3. Altitude Range Up to 10,000 feet (3,000 meters) 3.3.4. Vibration, Shock, and Bump The machine will perform correctly under conditions normally associated with vehicular transport on maintained roads. Off-road transportation (to include non-maintained roads) may result in incorrect machine operation. 3.3.5.
  • Page 17 Data Sheet MACHINE/ACCESSORY WEIGHT SPECIFICATIONS Item Weight (lbs) Weight (kg) Base Machine 1685-lbs 766-kg Machine Entry End Cover 7-lbs 3.2-kg Machine Exit End Cover 18-lbs 12.7-kg Machine Motor Cover 15-lbs 6.8-kg 5-in Rack and Pinion Shear 29-lbs 13.2-kg 6-in Rack and Pinion Shear 40-lbs 18.2-kg 5-in Cam Shear...

  • Page 18: Terminology

    4. TERMINOLOGY 4.1. MACHINE NOMENCLATURE Entry end - the end of the machine into which the material is fed, the end with the black curved guides; also called the front end or feed end Exit end - the end of the machine from which the finished gutter profile emerges, the end with the shear; also called the rear end or discharge end Forming rolls - the rotating contoured dies used to both drive the material through the machine and form the finished gutter profile;...
  • Page 19 Camber - lateral curvature in coil stock - camber may lead to an inconsistent profile Coil Set - longitudinal curvature induced in coil stock due to the winding or coiling process - excessive coil set may cause rippling in the gutter profile Edge wave - a ripple-like effect on the edge of the material - often caused by the slitting process Gauge - term used to reference the thickness of steel material per AISI thickness tolerance ranges - ex: 24 Ga = .0276"...

  • Page 20: Required Tools And Equipment

    5. REQUIRED TOOLS AND EQUIPMENT 5.1. HAND TOOLS 5.1.1. Combination or Open End Wrenches ½-in, 9/16-in, ¾-in, 15/16-in, 1-1/8-in 5.1.2. T-Handle Hex Wrenches 5/32-in, 3/16-in, 7/32-in, ¼-in, 5/16-in, 3/8-in 5.1.3. L-Handle Hex Wrenches 5/32-in, 3/16-in, ¼-in, 5/16-in (Ball Nose L-Handle Hex Wrenches Recommended) 5.1.4.

  • Page 21: Installation

    Check the contents of the shipment and compare them to the shipping package list. Check for any missing or damaged components. Some parts/sub-assemblies may be shipped inside the machine, and must be removed prior to any operation. Contact your Knudson Mfg., Inc. Distributor if any problems exist. 6.1.1.
  • Page 22 Note: In many cases, even a new truck may have as much as 2-in (50-mm) of twist in an eight-foot bed. 6.2.2. Location of Controls In order to comply with European Union Machinery Directive (98/37/EC), the controls (electrical enclosure) must be located between 20-in (.5-m) and 75-in (1.9-m) above the surface on which the operator will stand while operating the machine.
  • Page 23 READ THE TRUCK OR TRAILER MOUNTING INSTRUCTIONS AS WELL AS THIS SECTION BEFORE STATIONARY MOUNTING OF YOUR MACHINE. For stationary mounting, ensure the table, bench, rack or horses are solid and level. For both safety and stability, securely bolt the machine to the mounting arrangement.
  • Page 24 6.4.2. Electric Generators The electric motor draws about 4000 Watts when staring and can be driven by a 4500-Watt generator. DO NOT TRY RUNNING THE MACHINE ON A SMALLER GENERATOR! Damage to both the generator and motor will result. The manufacturer will not be held responsible for such damage. 6.4.3.

  • Page 25: Setup And Operation

    7. SETUP AND OPERATION • Note: determine what type of control package is installed on the machine. All operators should familiarize themselves with the appropriate controls prior to any operation. 7.1. MACHINE CONTROLS – STANDARD The Standard Control package includes a red drum switch (motor control) located on the exit end plate on the right side, and an E-Stop switch located on the right side near the entry end.
  • Page 26 The CE Certified control package includes a control box mounted on the right side near the exit end, and an E-Stop switch located on the right side near the entry end. Direction Selector E-top Button Advance Button Mode Switch E-stop Button Figure 7.2: View of CE control package.
  • Page 27 Switch Position Mode NORMAL Continuous Operation The mode switch will determine what will happen when the Advance Button is pushed. In the Jog Mode, the machine will only advance (forward or reverse) if the Advance Button is held down. In the Off Mode, the machine will not run.
  • Page 28 Verify the E-Stop Switch functions correctly by first pushing the E-Stop Switch. Attempt to jog the machine forward with the Motor Control drum switch. With the E-Stop switch pushed in, the motor should have no power supply and should not work. Now, place the Motor Control drum switch in the Off position. *** CAUTION - IF THE MOTOR CONTROL DRUM SWITCH IS SET TO FORWARD OR REVERSE AND THE E-STOP IS PULLED OUT, THE MOTOR WILL START TURNING*** Pull the E-Stop out to restore power to the motor and resume normal operation.
  • Page 29 Verify operation of the receptacle using a multi-meter, a light, or a piece of portable electrical equipment like a power tool. If power tools are used to test the receptacle, ensure the tool is rated for the same voltage as the machine’s power source. 7.4.5.
  • Page 30 Use 16-in (406-mm) or 20-in (508-mm) ID coil stock for easy placement on the appropriate spool. 7.8.2. Loading Coil Stock onto the Spool Loosen the ½-13 hex head bolts in the spool flange and slip it off the center pipe. With the coil standing upright, slip the spool through the coil, attach the flange snug against the coil stock and tighten the ½-13 hex head bolts.
  • Page 31 Feed the trimmed leading edge around the front feed roller and between the entry guide plates. Be sure the metal is directed between the first set of top and bottom rollers and is centered between the vertical bars of the entry guide plates. Allow slack for the rollers to grab the leading edge of the metal. A strong push is usually required to start the coil into the first pair of rollers after the guides.
  • Page 32 This procedure need be done only on each new coil or after removing the cut-off assembly from the machine for any reason. With metal in the machine and adjustments correctly set, the gutter will feed automatically through the cut-off assembly when the motor control switch is operated. 7.11.
  • Page 33 Gutter run-out stands must be used when forming gutter in lengths over ten (10) feet (3 meters). The stands (or table) must be level and in line with the machine rollers. Knudson Mfg., Inc. adjustable gutter stands are recommended and are available from the factory. Run-out tables are good for shop use if they have an adequate number of rollers or a non-scratching surface.

  • Page 34: Adjustment And Troubleshooting

    8. ADJUSTMENT AND TROUBLESHOOTING ENSURE ALL SETUP AND OPERATING PROCEDURES IDENTIFIED IN SECTIONS 7 AND 9 HAVE BEEN FOLLOWED AND VERIFIED PRIOR TO ADJUSTING THE MACHINE READ ALL SECTION 8 ADJUSTMENT PROCEDURES BEFORE ADJUSTING THE MACHINE UNPLUG ALL POWER SOURCES BEFORE REMOVING THE SAFETY COVERS 8.1.
  • Page 35 Left Side Exit End Right Side Box adjustment screws A B C Station 8 Exit end of Entry end of box Station 7 Station 6 Direction of Station 5 Material Flow Station 4 Station 3 Station 2 Station 1 Figure 8.1: Layout of adjustment screws.
  • Page 36 Adjustment Procedures REFER TO FIGURE 8.1 TYPE OF CURVATURE CORRESPONDING ADJUSTMENTS 1. Gutter curving to right, but relatively level. (1A) Loosen A and C of the right side of station 8 1/4 turn; tighten B 1/4 turn; check results and repeat as necessary (1B) Loosen A and C of the right side of station 7 ¼...
  • Page 37 Crimper adjustment screw Crimper adjustment screw A Figure 8.2: Crimper assembly. 5. Gutter curving downward on back (crimp) side. (5A) Tighten crimper adjustment screw B 1/4 turn to deepen crimp. This will help pull gutter up on backside. Check results and repeat as necessary. Extreme adjustment here will result in ripples in back of gutter.
  • Page 38 You need work with only the last cross bar adjustments (stations 7 and 8) to correct most twisting. In extreme cases, it may be necessary to use box elevation or lowering or a change of crimp to level the gutter. 8.5.
  • Page 39 8.6. WIDTH OF GUTTER ADJUSTMENTS Different materials and different gauges of the same material will cause a machine to produce gutter of varying widths. Several remedies are available for over wide gutters. 8.6.1. Right Angle (90 degrees) - Backside to Bottom Check the angle formed between the backside and bottom of the gutter.
  • Page 40 8.6.2. Box Unit Position Moving the exit end of the box unit (see figure8.1) inward will help narrow the gutter. 8.7. ADJUSTMENT FOR WIDTH OF COIL STOCK/IMPROPER HEMMING The machine will be factory-adjusted to form the proper hem on the top front inside edge of the gutter. Therefore DO NOT change the position of the right entry guide should the machine fail to hem properly.
  • Page 41 When changing from one gauge of stock to another, no adjustment is necessary in most cases. Should the product formed be unsatisfactory, the following adjustments may be attempted. 8.8.1. Curvature Check the bottom corners for curvature and adjust according to regular curvature adjustment procedures in sections 1-6 of this manual.
  • Page 42 8.10. ELECTRICAL • If a particular electrical component does not function properly, begin by inspecting the wiring and connections. Look for any unusual conditions, to include broken or burnt wires, smoke, or unusual noise. • If needed, wiring diagrams can be obtained from the factory. The diagrams will aid in electrical maintenance.
  • Page 43 Remove material back to a point where the partially formed profile has not been disrupted. At this point, cut a tapered leading edge on material. A rough estimation may be required since cutting a taper onto partially formed material can be difficult. Cut the coil stock at the entry guides so no additional material feeds into the machine.

  • Page 44: Changeover Procedures

    9. CHANGEOVER PROCEDURES 9.1. GENERAL Changeover parts for 5-in gutter are colored BLUE and/or stamped 5". Changeover parts for 6-in gutter are colored YELLOW and/or stamped 6". All bolts and set-screws to be moved during changeover are colored RED. UNPLUG THE MACHINE PRIOR TO PERFORMING ANY CHANGEOVER PROCEDURE 9.2.
  • Page 45 ROLLER STATION #2: Loosen the three (3) roller locating screws (two outside rollers on top and right side of bottom bell roller) just until rollers will slide towards the outside of machine. Once the roller stops sliding tighten the locating screw (locating screws will self align into additional holes). ROLLER STATION #3: Repeat the procedure used on station #2.
  • Page 46 SIDE ROLLER #8 CONTINUED: Replace the side roller and bolt, and tighten the bolt into the additional hole. 5-in hole 6-in hole Roller not shown in this view. Figure 9.3: Close up of station 8 bottom rollers. The left side roller moves from the 5-in hole to the 6-in hole when changing profiles.
  • Page 47 CRIMPER ASSEMBLY: Remove the two (2) crimper hold down bolts and move the crimper to the upper holes in the face plate and secure into place. 6-in crimper holes 5-in crimper holes Figure 9.4: Close up showing crimper mounting locations for both 5 and 6-in profiles. SHEAR ASSEMBLY: Rotate the shear so that the blade is in the down position, then remove the four (4) shear locating bolts and remove shear.

  • Page 48: Machine Maintenance

    10. MACHINE MAINTENANCE 10.1. CLEANLINESS Keep both the machine and the surrounding work area clean and free of dust, dirt and debris. Routine cleaning of the entire machine will help extend the life of all mechanical and electrical components. In particular, a clean machine and work area will help prevent the introduction of foreign objects into the machine, which can significantly damage mechanical components.
  • Page 49 10.5.1. KR-56A, KR-50A, KR-60A Changeover Lubrication Areas • Monthly, grease the top and bottom roller shafts at stations #1, #2, #3, and #7. • Monthly, grease the left side skate rollers and shafts where the two slide together. • Twice a year, lubricate all changeover bolts with a spray lubricant or grease. 10.6.

  • Page 50: Transport And Moving

    11.2. PRECAUTIONS Knudson Mfg., Inc recommends keeping coil stock threaded through the machine during transport. Material between the forming rolls prevents the rollers from touching one another, reduces possible vibration, and helps maintain critical adjustments.

This manual is also suitable for:

Kr-50aKr-56aKr-60a

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