Knudson EL 2002 User manual

7/11/2005 VERSION 2.0 1
EL 2002
Manual Elbow Forming Machine
GENERAL OPERATING AND MAINTENANCE INSTRUCTIONS
© Knudson Mfg., Inc. 2002
Knudson Mfg., Inc.
10401 W. 120th Avenue
Broomfield, CO 80021
USA
[phone] (tel) Version: 2.0
[phone] (fax) Date: 08/02

7/11/2005 VERSION 2.0 2
Change Record Page:
Date Change Authorization
08/02 Initial Release MCD
08/03 Added new logo, fixed minor typos, raised footer MCD

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TABLE OF CONTENTS
1. INTRODUCTION...................................................................................................4
2. SAFETY RULES ....................................................................................................5
4. MACHINE SPECIFICATIONS..........................................................................8
5. TERMINOLOGY..................................................................................................10
6. REQUIRED TOOLS AND EQUIPMENT.....................................................11
7. SUB-ASSEMBLY OVERVIEW ......................................................................12
8. SETUP AND OPERATING PROCEDURES ...............................................14
9. GENERAL OPERATING PROCEDURES ...................................................16
10. PROFILE CHANGEOVER PROCEDURES..............................................20
11. ADJUSTMENTS AND TROUBLE SHOOTING .....................................23
12. GENERAL MACHINE MAINTENANCE .................................................28
13. TRANSPORTATION / MOVING THE MACHINE................................29

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1. INTRODUCTION
1.1. Introduction from Knudson Mfg., Inc.
Congratulations!!! You have purchased a top quality product from the world’s leading manufacturer of
portable, semi-portable and in-plant roll forming equipment, Knudson Mfg., Inc. Your new EL-2002’s high
standards of performance and durability will serve you reliably for years to come. Each Knudson Mfg., Inc.
product is backed by our dedication to high quality manufacturing, commitment to customer service, and
innovation in equipment design. Prior to any operations, read this manual thoroughly to familiarize
yourself with the machine, its operation, care and service. Remember to strictly observe all safety
requirements.

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2. SAFETY RULES
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. Steel toe boots are recommended. No loose clothing or jewelry. Long hair,
loose clothing, and gloves should be kept away from all moving parts. Keep the handles dry, clean, and
free of oil and grease.
Do not operate without safety glasses and leather gloves.
Do not operate without adequate training.
2.2. Machine Specific Safety Features
This machine is designed to pinch and form sheet metal. During the pinching process, there is the potential
to get ones fingers and hands pinched between the knives and mandrel. The risk is such that loss of fingers
could result if one is not careful enough. Use extreme caution at all times when operating this machine,
especially around the knives and mandrel.
Proper mounting of this machine will also reduce the risk of injury. Ensure that the mounting surface is
stable, level, and strong enough to hold the weight of the machine. If the machine is mounted on a table,
make sure the table is properly secured to the ground or floor.
This machine is to be used by one operator at a time. The design of the machine requires that the
operator leave both hands on the machine at all times. Multiple operators greatly increases the risk of
finger and hand injury to all involved. Keep others clear of the area of operation.
If the machine crashes (see Section 11), use extreme caution when clearing the crash. A crash presents a
potentially hazardous situation for the machine operator. Crashes often produce sharp, jagged metal edges
that ultimately require handling. Suitable hand and eye protection, to include leather gloves and safety
glasses, should always be worn when clearing a crash.
The machine is equipped with a variety of safety measures:
Item Name QTY KMI Part Number
Crimping Asssembly Cover 1 4030701
Bottom Advance Assembly Cover 1 4030702
Top Right Advance Assembly Cover 1 4030703
Top Left Advance Assembly Cover 1 4030704
Crimp Stops 2 4030606
Finger Pinch Warning Sticker 2 STKR-1005
Heavy Lifting Warning Sticker 2 STKR-5101
-four safety covers - three covers encasing the advance assembly and one surrounding the crimping
assembly prevent both the operator and foreign objects from being introduced into moving machine
components.

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-crimp stop – the two crimp stops are attached to the advance plate and prevent the crimp handle from being
pulled when the advance assembly is in its furthest forward position. Moving the advance assembly
backwards will not allow the crimp stops to function properly and open up the potential for serious injury.
*This machine should not be operated without the covers in place. *
Despite the presence of safety features, this machine does have exposed knives.
To remind the operator of the potential risks involved in using this machine, the factory has placed warning
stickers on the safety covers. Two finger pinch warning stickers have been placed on the top safety cover at
the front of the machine and two heavy lifting warning stickers have been placed near the back of the
machine on the advance assembly covers. If these covers are re-ordered, the stickers will be attached to the
replacement covers. Refer to the following picture and contact the factory or distributor if the warning
stickers are not present. Do not use machine without these warning labels.
Figure 2-1: Warning labels on the EL-2002
**Extreme caution must be used at all times but especially when hands
and fingers are in the vicinity of the knives and mandrel assembly. **
**This machine weighs in excess of 85 lbs. Proper Lifting techniques
should be executed when moving this machine. **
STKR-1005 STKR-5101

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3. PROFILE SPECIFICATIONS
3.1. PROFILES
2 X 3 (51-mm x 76-mm)– A Elbow – crimped up to 90 degrees.
2 X 3 (51-mm x 76-mm)– B Elbow – crimped up to 90 degrees.
3 X 4 (76-mm x 102-mm)– A Elbow – crimped up to 90 degrees.
3 X 4 (76-mm x 102-mm)– B Elbow – crimped up to 90 degrees.
3.2. MATERIAL TYPES AND THICKNESSES
Aluminum/Copper:
0.019-in and 0.027-in Aluminum Downspout Blanks
16-oz Copper Downspout Blanks
3.3. MATERIAL STRENGTH
Aluminum/Copper:
Maximum Tensile Strength = 33 ksi (230 MPa)
Maximum Yield Strength = 28 ksi (195 MPa)

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4. MACHINE SPECIFICATIONS
4.1. STANDARD BASE UNIT SPECIFICATIONS
Length = 20.75-in (525-mm) [mount to mount]
Width = 22.75-in (575-mm) [handle to handle]
Height = 26.75-in (680-mm) [base to vertical handle]
Weight = 74.5-lbs (34-kg) [chassis only]
Weight = 90.0-lbs (41-kg) [with four (4) tooling sets]
4.2. STANDARD EQUIPMENT FEATURES
4.2.1. Profiles
Each profile requires the use of a specific tooling set, which includes:
- Top Knife
- Side Knife – Left
- Side Knife – Right
- Mandrel assembly
4.2.2. Forming Details
Manually Operated Crimping Mechanism
- Adjustable crimp depth
- Adjustable side knife position
- Rack and Pinion Crimp Gears
- Spring Return to Neutral Position
Manually Operated Advancing Mechanism
- Rack and Pinion Advance Gear
- Locking/Release Pin for Advance Handle
- Crimp Stop in Final Advance Position
4.2.3. Production Speed
Elbows per minute = approximately two (2).
Time required to change tooling sets = approximately 10-min. (See Section 9)
4.3. ADDITIONAL EQUIPMENT FEATURES
4.3.3. Accessories
Push Tool
Multiple Tooling Sets (Optional)
Side mount/Storage bars for additional tooling (Optional)

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4.4. INTENDED USE
The EL-2002 Manual Elbow Forming Machine is intended to form the aforementioned specific profiles
from the designated material specifications. The machine is in no way intended for any other purpose. Any
attempt to use the machine for a different purpose may result in serious personal injury or significant
damage to the machine. In particular, the machine is not intended to form partial or different profiles nor
intended to run unspecified material gauges or strengths.

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5. TERMINOLOGY
5.1. MACHINE NOMENCLATURE
Front End - the end of the machine where the crimping mechanism is located.
Back End - the end of the machine opposite the crimping mechanism.
Left Side - when viewing the crimping mechanism, the side located to the left
Right Side - when viewing the crimping mechanism, the side located to the right
5.2. PROFILE SPECIFIC TERMS
The profile is described as if it were being viewed from the front end of the machine as the material exits
the machine:
Left Curve– the profile is horizontally level, but curves to the left as it exits the machine
Right Curve– the profile is horizontally level, but curves to the right as it exits the machine.
Crimp Depth – depth to which the top, left side, and right side knives press into the blank.
5.3. MACHINE SPECIFIC TERMS
Push Tool – An accessory used to aid in insertion of the blank.
Mandrel Assembly– the rectangular parts that fit inside the downspout blanks, over which the material is
formed/crimped.
Knife – the flat, contoured bars that push the material between the mandrels in the forming/crimping
process.
Advance Handle – Handle extending from the right side of the machine responsible for advancing the
elbow.
Crimp Handle – Handle extending from the left side of the machine responsible for crimping the elbow.
Crimp Depth Adjustment Knob – knob used to adjust the crimp depth (see Figure 11-5)
Return Height Adjustment Nut – a nut located on the underside of the front plate below the crimp depth
adjustment knob that keeps the crimping assembly from moving too far up and causing the crimping dies to
become misaligned.