Electric heater could gather rust on account of humidity by HC12080908749

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									                              Kukdong




       USER GUIDE
                 KD-BCM5DC
Back Counter Molding Machine




          K I K I Kukdong Of
              Kukdong Institute Institute Of
                 T Machinery and Technology
            T Machinery and Technology
                                                                      Kukdong




Introduction




Thank you for selecting Kukdong’s equipment. If installed and operated properly it
should provide years of trouble free service ; therefore, it is important that you
study this manual before installing or operating your equipment.



This manual contains proven procedure that will save hours of downtime. Much of
this information has been acquired through hours of experimentation with various
shoes. Take advantage of it and enjoy a successful start-up




               Kukdong Job #
                     Customer
               Types of Shoes
                        Others




                                                       K I     Kukdong Institute Of
                                                         T     Machinery and Technology
                            Kukdong




EQUIPMENT SPECIFICATIONS




               K I   Kukdong Institute Of
                 T   Machinery and Technology
                                                                   Kukdong




 Equipment Specifications


1. Feature
-. At the end of sewing process, this machine is to form the back counter in the
heel upper after the shape of last’s heel by cooling aluminum mold.

-. Airbag system is able to come true ideal flexibility that can cope with many
type of shoe and shape. Exchanging only cooling mold is needed in case of
manufacturing other item




2. Specification

             DIEMSION                1750Lx760Wx1820H
             WEIGHT                  600 kg
             AIR PRESSURE            5 ~ 6 kg /㎠
             CONSUMPTION             33 L / pair
             TEMP. RANGE             -10 ~ -20 ℃
             COMPRESSOR              2.0 RT
             CAPACITY                1,300 ~ 1,500 PRS / 8hr




                                                    K I     Kukdong Institute Of
                                                      T     Machinery and Technology
                                                         Kukdong




Back counter molding machine




   Air bag band
 Left & Right pair/
 position adaptable        A self lighting



                               Air holes to mold for Quick chilling



                                    Heat activator


                      Digital temperature display


                             Chilled Mold standby-station




                                    Movable Wheel &
                                    Individual Control




                                        K I     Kukdong Institute Of
                                          T     Machinery and Technology
                                                                       Kukdong




3. Installation

(1) Unpacking Instructions
A.   Immediately upon receipt of the equipment, Carefully unpack and check for
     shipping damage. If there is shipping damage, please notify the carrier and
     Kukdong as soon as possible. Please note that our standard packaging is not
     suitable for outdoor storage.

B.   Remove wooden packing carefully that will enable inspection of the
     transparent cover and other parts. Remove shipping support blocks from
     under the bottom wooden plate.

C.   If spare parts have been ordered with your equipment, they are usually
     packaged or secured either inside of the equipment or on the shipping skid.
     Inspect the system and locate all tagged spare parts. If any parts are missing,
     notifying Kukdong immediately in order to minimize possible delays.




                                                       K I     Kukdong Institute Of
                                                         T     Machinery and Technology
                                                                        Kukdong




(2) Assembly & Set up
A.   Must be turned off while installation or movements
B.   Should be located on the plane ground and fixed on it
C.   Should be isolated from bumping and oscillation from impact.
D.   Should be blocked from dust or strange substance
E.   Should be seated indoor and not be shined sunlight directly
F.   Permitted room temperature      : 1~ 40℃
G.   Must be far proper distance from High frequency or other strong strange
     Voltage
H.   The machine shall be installed at the sides of the area to be secured at the
     required distance and shall be fixed by proper brackets. it must be perfectly
     aligned and keep the horizon
I.   Before connecting up the machine, ensure that the factory voltage
     corresponds with that of the machine which is shown in the electric panel.
J.   Ground and install the no fuse brake. Please do not install the N.F.B. in the
     place where there are dust or moisture which is causing a serious problem
K.   Make sure to idle the machine for more than 3 minutes for warm-up to keep
     the proper conditions and daily inspection before starting the machine
L.   When the operation is finished, turn the N.F.B. switch “off “ position and then
     clean up the operating parts




                                                        K I     Kukdong Institute Of
                                                          T     Machinery and Technology
                                                                        Kukdong




(3) Caution
A.   Check daily the level of lubricant in the air lubricator.
B.   Check daily the level of water in the tray of cooling unit & remove
C.   Clean the cooling unit weekly ensuring that radiator is maintained clean with a
     free flow of air. lf not, the cooling unit cannot cool efficiently
D.   The guides and pistons should be greased with a general propose grease
     weekly
E.   Ensure that there is free access at the side of the machine to allow air to
     circulate easily to the cooling unit.
F.   After moved, machine has to be stayed with power off at least 20 minute.
G.   When the machine is not served for a long period of time, the machine should
     be cleaned for preservation.
H.   Don’t operate without shoe’s upper, it may be a cause of air bag damage.




                                                           K I   Kukdong Institute Of
                                                             T   Machinery and Technology
                                                                           Kukdong




4. Description

                                            10
                                                      6
                                                               11


                              1                            7


                              2


            3



                          4
                                                               8



                            5
                                                 9



  1   Forming Part of Air Bag – Station 1                 10   Self Lighting
  2   Cooling Part                                        11   Center alignment Light

  3   Heel Heating Blower
  4   Control Panel
  5   Foot Switch - Starting Point of Left & Right
  6   Air Bag Cylinder – Station 4
  7   Emergency Switch – Return to initial position

  8   Spare mold keeping container
  9   Front Door



                                                          K I       Kukdong Institute Of
                                                            T       Machinery and Technology
                           Kukdong




OPERATING INSTRUCTIONS




              K I   Kukdong Institute Of
                T   Machinery and Technology
                                                                  Kukdong




 Operating Instructions


1. Description of Location & Operation of every control

  (1) Back counter molding machine


           1     2               3         4   5



                                                             6



                                                             7




                                                       8



           1   Start Button – Station 1
           2   Emergency – Station 1
           3   Main Power Switch & Lamp
           4   Digital chill Temperature
           5   Chill Compressor on-off toggle switch
           6   Center alignment lamp on-off toggle switch
           7   Timing device for Air bag delay time set

           8   Timing device for Total molding time




                                                   K I     Kukdong Institute Of
                                                     T     Machinery and Technology
                                                                          Kukdong




(2) Heating Blower

                              5 6 7       8 9   10
                    1

                    2
                3
                                                     11




                        4




   1   Electric Panel                 7   Thermometer for Right Heating Station
   2   Main Frame                     8   Operation Signal Lamp for Left Station
   3   Upper Holding Rack             9   Start Button for Left Station
   4   Blower                     10      Cycle time setting Timer
   5   Thermometer                11      Heating beak
   6   Power Switch



    Normal Operating Instructions
    Heater switch on
    Temperature set ▷ Normal 0 ~ 150 ℃
    Put the upper on the Station
    Heating Time set        ▷ Normal 45sec.
    Press Hand switch ▷ Start Heating
    Lamp off after operating time (Cycle finished)
    ☞ If the machine is left without operating for long time,
         Electric heater could gather rust on account of humidity in the room.



                                                          K I    Kukdong Institute Of
                                                            T    Machinery and Technology
                                                                  Kukdong




(3) Controller Setting Tips



  A. Cooling Temperature Controller
  Press ‘SET’ button

  Set temperature into - 8 oC with button +,-

  Too low degree might cause to over loading to compressor

  Press ’End’ button


  B. Time Set
  Forming time(operating time) - It depends on the kind of back counter

  Heating time - It depends on the kind of back counter


  Pressure of Air Compressor 4 ~5 kg/cm2


  C. Forming Pressure
  Be ware of not excess 2 kg/cm2

  Too high air pressure might be reason of breaking tube of air bag




                                                   K I     Kukdong Institute Of
                                                     T     Machinery and Technology
                                                                   Kukdong




2. Normal Startup/ Shutdown Procedure




    1                                        2




        Main Power s/w ON                     Chill Compressor s/w ON



    3                                        4




        Chill Temperature set                Center Alignment lamp ON


   Shutdown Procedure is the inverse against Start up procedure




                                                    K I     Kukdong Institute Of
                                                      T     Machinery and Technology
                                                                       Kukdong




3. Abnormal & Emergency Shutdown Procedure


                                                Emergency Button




               Push the Emergency to return Original Position




4. Normal Operating Instruction for Each cycle

 • Make sure of same voltage as that your are using in your factory

 • Turn on MAIN S/W

 • Turn on Cooling temperature

 • Center Alignment Lamp On

 • Set heating temperature and cooling temperature ( REF. Setting tips for Controller )

 • Add heat to heating part ▷ REF. Controller for Heating blower

 • Equip heated back counter in the upper with chilled mold

 • Locate center position of upper with center lamp

 • Press once foot S/W, Pincer bites upper and fix.

 • Operating S/W Once more, Air supplied to air bag and doing forming process




                                                        K I     Kukdong Institute Of
                                                          T     Machinery and Technology
                                                                        Kukdong




5. Safety Features
   Maintain Hydraulic Oil in good condition
   • Should keep under 60degree of oil during running the machine
   • Supply Dried Air for protecting Cylinders & other parts
   • Cleaning Air regulator once every 6 month
   • Oil change : firstly in 1,000 hours then every 3,000shours


   Regular maintenance inspection : from specialist
   • guarantee 1year free customer service except for user’s fatal fault
   • All components replaced must be return to seller. If not it is regarded as sales




                                                         K I     Kukdong Institute Of
                                                           T     Machinery and Technology
                            Kukdong




MAINTENANCE INSTRUCTIONS




               K I   Kukdong Institute Of
                 T   Machinery and Technology
                                                                                             Kukdong




Maintenance Instructions



1. Preventive Maintenance Procedure & Schedule

  Hydraulic Part
  Checking a every month…
  If there is any oil leakage with the joint of each hydraulic hose ?
  The cooling water for heat exchange is working normally? (If any)


  Checking a every 6 month…
  The hydraulic oil level is between high and low position?
  Enough cooling water for heat exchange ? Otherwise replace.


  Replace a year…
  Hydraulic oil and keep the oil tank unit clean
  The coupling of motor and pump in case of loose


  Sliding & Friction Part
  Check a every day…
  If Liquid Level of auto lubricating is between the high and low level, otherwise refill.


  Grease a week
  The All moving which are not equipped with auto lubrication system.




                                                                        K I     Kukdong Institute Of
                                                                          T     Machinery and Technology
                                                                             Kukdong




2. Warranty Terms


 Warranty Term
  12 Month after finishing trial run & adjustment of the machine for Normal
operation. Where, 2 month available for keeping without running the machine & in
this case, WARRENTY TERM may be 14 Months under a mutual agreement.


 No-Warranty Machine Trouble
  (A) Trouble caused by running machine against Normal Machine Treatment.
  (B) Trouble caused by neglecting Maintenance instructed.
  (C) 2nd Trouble caused by Neglecting 1st Trouble.
  (D) Repair done by Other Company, Not Kukdong Or Its Nominated Agent.
  (E) Revise to Affect the Machine performance or Reinstall at other place without
     Notice.
  (F) Rent and Move the machine to the other without Notice.
  (G) In Case of Natural Disaster, i.e. Fire, Earthquake, Flooding.
  (H) Any other Trouble Case not caused by Kukdong.


(3) Repair Cost
  A Trouble after Warranty Term or No-Warranty Machine Trouble Under above
mentioned will cost concerned parts, Reasonable Lodging and Board, Labor Cost on
the base of Kukdong Regulation.




                                                           K I        Kukdong Institute Of
                                                             T        Machinery and Technology
                                                          Kukdong




Daily Inspection




       Keep heating Beaks clean?     Keep air bag bands Clean?




                                                          Between
                                                          “H” and ”L”




         Keep clean condition?     Keep evaporator & piping clean?




           Plug fixed firmly?




                                           K I     Kukdong Institute Of
                                             T     Machinery and Technology
                                                Kukdong




3. Bill Of Materials

  Main Assembly




                           (3) Air Bag Pressing Pad Part




      (1) Body Part
                                        (2) Chilling Mold Part
 (4) Heating Blower Part




                                         (5) Control Part




                                 K I     Kukdong Institute Of
                                   T     Machinery and Technology
                                                 Kukdong




(1) Body Part




                            1

                    2


                                      3




                                          4

                        5

                                          6

                                          7




                8
                                          9

                                      10




                                K I       Kukdong Institute Of
                                  T       Machinery and Technology
                                                                        Kukdong




BOM – Body Part

NO SERIAL NO   DESCRIPTION                                   STANDARD        REMARK
1    B1001     하강 실린더        DOWN PNEUMATIC CYLINDER
2    B1002     센터 램프         CENTER ALIGNMENT LAMP
3    B1003     거울            MIRROR
4    B1004     거울 지지대        MIRROR HOLDER
5    B1005     히팅 블로어 고정대    HEATING BLOWER HOLDER
6    B1006     본체            MAIN BODY
7    B1007     컨트롤 박스        CONTROL BOX
8    B1007     냉각 몰드 준비대     CHILLING MOLD HOLDER
9    B1008     기계 고정 볼트      FIXING BOLT
10   B1009     바퀴            WHEEL




                                                       K I     Kukdong Institute Of
                                                         T     Machinery and Technology
                                                                             Kukdong




(2) Chilling Mold Part
                                             Chilling Mold


                                         1


                                                             9

                         2


                                                                 10
                             3
                                     4

                                                    6
                                 5



                             7
                     8



                                                                 11

                                                                 12
                                 13



                                                                 14




                                                         K I          Kukdong Institute Of
                                                           T          Machinery and Technology
                                                                            Kukdong




BOM – Chilling Mold Part

NO SERIAL NO   DESCRIPTION                                       STANDARD        REMARK
1    B1010     냉각봉           CHILLNG BAR
2    B1011     갑피 잡이         PINCER FOR UPPER
3    B1012     갑피 잡이 주물      PINCER CASTING
4    B1013     갑피 잡이 지지대     PINCER SUPPORTER
5    B1014     갑피 텐션 잡이      UPPER TENTION HOLDER
6    B1015     스프링 지지봉       SPRING SUPPORT BAR
7    B1016     회전판           ROTATING PLATE
8    B1017     회전판 고정대       ROTATING PLATE FIXING PLATE
9    B1018     신골 조절대        MOLD POSITION ADJUSTMENT
10   B1019     주광 지지대        MOLD SUPPORTER
11   B1020     실린더 연결판 A     CYLINDER CONNECTING PLATE A
12   B1021     실린더 연결판 B     CYLINDER CONNECTING PLATE B
13   B1022     에어 실린더 A      AIR CYLINDER A
14   B1023     에어 실린더 B      AIR CYLINDER B




                                                           K I     Kukdong Institute Of
                                                             T     Machinery and Technology
                                                     Kukdong




(3) Air Bag Pressing Pad Part




                8

                9




                                    1



                                    2



                                    3


                    4
                                5
                                6
                                7




                                        K I   Kukdong Institute Of
                                          T   Machinery and Technology
                                                                     Kukdong




BOM - Air Bag Pressing Pad Part

NO SERIAL NO   DESCRIPTION                                STANDARD          REMARK
1    B1024     실린더 가이드 봉     CYLINDER GUIDE BAR
2    B1025     실린더 고정판       CYLINDER FIXING PLATE
3    B1026     박스 고정판        BOX FIXING PLATE
4    B1027     에어 박스         AIR BAG BAND
5    B1028     에어 잡이판 A      AIR BAG FIXING BRACKET A
6    B1029     에어 잡이판 B      AIR BAG FIXING BRACKET B
7    B1030     에어 잡이판 C      AIR BAG FIXING BRACKET C
8    B1031     리미트 스위치 봉     LIMIT DOG
9    B1032     스위치봉 셋팅 너트    LIMIT DOG SETTING BOLT




                                                        K I   Kukdong Institute Of
                                                          T   Machinery and Technology
                                                                                Kukdong




(4) Heating Blower Part



                                 5 6 7   8 9     10
                         1

                         2
                     3
                                                         11




                             4




 NO SERIAL NO   DESCRIPTION                                          STANDARD        REMARK
 1    B1033     전기 명판               ELECTRIC PANEL
 2    B1034     본체                  MAIN FRAME
 3    B1035     갑피 고정대              UPPER HOLDING RACK
 4    B1036     블로어                 BLOWER
 5    B1037     온도계                 THERMOMETER
 6    B1038     주 전원 공급 스위치         POWER SWITCH
 7    B1039     온도계                 THERMOMETER
 8    B1040     작업 알림 램프            CYCLE START LAMP
 9    B1041     시작 버튼               CYCLE START BUTTON
 10   B1042     작업 시간 설정 타이머        CYCLE TIME SETTING TIMER
 11   B1043     열풍구                 HEATING BEAK




                                                               K I    Kukdong Institute Of
                                                                 T    Machinery and Technology
                                                                               Kukdong




(5) Control Part


                 1      2          3         4           5



                                                                          6



                                                                          7




                                                               8


 NO SERIAL NO   DESCRIPTION                                                STANDARD      REMARK
 1    B1044     시작 버튼              CYCLE START BUTTON
 2    B1045     비상 해체 스위치          EMERGENCY SWITCH
 3    B1046     주 전원 공급 스위치        MAIN POWER SWITCH
 4    B1047     냉동 온도계             CHILL TEMPEARTURE
 5    B1048     냉동기 전원 공급          CHILLER ON SWITCH
 6    B1049     센터 램프              CENTER ALIGNMENT SWITCH
 7    B1050     에어백 작동 시간 설정 타이머   AIR BAG DELAY TIMER
 8    B1051     총작업 시간 설정 타이머      TOTAL OPERATION TIME SETTING TIMER




                                                             K I        Kukdong Institute Of
                                                               T        Machinery and Technology
                                                                                    Kukdong




4. Recommended Spare Parts for one year of Operation


 NO.                 Description       Specification   Life Expectancy    Time to Change       Price
 1     Leather Pad                                     6 month           30 min            $           13
 2     Rubber Pad                                      1 year            30 min            $            4
 3     Pincer Spring                                   8 month           5 min             $            3
 4     Pincer Urethane                                 5 month           3 min             $            6
 5     Halogen Lamp                12V 20W             1 year            3 min             $            3
 6     Pneumatic Solenoid Valve    SF5130(NS530S-8)    1 year            10 min            $           29




                                                                 K I      Kukdong Institute Of
                                                                   T      Machinery and Technology
                                                                           Kukdong




5. Trouble Shooting



     Problem           Possible Cause                  Corrective Action



Lower Chilling      • Coolant
                                          Check & Fill Coolant or Gas
Capacity            • Gas


Not Proper Pincer                         Check Pneumatic Solenoid for Pincer and
                    • Pincer Solenoid
Operating                                Fix


Frequent Air bag                          Check whether proper air bag pressure is
                    • Air Bag Pressure
damage or broken                         applied and adjust


Mold station                              Check Mold stating moving air solenoid
                    • Solenoid Valve
doesn’t come out                         valve


Support doesn’t
                    • Solenoid Valve      Check Support Air Solenoid valve
move up


Air bag grasps
                                          Check Air bag delay time
mold




                                                       K I      Kukdong Institute Of
                                                         T      Machinery and Technology

								
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