KWM Gutterman 6" IROMAN, Operating And Maintenance Troubleshooting Manual

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Page 2: ...achine Forming Components and Assemblies Pg 15 12 Machine Lip Forming Box Pg 16 19 12D Machine Lip Forming Box Drawings Pg 16 19 13 Machine Exit End Forming and Drive Assembly Pg 19 21 13D Machine Top Exit Drive Adjustment and Assembly Drawings Pg 19 21 14 Machine Bead Roller Assembly Pg 22 14D Machine Bead Roller Drawing Pg 22 15 Guillotine and Face Plate Assembly Pg 23 15D Guillotine and Face Pl...

Page 3: ...cm 48 122 cm 48 122 cm WIDTH 24 61 cm 24 61 cm 24 61 cm 24 61 cm APPROXIMATE WEIGHT 1100 lbs 499 kg 1300 lbs 589 7 kg 1400 lbs 635 kg 1490 lbs 675 85 kg DRIVE Powered by polyurethane drive rollers via chain and sprockets SHEAR Front pull guillotine style shear SPEED APPROX 35 ft per minute CONTROLS Push button entry exit end manual controls with JOG feature power interruption safety wiring MATERIA...

Page 4: ...in 4 places to the bed of the vehicle using 3 8 dia bolts grade 5 Do not draw machine down to an un flat surface shim as needed to insure four place mounting NOTES _________________________________________________________________________________________________ _________________________________________________________________________________________________ ________________________________________...

Page 5: ...1 O G FACE GUIDE SHOE RIGHT SHOE 2 O G FACE GUIDE BAR ASSEMBLY 3 O G FACE FORMING BOX ASSEMBLY 4 O G FACE LIP FORMING BOX ASSEMBLY 5 O G FACE BELL ROLLER D LEFT SIDE The LEFT SIDE is determined by facing the entrance end of the machine The LEFT SIDE of the machine is where the back of the gutter is formed COMPONENTS ON LEFT SIDE 6 BACK GUIDE SHOE LEFT SHOE 7 BACK GUIDE BAR ASSEMBLY 8 MOTOR AND GEA...

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Page 7: ... gutter is formed COMPONENTS ON LEFT SIDE 6 BACK GUIDE SHOE LEFT SHOE 7 BACK GUIDE BAR ASSEMBLY 8 MOTOR AND GEAR BOX 9 EXIT BACK BELL ROLLER 10 BEAD ROLLER ASSEMBLY E CENTER of MACHINE The CENTER of the machine forms bottom section of gutter drive assembly COMPONENTS IN CENTER OF MACHINE 11 1 SKATE ASSEMBLY 12 1 DRIVE ASSEMBLY 11A 1A SKATE ASSEMBLY 12A 1A DRIVE ASSEMBLY 13 2 SKATE ASSEMBLY 14 2 DR...

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Page 9: ...ht side FEEDING THE MACHINE 1 Position selector switch to the JOG position 2 Position selector switch to the FORWARD position 3 Remove pressure on spool brakes SEE PG 10 4 Trim both corners of the coil material removing two 3 X 3 triangles SEE PG 12 5 Standing at entrance of machine position material through the entrance guides to the 1 drive assembly 6 Activate the JOG button using your right han...

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Page 12: ...the center of the coil 5 Replace spool half on the spool shaft and reinstall the 5 16 quick release pin 6 The spool assembly and coil are now ready to load onto the upright NOTE The spool assembly is adjustable to accept both 5 gutter material 11 12 and 6 gutter material 15 PLACING SPOOL COIL IN THE UPRIGHT Use an approved lifting device in the designated spool lifting area to position the spool a...

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Page 14: ...int to measure and move from You can easily return to your original location if you move the guide in the wrong direction TO MOVE THE GUIDES 1 Loosen the bolt on the locking collars C or D 2 Move guide A To INCREASE the amount of lip turned under Move the guides toward the RIGHT side FACE side of the machine B To DECREASE the amount of lip turned under Move the guides toward the LEFT side BACK sid...

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Page 16: ...counter clockwise loosening the adjustment bolts A at all four places 2 Turn locking bolt B counter clockwise a 1 4 turn to loosen all four bolts Only turn the bolts just enough to break them free 3 Turn adjustment bolts A clockwise 1 16 of a turn 4 Tighten locking bolts B 4 places 5 Tighten locking nuts C Run machine forward if more traction is needed repeat the above procedure on top 2 drive ass...

Page 17: ...h on gutter To clean guide bars lightly sand guide with a fine grit emery cloth polish out any remaining marks with Scotch Brite FACE FORMING BOX ASSEMBLY This assembly consists of two forming planes four forming rollers per plane This assembly s sole purpose is to form the face of the gutter it does not do any driving of material The unique design of this assembly requires no adjustment for align...

Page 18: ...g pressure to this assembly will cause the top lip of the gutter to run into the fascia Relieving pressure will cause the top lip of the gutter to run away from the fascia ADJUSTING SWING SHAFT ASSEMBLY 1 Loosen swing shaft locking bolt 2 places to allow swing shaft assembly to slide a TO ADD PRESSURE turn swing shaft adjustment bolt clockwise b TO RELIEVE PRESSURE turn swing shaft adjustment bolt...

Page 19: ... on adjustment bolts B 2 Turn LOCKING BOLT A counter clockwise 3 Equally turn the two ADJUSTMENT BOLTS B clockwise to the desired height 4 Tighten LOCKING BOLT A and LOCKING NUTS C B TO LOWER THE STATION 1 Loose the two LOCKING NUTS C on adjustment bolts B 2 Equally turn the two ADJUSTMENT BOLTS B counter clockwise to the desired height 3 Tighten LOCKING BOLT A and LOCKING NUTS C in 2 places C Run...

Page 20: ...ER i Loosen ADJUSTMENT BOLT M 2 and tighten ADJUSTMENT BOLT M 1 2 After completing adjustment tighten LOCKING NUTS L 1 L 2 and MOUNTING BOLTS K 2 places COMBO MACHINE A ADJUSTING LIP FORMING BOX 5 TO 6 1 Pull retractable pins on outside box roller shafts 2 Lower station rollers individually to the 6 position 3 Release retractable pin 4 Remove the 6 inside roller bar from the storage position on th...

Page 21: ...ss but it also drives the material out of the machine IMPORTANT The 3 SKATE and the EXIT END FORMING DRIVE STATION are bolted together by BOLTS K to insure that the drive roller stays square to the skate Before making any adjustment to this assembly you must loosen BOLTS K 2 places CAUTION Always make sure BOLTS K is retightened after adjustment ...

Page 22: ... 1 Loosen HORIZONTAL LOCKNUT V on HORIZONTAL ADJUSTMENT BOLT J 2 Loosen VERTICAL LOCKING BOLT H and the LOCK NUT on VERTICAL ADJUSTMENT BOLT I 3 TO ADD PRESSURE turn ADJUSTMENT BOLT I clockwise a TO RELIEVE PRESSURE turn ADJUSTMENT BOLT I counter clockwise 4 Tighten LOCKING BOLTS and NUTS 3 ADDING PRESSURE TO EXIT POLYURETHANE DRIVE ROLLER The top exit roller is very responsive to adjustment make ...

Page 23: ...heel needs to be moved towards the center of the machine b FOR 6 OPERATION move the back bell wheel away from the center COMBO ADJUSTMENT 5 Gutter Position 1 Remove BOLT W and Bell Wheel 2 Install BACK TOP 3 DRIVE ROLLER in 5 Position SEE PG 20 3 Install Bell Wheel and BOLT W in the 5 Position 6 Gutter Position 1 Remove BOLT W and Bell Wheel 2 Install BACK TOP 3 DRIVE ROLLER in 5 Position SEE PG 2...

Page 24: ...s to align bead roller assembly and retighten after alignment is made b TO INCREASE OR DECREASE PRESSURE to bead itself loosen LOCKING NUT C and LOCKING BOLT B and turn eccentric shaft using a 3 16 Allen wrench in the adjustment hole to desired spacing c Adding too much pressure to the bead will cause the back of the gutter to run uphill If this happens simply relieve pressure from bead and retigh...

Page 25: ...After desired position is acquired tighten locking bolts C 6 places 5 Tighten locking nuts A on adjustment bolts B 2 places To move guillotine side to side 1 Loosen locking bolts D 4 places GUILLOTINE is now free to move in all directions 2 After desired position is acquired tighten locking bolts D 4 places COMBO MACHINE The 5 6 IRONMAN Combo Gutter Machine comes equipped with both a 5 6 guillotin...

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Page 27: ...e blue half inch adjustment block station 6 to the outside edge of the box top plate i 4 SWING SHAFT DIMENSIONS 5 LIP FORMING BOX VERTICAL ENTRANCE PLACEMENT 6 LIP FORMING BOX VERTICAL EXIT PLACEMENT a The dimension labeled as 5 and 6 on PG 26 is the vertical position of the lip forming box b This measurement is from the top of the skate rail to the top edge of the box i 5 LIP BOX ENTRANCE VERTICA...

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Page 29: ...ere the ends of the gutter are closer to the fascia board than the center Looking from the machine the gutter has a left hand curve AWAY FROM THE HOUSE This term describes a condition where the center of the gutter is closer to the fascia board than the ends Looking from the machine the gutter has a right hand curve TOP LIP INTO THE HOUSE This term describes a condition were the end of the top lip...

Page 30: ...out support stands must be used to support gutter after 8 10 Prior to the completion of the last piece of gutter being produced cut the coil stock before the entrance guides to clear machine The IRONMAN MACHINE should be empty when transporting from job to job SECTION 19 ANALYZING GUTTER STEP 1 Feed the machine with the material through entire machine STEP 2 Run gutter through the guillotine appro...

Page 31: ...NG BOLT E SEE PG 16 NOTE After adjustment is made run an 8 section of gutter to inspect it If more adjustment is needed repeat procedure NOTE Adjusting SWING SHAFT will not increase or decrease the amount of lip NOTE The SWING SHAFT should not be used to try and change the size of the hanger lip 2 ADJUSTING THE BOTTOM PORTION OF GUTTER The two conditions listed below will be corrected using the EX...

Page 32: ...stment is made run an 8 section of gutter to inspect If more adjustment is needed repeat procedure 3 ADJUSTING THE WIDTH OF THE GUTTER If gutter is too wide or narrow between lines 3 and 9 SEE PG 42 1 Check lines 6 7 for being at a 90 degree angle to the bottom SEE PG 21 A If less than a 90 degree angle is present Add pressure to bell wheel i Turn LOCKING BOLT A and PIVOT BOLT B counter clockwise ...

Page 33: ...ial i If the guides are correct and the spools are unlocked add pressure to the 1 2 drive assemblies SEE PG 14 SECTION 10 ii When metal slippage occurs while clearing machine and after metal is past the 2 drive add equal pressure to the 3 DRIVE FORMING ROLLER SEE PG 19 6 OIL CANNING OR RIPPLING ON BOTTOM a An imperfect bottom on the gutter is very uncommon from the IRONMAN i Check all bottom rolle...

Page 34: ...LLER AND SET ASIDE SEE 37 To remove back bell roller unscrew the back bell wheel bolt W that holds the center shaft in place STEP 5 MOVE BACK GUIDE BAR TO 6 POSITION SEE PG 35 Loosen the five bolts on the back guide bar Move it as far away from the skate as possible Tighten the five bolts STEP 6 FLIP TOP 3 DRIVE BACKSIDE ROLLER SEE PG 37 To flip the top 3 drive backside roller remove the RED stati...

Page 35: ...ower the bottom portion of the outside roller down to the 6 position Release the retractable pin Repeat this step for each of the lip box stations STEP 16 INSTALL THE 6 INSIDE BOX ROLLER BAR ASSEMBLY SEE PG 37 Remove the 6 inside box roller bar assembly from the storage location this assembly is labeled as 6 Install the 6 inside box roller bar assembly in the lip box replace the two RED station F ...

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Page 40: ...l the back bell roller in the 5 position labeled Positions are marked STEP 6 MOVE BEAD ASSEMBLY TO 5 POSITION SEE PG 37 Loosen the two locking bolts Slide the bead assembly up for the 5 position Positions are marked Tighten the locking bolts STEP 7 INSTALL 5 GUILLOTINE SEE PG 23 24 Remove the 5 guillotine from the side of the machine SEE PG 35 Install it onto the frame using the mounting bolts rem...

Page 41: ...rom the storage location STEP 16 MOVE THE SIX OUTSIDE BOX BOTTOM ROLLERS SEE PG 37 Pull the retractable pin and raise the bottom portion of the outside roller up to the 5 position Release the retractable pin Repeat this step for each of the lip box stations STEP 17 MOVE LIP BOX ASSEMBLY SEE PG 37 Loosen the two MOUNTING BOLTS on the ENTRANCE MOUNT ASSEMBLY BLACK Loosen the two MOUNTING BOLTS on th...

Page 42: ...back into storage position 11 ___ MOVE SKATE ROLLERS Pull retractable pins on skate rollers and move outward to 6 position 12 ___ MOVE ENTRANCE GUIDES Loosen cap screw on both entrance guides and move outward to stop at 6 position 13 ___ MOVE FACE BOX ROLLERS Pull retractable pins and raise face box rollers to 6 position 14 ___ MOVE COMPLETE LIP BOX Loosen mounting bolts and move lip box to 6 posi...

Page 43: ... inward to 5 position 11 ___ MOVE BACK GUIDE ROD Loosen guide rod bolts and slide guide rod inward to 5 position 12 ___ MOVE ENTRANCE GUIDES Loosen cap screw on both entrance guides and move inward to stop at 5 position 13 ___ MOVE FACE BOX ROLLERS Pull retractable pins and lower face box roller to 5 position 14 ___ REMOVE 6 INSIDE ROLLER BAR FROM LIP BOX Remove red colored screws remove roller ba...

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Page 45: ...ges in connection with the replacement or repair of defective parts nor shall it apply to a machine upon which repairs or alterations have been made unless authorized by KWM GUTTERMAN INC KWM GUTTERMAN INC shall in no event be liable for consequential damage or contingent liabilities arising out of the failure of any machine or parts to operate properly KWM GUTTERMAN INC shall in no event be liabl...

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