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Summary of Contents for KWM Gutterman IronMan
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Page 2: Table Of Contents
TABLE OF CONTENTS SECTION: PAGE # IRONMAN and JUNIOR Machine Specifications…………………………………….. Pg. 1 Machine Safety and General Maintenance.…………………….……………………… Pg. 2 Machine Mounting…….……………………………………………………………….. Pg. 2 5” Gutter Machine Orientation………………………………………………………… Pg. 3 IRONMAN 5” Gutter Machine Drawing……………………………………………… Pg. 4 6” Gutter Machine Orientation…………………………………………………………... -
Page 3: Ironman And Junior Machine Specifications
RECOMMENDED MATERIAL JUNIOR MACHINES ALUMINUM - MAX .032 THK COPPER - 16 OZ to 20 OZ. MINIMUM ¾ HARD RECOMMENDED MATERIAL IRONMAN MACHINES PAINTED STEEL - MAX 24 GAUGE GALVANIZED STEEL - MAX 24 GAUGE ALUMINIZED STEEL - MAX 24 GAUGE TERNECOAT STEEL - MAX 24 GAUGE ALUMINUM - MAX .032 THK... -
Page 4: Machine Safety And General Maintenance
SECTION: 2 SAFETY AND GENERAL MAINTENANCE Read the entire manual prior to operation of this machine. • Always keep covers and lids on machine during transportation, operation and storage. The covers are for the • operator’s safety. Not only will the covers protect the operator against injury, but they will also protect the machine from outside elements. -
Page 5: 5" Gutter Machine Orientation
SECTION: 4 5” GUTTER MACHINE ORIENTATION For communication purposes in the manual, the machine orientation is as follows: (SEE PG. 4) A. ENTRANCE The ENTRANCE of the machine is where the forming process begins and where the material is fed. B. -
Page 7: 6" Gutter Machine Orientation
SECTION: 4A 6” GUTTER MACHINE ORIENTATION For communication purposes in the manual, the machine orientation is as follows: (SEE PG. 6) A. ENTRANCE The ENTRANCE is where the forming process begins and where the material is fed. B. EXIT The EXIT is where the forming process is complete and where the finished gutter exits the machine. C. -
Page 9: Machine Electrical Controls, Operator Panels, And Basic Feeding Operation
SECTION: 5 ELECTRICAL SYSTEM AND CONTROL LOCATIONS FEEDING THE MACHINE MAIN OPERATOR’S PANEL The MAIN OPERATOR’S PANEL is located on the right side at the exit end of the machine. THE MAIN OPERATOR’S PANEL CONSISTES OF: 2 SELECTOR SWITCHES JOG-RUN •... -
Page 12: Upright Turnstile Assembly
SECTION: 7 SPOOL UPRIGHT SUPPORTS The IRONMAN TURNSTILE UPRIGHT is a modular turnstile support used to hold coil. Your machine may have up to three uprights. ONE TURNSTILE UPRIGHT ASSEMBLY CONSISTS OF: (SEE PG. 11) TURNSTILE UPRIGHT (1) TENSION BRAKE (2) -
Page 14: Machine Entrance Guide System
SECTION: 9 ENTRANCE GUIDE SYSTEM PURPOSE AND PRECAUTIONS OF THE ENTRANCE GUIDE SYSTEM: The ENTRANCE GUIDE system is a very important part of this machine. Not only is it used to position material being fed into the machine, but it also controls the lateral relationship of the material to the forming stations. ENTRANCE GUIDE CONSISTS OF: (SEE PG. -
Page 15: Machine Entrance Guide Assembly Drawing
NOTES: _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ ______________________________________________________________... -
Page 16: Machine Polyurethane Drive System
SECTION: 10 POLYURETHANE DRIVE SYSTEM The drive train of this machine is in most circumstances maintenance free. If a material traction problem arises or a roller is replaced, the top roller is adjustable up and down. CAUTION: DO NOT OVER TIGHTEN DRIVE ROLLERS The factory setting for the rollers is 1/4 turn past the point of contact. -
Page 17: Machine Forming Components And Assemblies
SECTION: 11 FORMING COMPONENTS AND ASSEMBLIES GUIDE BAR COMPONENTS: The guide bars are in a fixed positive relative to the forming stations. • The back guide bar must be in contact with the material at all times. • The face guide bar supports the face portion of material guiding it into the face forming box assembly. •... -
Page 18: Machine Lip Forming Box
SECTION: 12 LIP FORMING BOX (FORMS THE LIP PORTION OF THE GUTTER) The FORMING BOX consists of 7 stations (#1 = ENTRANCE & #7 = EXIT) and three color-coded adjustment areas. COLOR-CODED ADJUSTMENTS: BLUE: Swing Shaft Assembly BLACK: Entrance Box Mount GREEN: Exit Box Mount ROLLER MAINTENANCE: The forming rollers in this assembly are made from stainless steel. - Page 19 ENTRANCE BOX MOUNT LOCATION: • The ENTRANCE BOX MOUNT has primary purpose in aligning the entrance of the forming box with the exit of the face-forming box. • Looking through the guillotine, see that the lateral alignments between the forming rollers of both boxes are in line. THIS LOCATION IS FACTORY SET &...
- Page 20 EXIT BOX MOUNT LOCATION The VERTICAL exit box mount adjustment is used to control the up and down hill on the face-side of the bottom. • The LATERAL adjustment is used to control the width across the opening of the gutter. •...
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Page 21: Machine Exit End Forming And Drive Assembly
SECTION: 13 EXIT END FORMING AND DRIVE ASSEMBLY This assembly is a very important part of the machine. Not only does it finish the forming process, 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. - Page 22 FACE-SIDE OF TOP EXIT ROLLER ASSEMBLY: This area will control into the house and also up & downhill on the face-side bottom of the gutter. • This station is very responsive; make small incremental adjustments of less than 1/32 of a turn. •...
- Page 23 FACE BELL ROLLER AND BACK BELL ROLLER: Adjusting bell rollers will control the squaring of the bottom corners of the gutter as well as into and away • from the house. ADJUSTMENT Loosen PIVOT BOLT, LOCKING BOLT, and the LOCKNUT on ADJUSTMENT BOLT. TO MOVE BELL ROLLER CLOSER TO THE TOP DRIVE ASSEMBLY: Turn ADJUSTMENT BOLT counter-clockwise (this will allow bell wheel to move towards top roller).
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Page 24: Machine Bead Roller Assembly
SECTION: 14 BEAD ROLLER ASSEMBLY The BEAD ROLLER is used to give the back section of the gutter some form and structure. The amount of pressure will also control up & downhill on the back of the gutter. FACTORY SETTING: VERTICAL height of bead roller is 3/8” down from the top of the back of the gutter; HORIZONTAL position is a 1/32”... -
Page 25: Guillotine And Face Plate Assembly
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” guillotine. CHANGING THE 5” or 6” GUILLOTINE (SEE PG. 23): CHANGE OVER FROM 5” to 6”: Remove the 6”... -
Page 27: Basic Machine Setup Dimensions
Set the right shoe first, and then bring the left shoe to the right (Snug enough to support material without binding). i. (1) RIGHT ENTRANCE GUIDE DIMENSIONS 5” IRONMAN: 1 ½” COMBINATION 5” POSITION: 1-5/8” 6” IRONMAN: 5/16” COMBINATION 6” POSITION: ½”... -
Page 28: Basic Machine Setup Drawing
BASIC MACHINE SETUP DRAWING... -
Page 29: Gutter Talk
SECTION: 17 GUTTER TALK Common terms describing the condition of the gutter: RUNNING UPHILL This term describes a condition where the ends of the gutter are higher along the fascia board than the center. RUNNING DOWNHILL This term describes a condition where the ends of the gutter are higher along the fascia board than the center. -
Page 30: Machine Operation Recap And Summary
Jog gutter to desired length and cut off using guillotine. Run 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). -
Page 31: Trouble Shooting
SECTION: 20 TROUBLE SHOOTING ADJUSTING THE TOP LIP OF GUTTER The two conditions listed below will be corrected using the SWING SHAFT (BLUE station). (SEE SWING SHAFT ASSEMBLY PG. 16) Top lip lines #3 & #4 are running DOWN and AWAY from the fascia. (SEE PG. 42) The bottom lines #6 &... - Page 32 Use #3 DRIVE FORMING ROLLER and SWING SHAFT ASSEMBLY as a secondary option to acquire the same results. (SEE PG. 20) NOTE: Loosen LOCKING BOLT K prior to adjusting the top #3 DRIVE FORMING ASSEMBLY. ** CAUTION: Over-adjustment will cause OPPOSITE reaction. ** A.) To correct for DOWN and AWAY from the fascia board: Add pressure to the face side of the top #3 DRIVE FORMING ROLLER.
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Page 33: Drawing Of Gutter Profile
#3 DRIVE FORMING ROLLER (SEE PG. 19). OIL CANNING OR RIPPLING ON BOTTOM An imperfect bottom on the gutter is very uncommon from the IRONMAN. i. Check all bottom rollers, drive rollers, and skate rollers for tape, debris, or buildup. -
Page 34: Combo Machine Conversion 5" To
SECTION: 22 COMBO CONVERSION INSTRUCTIONS • The process to change from the 5” gutter profile to the 6” gutter profile and then back again is considerably simplified by using retractable pins with two secured positions that provide an easy change. •... - Page 35 STEP 11: MOVE ENTRY GUIDE SHOES. (SEE PG. 36) • There are two split collars used as stops on the entrance guide shaft to locate each entrance guide shoe for the 5” and 6” gutter position. • To position the entrance guide shoes from the 5” to the 6” position, loosen cap screws and slide the entrance guide shoes against the outer most collars on the shaft.
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Page 40: Combo Machine Conversion 6" To
6” to 5” CONVERSION CAUTION: Make sure that the machine has been disconnected from the power source before starting conversion. The order to convert 6” to 5” is NOT the same as for 5” to 6”, so follow the instructions carefully. •... - Page 41 STEP 12: MOVE THE THREE FACE BOX ASSEMBLY STATIONS. (SEE PG. 37) Pull the retractable pin that is located at the top of each station assembly. • Lower the face roller assembly down to the 5” gutter position and release pin. •...
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Page 42: Conversion Check List 5" To
SECTION: 23 ” to 6” COMBO CHANGE OVER CHECK LIST ___ UNPLUG MACHINE: Eliminate electrical power source. ___ REMOVE COVERS: Remove covers containing quick-release fasteners. ___ REMOVE GUILLOTINE: Remove 5” guillotine from machine. ___ MOVE BEAD ROLLER ASSEMBLY: Loosen and slide bead roller assembly into 6” position ___ REMOVE BACK BELL ROLLER: Remove from 5”... -
Page 43: Conversion Check List 6" To
SECTION: 24 6” to 5” COMBO CHANGE OVER CHECKLIST ___ UNPLUG MACHINE: Eliminate electrical power source. ___ REMOVE COVERS: Remove covers containing quick-release fasteners. ___ REMOVE GUILLOTINE: Remove 6” guillotine from machine. ___ REMOVE BACK BELL ROLLER: Remove from 6” position, and set it to the side. ___ FLIP TOP #3 EXIT DRIVE ROLLER: Remove &... -
Page 45: Warranty Information
KWM GUTTERMAN, INC. shall, in no event, be liable to bear costs of lost work, material, travel, or freight, caused by any part(s) of the machine that are defective in workmanship or material. All warranty work must be returned to 795 S.
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