KWM Gutterman IronMan Half-Round G2 Operating instructions

OPERATING AND MAINTENANCE
TROUBLESHOOTING GUIDE
Half Round G2
Half Round G2

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In purchasing a KWM Gutterman Inc. gutter-forming machine, you are welcomed to the growing
group of people who recognize quality and precision. KWM is proud of our modern facility and
highly trained personnel that allow KWM Gutterman Inc. to manufacture the very best roll-forming
equipment.
The operating and maintenance guide explains the features of your new KWM Gutterman Inc. gutter
machine. Please read it and follow the instructions carefully.
As the manufacturer of your roll-forming machine, KWM wants you to be completely satisfied with
your purchase. The maintenance and troubleshooting guide is designed to help answer most questions
or concerns on your roll-forming machine. A copy of our warranty is included in our maintenance
guide.
“Manufacturing the Best, Built to Stand the Test”
Please visit us at www.kwmgutterman.com for product information.
Our family business will only succeed by making you, our customer, our top priority! We are only a
phone call or a click away.
1- 888-729-4290
[email protected]
Thank you for your purchase!
At Your Service, We Remain.
Kenneth W. Minor Sr.
Keith W. Minor Sr.

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TABLE OF CONTENTS
SECTION PAGE #
pg. 4
pg. 5-6
pg. 7-9
pg. 10-11
pg. 12
pg. 13
pg. 14
pg. 14-16
pg. 17
pg. 18
pg. 19
pg. 20
1. Machine Specifications
2. Safety and General Maintenance
3. Electrical System and Control Locations
4. Spool Upright Supports
5. Entrance Guide System
6. Gutter Talk
7. Daily Operation
8. Adjusting Straightness of Gutter
9. Adjusting Width of Gutter
10. Guillotine and Face Plate Assembly
11. Troubleshooting
12. Gutter Profile

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SECTION 1
HALF ROUND GUTTER MACHINE SPECIFICATIONS
POWER:
- 1.5 HP, FAN COOLED (T.E.F.C.) MOTOR
- SINGLE PHASE
- 110V
- 18 AMP
DIMENSIONS:
-
LENGTH 162”
(411.50 cm)
-
HEIGHT 51”
(129.5 cm)
WEIGHT:
DRIVE:
SHEAR
SPEED:
CONTROLS:
- WIDTH 34.5”(87.6 cm)
- APPROX. 2000 LBS. (907.2 kg)
- TOP AND BOTTOM STEEL/ALUMINUM/POLYURETHANE ROLLERS
- VIA CHAINS & SPROCKETS
- FRONT PULL GUILLOTINE STYLE SHEAR
- APPROXIMATELY 35’ PER MINUTE
- ENTRANCE END
oEMERGENCY STOP
oJOG PUSH BUTTON
- EXIT END
oSTOP BUTTON
oFORWARD & REVERSE SWITCH
oRUN & JOG SWITCH
oSTART BUTTON
RECOMMEND MATERIALS:
- PAINTED STEEL
ALUMINUM STEEL
TERNECOAT STEEL
ALUMINUM
COPPER
(MAX: 24 GAUGE)
(MAX: 24 GAUGE)
(MAX: 24 GAUGE)
(MAX: .032”)
(MAX: 16/20 OZ. 3/4” HARD)
WARNING: NO RAW OR UNCOATED MATERIAL
CALL MANUFACTURER FOR PAINT GRIP & RAW
GALVANIZED

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SECTION 2
SAFETY AND GENERAL MAINTENANCE
1. Read the entire manual prior to operation of this machine.
2. Always keep covers and lids on during transportation, operation and storage. The covers are for the
operator’s safety. Not only will this protect the operator against injury, the covers protect the machine
from outside elements.
3. Read all warning labels on machine.
4. Disconnect the machine from power source prior to cleaning, or performing any maintenance.
5. Perform a daily inspection for debris, loose nuts, and or bolts. With a clean machine you can expect
longer life from your machine and a better-finished product.
6. Lubricate guillotine and chains weekly using WD40.
7. OUTSIDE STORAGE. If machine must be stored outside on an open trailer, tarp machine loosely
providing good ventilation to prevent condensation.
8. BE SURE the operator is trained in the operating procedures of this equipment, and all local and
national safety codes concerning the operation and the lifting of coils.
MOUNTING MACHINE
Mounting machine in truck and or trailer.
1. When choosing a vehicle or trailer for your machine, consider the gross machine weight including
coil.
2. Check mounting surface for its integrity and make any repairs necessary prior toinstallation.
3. Bolt machine to the bed of the vehicle using 3/8" dia. bolts grade 5 four places. DO NOT DRAW
MACHINE DOWN TO AN UN-FLAT SURFACE. Shim as needed to insure four place mounting.
*REMOVE MACHINE FROM WOODEN SHIPPING SKID*

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MACHINE ORIENTATION
Machine orientation is as follows: (For communication purposes in the manual.)
A. Entrance
The entrance is where the forming process begins, where the material is fed.
B. Exit
The exit is where the forming process is complete and the finished gutter exits the machine.
C. Right Side
The right side of the machine is determined when facing entrance end of the machine. This is where
the LIP of the gutter is formed.
Components on Right Side:
1. Lip Side Guide Shoe (Right Shoe)
2. Lip Side Assemblies
3. Motor and Gearbox
D. Left Side
The left side of the machine is determined when facing the entrance end. This is where the HEM of
the gutter is formed.
Components on Left Side:
6. Hem Side Guide Shoe
7. Hem Assemblies
8. Bead Roller Assembly
9. Crimper Support Assembly
E. Center of Machine
The center of machine forms bottom section of gutter and is the drive assembly.
Components in Center of Machine:
10. Entrance Guide Assembly
11. Drive Assemblies
12. FPG

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SECTION 3
ELECTRICAL SYSTEM AND CONTROL LOCATIONS
1E. MAIN OPERATORS PANEL (located on the lip side of the machine at the exit end)
The main operators panel consists of:
(2) Selector switch. (JOG/RUN & FORWARD/REVERSE)
(2) Push button. (START & STOP)
2E. ENTRY OPERATORS PANEL (located on the lip side of the machine at the entrance end)
The entry operator’s panel consists of:
(1) Jog button (push button)
(1) Emergency stop button. (power shut off)
ELECTRICAL CORD REQUIREMENTS
It is important that the motor manufactures minimum wire gage be adhered to in order to maintain the
warranty on motor.
LENGTH GAGE CORD
0 –25’ 12 ga
25 –50’ 10 ga
50 –100’ 7 ga

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SECTION: 4
SPOOL UPRIGHT SUPPORTS
The IRONMAN TURNSTILE UPRIGHT is a modular turnstile support used to hold coil.
Your machine may have up to two uprights.
ONE TURNSTILE UPRIGHT ASSEMBLY CONSISTS OF: (SEE PG. 13)
TURNSTILE UPRIGHT (1)
UPRIGHT BRAKE (2)
BASE PLATE (1)
LOCK THUMB SCREW (1)
TURNSTILE LOCKING PIN (1)
BRAKE THUMB SCREW (2)
WING NUT (1)
SAFETY PIN (2)
LOCK BLOCK (1)
TO ROTATE TURNSTILE FOR TWO-SIDED COIL:
1. Loosen WING NUT loosen LOCK THUMB SCREW.
2. Slide LOCK BLOCK outward.
3. Rotate TURNSTILE 180 degrees.
4. Slide LOCK BLOCK inward.
5. Tighten LOCK THUMB SCREW then tighten WING NUT.
SPOOL ASSEMBLY AND LOADING COIL
ONE SPOOL ASSEMBLY CONSISTS OF: (SEE PG. 13)
SPOOL SHAFT (1)
SPOOL HALF (2)
5/16” QUICK RELEASE PIN (2)
TO LOAD COIL ONTO SPOOL ASSEMBLY:
1. Remove Safety Pins, Loosen Thumb Screws, Release the safety brakes.
2. Place the empty spool assembly on the ground or on a flat surface.
3. Remove one of the 5/16” quick release pins.
4. Slide the spool half off of the 1¼” spool shaft.
5. Insert the spool shaft through the center of the coil.
6. Replace spool half on the spool shaft, and reinstall the 5/16” quick release pin.
7. Install loaded spool assembly onto the upright. Use of mechanical lifting device recommended.
8. Engage Safety Brakes; lightly tighten thumb screws And Install Safety Pins.
NOTE: The spool assembly is adjustable to accept both 5” gutter material (11 ¾” – 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 assembly into the turnstile upright.
(IMPORTANT! –Please read PRECAUTIONS)
PRECAUTIONS:
➢ Make sure loading area is clean and clear of debris.
➢ Make sure Turnstile Locking Pin is securelyinstalled.
➢ Always wear protective footwear when handling coil.
➢ Never load coil with the brake in closed position.
➢ Never operate machine without first checking brake & pin positions.
➢ Never transport machine without locking brake in closed position and safety pins installed.
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SECTION 5
ENTRANCE GUIDE SYSTEM
ADJUSTING ENTRACE GUIDE SYSTEM
THE LOCATIONS OF THE ENTRANCE GUIDE SHOES ARE
FACTORY SET AND SHOULD NOT BE ALTERED
UNLESS AUTHORIZED –PLEASE CALL
To INCREASE THE AMOUNT OF LIP TURNED UNDER;
Move the guides toward the right side (face side) of the machine.
To DECREASE THE AMOUNT OF LIP TURNED UNDER;
Move the guides toward the left side (back side) of the machine.
TO MOVE GUIDES
1.) Loosen the set screws on right collar.
2.) Side shoes towards the direction needed using a tape measure
3.) Tighten the set screws on right collar
4.) Loosen the set screws on the left collar
3.) Adjust width between the guide shoes using a piece of coil as a gauge
4.) Tighten set screws on left collar

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SECTION: 6
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.
INTO THE HOUSE
This term describes a condition where 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
is closer to the fascia board than the middle.
TOP LIP AWAY FROM THE HOUSE
This term describes a condition were the end of the top lip
is further away from the fascia than the middle.

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SECTION 7
Daily operation
Feeding Machine
1. Position selector switch to jog.
2. Position selector switch to forward position.
3. Loosen upright brakes
4. Trim corners of coil 3" X 3"
5. Standing at entrance of machine, position material in the center of the entrance guides and
hand feed to material into first drive.
6. Activate jog button using your right hand at the same time using your left hand to push the
material so as to engage with #1 drive assembly, Jog material approximately two feet.
Release jog button.
7. Continue feed material, using exit end start button.
8. Stop material before guillotine and make sure it clears.
9. Jog material thru guillotine using start push button.
ADJUSTING STRAIGHTNESS OF GUTTER
ONLY MAKE 1/2 TURN ADJUSTMENTS AT A TIME
Adjusting an into the house curve
1. This is controlled by the Blue Station
2. Loosen nut "B" and bolt "A", turn bolt “C” counter-clockwise to move the center roller
away from the outside rollers by jogging material forward
3. Tighten bolt "A" and nut "B" to lock back in place.
Adjusting an away from the house curve
1. Loosen nut "B" and bolt "A" turn bolt “C” clockwise to move center roller towards the
outside rollers
2. Tighten nut “B” and bolt “A” to lock back in place
SECTION 8

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BLUE STATION

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Adjusting a downhill curve
1. Station #9 (Green Station) is too low, raise drive station #9, you may need to raise the
FPG to line up.
2. Loosen 8 C bolts outside machine, loosen push bolts B 1/2 turn
3. Tighten pull bolt A 1/2 turn
Adjusting an uphill curve
1. Station #9 (Green Station) is too high, lower drive station #9, you may need to lower the
FPG to line up.
2. Loosen 8 C bolts outside machine, push bolts B 1/2 turn
3. Loosen pull bolt A 1/2 turn
GREEN STATION

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SECTION 9
Adjusting width of
gutter
Making the gutter wider
1. Loosen push bolts B 1/2 turn
2. Tighten pull bolt A 1/2 turn
Making the gutter narrower
1. Loosen push bolts B 1/2 turn
2. Loosen pull bolt A 1/2 turn
RED STATION
NOTE: DO NOT LET TOP ROLLER CONTACT BOTTOM ROLLER!
APPRX. 1 TURN FROM AL SETTING .055"

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SECTION 10
GUILLOTINE AND FACE PLATE ASSEMBLY
The guillotine assembly is machined to very tight tolerance, requiring that it be maintained on a
regular basis. If the guillotine assembly is kept clean, lubricated and all hardware tight, you can
expect trouble free performance for years to come.
DAILY MAINTENANCE:
Lubricate GUILLOTINE blade using WD40.
ADJUSTING GUILLOTINE POSITION
The guillotine is moveable in all directions.
UP & DOWN ADJUSTMENT
1. loosen bolt A six places, loosen locking nut C on adjustment bolt B two places.
2. Turn adjustment B clockwise to raise and counter clockwise to lower.
3. Retighten locking nut C when desired position is reached
SIDE TO SIDE ADJUSTMENT
1. Loosen bolt A six places, The guillotine is now free to move in all directions.
2. After the desired position is acquired, retighten A six places.

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SECTION 11
TROUBLESHOOTING
This section is only a brief summary. Please read the entire manual prior to operating machine.
COMMON PROBLEMS
MACHINE NOT RUNNING
No power - check power supply (outlet, generator, power cord) Check that emergency
stop has been disengaged
COIL DOES NOT FIT GUIDES
Adjust Left Guide (Section 5)
GUTTER TOO WIDE
Adjust Red Station (Section 9)
GUTTER TOO NARROW
Adjust Red Station (Section 9)
For helpful tips & more download the KWM Gutterman App!