Fast Framer Gen

OPERATION & MAINTENANCE MANUAL

Serial Plates

WARNING This machine must only be used by personnel who have been properly instructed in all aspects of the machine’s safe operation.

Operators must also wear the recommended personal protective equipment and have thoroughly read and understood this manual.

All enquiries should be directed to: SM2012 Ltd - Known as Spida Machinery Australia free phone 1800 146 110 America free phone 1888 262 9476 NZ free phone 0800 SPIDAS or +64 7 579 5010 Below is a copy of the serial plate displayed on the back of the machine

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1 Contents 2 Overview ...... 7 3 Specifications ...... 7 4 Installation ...... 8 4.1 Handling & Transport ...... 8 4.2 Installation ...... 8 5 Safety ...... 10 5.1 Young Persons ...... 10 5.2 Long Hair and Loose clothing ...... 10 5.3 Cleaning and Maintenance of Machinery ...... 10 5.4 Training and Supervision of Frame Nailer Operators ...... 10 5.5 Responsibilities of Frame Nailer Operators ...... 10 5.6 Operating Speeds and Vibration ...... 11 5.7 Machinery Stability and Location...... 11 5.8 Electrical Safety ...... 11 5.9 Isolation, hold cards and lock out devices ...... 11 5.10 Noise control ...... 12 5.11 Manual Handling ...... 12 5.12 Recommended Service Interval ...... 12 6 Safe Operation ...... 13 6.1 User Warnings ...... 13 6.2 Manual Handling ...... 14 6.3 General ...... 15 6.4 Operation ...... 16 6.5 Maintenance ...... 17 6.6 Recommendations ...... 18 7 Operating Controls ...... 19 7.1 Frame Nailer controls...... 19 7.2 Pneumatic Controls ...... 21 7.3 Pneumatic filter/regulator ...... 23 8 Operation ...... 24 8.1 Machine Set-up ...... Error! Bookmark not defined. 8.2 Stations Right/Left/or Both ...... Error! Bookmark not defined. 8.3 Guns Top/Bottom/or Both ...... Error! Bookmark not defined. 8.4 Guns in correct position ...... Error! Bookmark not defined.

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8.5 Trolley and Carriage Clamps ...... 25 8.6 Loading ...... Error! Bookmark not defined. 8.7 Clamping and Firing Operation ...... Error! Bookmark not defined. 8.8 Air Dump ...... Error! Bookmark not defined. 8.9 Machine Shut-down ...... Error! Bookmark not defined. 9 Parts Identification ...... 28 9.1 Top Level Assembly (2001000) ...... 28 9.2 Main Frame Assembly (1701100) ...... 30 9.3 Nog Trolley Assembly (1701660) ...... 32 9.4 Fixed Carriage Assembly (1701200 L or R) ...... 34 9.4.1 Exploded Horizontal Stud Clamp Assembly (1701130) ...... 36 9.5 Floating Carriage Assembly (1701200 L or R) ...... 38 9.6 Plate Clamp Assembly (2001200 L or R - B) ...... 40 9.7 Gun Mount Assembly (SMPGMA02) ...... 42 9.8 Computer Monitor and Electrical Enclosure Assemblies (0605000 and EEHW) ...... 44 9.9 Progressor Tables (1804420) ...... 45 9.9.1 Fence Assembly (SMPGPFA6300) ...... 47 9.9.2 Gearbox Kit 2 (SMPGPGK2) ...... 49 9.9.3 Guide Profile Trolley Kit (SMPGPTK2) ...... 50 10 Maintenance ...... 51 10.1 Maintenance Items ...... 52 10.1.1 Guards ...... 52 10.1.2 Air Line Lubrication ...... 52 10.1.3 Keep work area clear ...... 52 10.1.4 Inspect Clamps ...... 52 10.1.5 Plate Sensor ...... 53 10.1.6 Clean Frame Nailer of any build up ...... 53 10.1.7 Noises or vibrations ...... 53 10.1.8 Emergency Stop Buttons ...... 53 10.1.9 Dry Air Supply ...... 54 10.1.10 Air Supply ...... 54 10.1.11 Check Filter/Regulator ...... 54 10.1.12 Nog Trolley Assemblies ...... 54 10.1.13 Carriage Assemblies ...... 54 10.1.14 Loose Fasteners and Fixings ...... 55

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10.1.15 Guide Trolley Slides ...... 55 10.1.16 Bench Top ...... 55 10.1.17 Maintain Brake Materials ...... 55 10.1.18 Maintain Frame Nailer ...... 55 10.1.19 Nail Guns ...... 55 10.2 Replacing Guide Trolley Slides ...... 56 10.2.1 Reference Distances for Guide Trolley sliders ...... 57 11 Foreseeable Misuse ...... 58 12 Trouble Shooting ...... 59 13 Distributor & Repairer Contacts...... 60 13.1 Agent/Distributor ...... 60 13.2 Automation Repairs ...... 60 13.3 Mechanical Repairs ...... 60 14 Warranty ...... 61 15 Pneumatic Drawings ...... 63 16 Training Certificate ...... 64 17 Frame Nailer Training Check List ...... 65

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Tables Table 1, Frame Nailer Specifications ...... 7 Table 2, General Hazards ...... 15 Table 3, Operational Hazards ...... 16 Table 4, Maintenance Hazards...... 17 Table 5, Control functions (see Figure 2) ...... 20 Table 6, Pneumatic Control functions (see Figure 3) ...... 22 Table 7, Valve/Filter/Regulator/Dump parts ...... 23 Table 8, Parts List – Frame Nailer ...... 29 Table 9, Main Frame Assembly parts list ...... 31 Table 10, Nog Trolley Assembly parts list ...... 33 Table 11, Fixed Carriage Assembly parts list ...... 35 Table 12, Exploded Horizontal Stud Clamp Assembly parts list ...... 37 Table 13, Floating Carriage Assembly parts list ...... 39 Table 14, Plate Clamp Assembly parts list ...... 41 Table 15, Gun Mount Assembly parts list ...... 43 Table 16, Computer Monitor and Electrical Enclosure Assemblies Parts List ...... 44 Table 17, Progressor Table Assembly Parts List ...... 46 Table 18, Fence Assembly Parts List ...... 48 Table 19, Gearbox Motor Assembly Parts List ...... 49 Table 20, Guide Profile Trolley Assembly Parts List ...... 50 Table 21, Maintenance intervals ...... 51 Table 22, Common misuse issues ...... 58 Table 23, Trouble shooting ...... 59

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Figures Figure 1, Recommended exclusion zone around the Frame Nailer...... 11 Figure 2, Frame Nailer controls ...... 19 Figure 3, Frame Nailer pneumatic controls ...... 21 Figure 4, Valve/Filter/Regulator/Dump assembly ...... 23 Figure 5, Nog centres adjustment ...... 25 Figure 6, Frame Nailer with guns...... 28 Figure 7, Main Frame Assembly ...... 30 Figure 8, Nog Trolley Assembly ...... 32 Figure 9, Fixed Carriage Assembly ...... 34 Figure 10, Exploded Horizontal Stud Clamp Assembly ...... 36 Figure 11, Floating Carriage Assembly ...... 38 Figure 12, Plate Clamp Assembly ...... 40 Figure 13, Gun Mount Assembly ...... 42 Figure 14, Computer Monitor and Electrical Enclosure Assemblies ...... 44 Figure 15, Progressor Table Assembly ...... 45 Figure 16, Fence Assembly ...... 47 Figure 17, Gearbox Motor Assembly ...... 49 Figure 18, Guide Profile Trolley Assembly ...... 50 Figure 19, Plate Sensor locations ...... 53 Figure 20, Trolley slide replacement ...... 56 Figure 21, Stop Slider distances ...... 57 Figure 22, Pneumatic diagram ...... 63

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2 Overview The Spida Gen III Fast Framer (heretofore referred to as the Frame Nailer) is designed to accurately nail timber frames, using pneumatically operated nail guns.

The Frame Nailer must be used per the standard operating procedures set out in this manual. Any actions carried out which are not contained in this manual are not endorsed by Spida Machinery and cannot be warranted.

All operators should read and then sign the register of this manual before operating the Frame Nailer to ensure they are thoroughly familiar with the machine capabilities, limitations and to ensure correct operating procedures are adhered too.

Only those operators that have received training on the correct operation of the Frame Nailer are deemed competent and qualifies to operate the machine.

The Frame Nailer test procedures must be performed at installation and after any maintenance, adjustment, repair or modification of the machine. The test procedure is available on request.

The competent operator must also regularly perform the recommended maintenance procedures and checks detailed in this manual.

All pneumatic lines must be set as to not allow its movement through the nailing area of adjacent machinery.

This manual offers many safety tips, but its purpose is not to provide instruction in all the skills and techniques required to manufacture timber frames safety and efficiently.

Due to improvements in design and performance during production, in some cases there may be minor discrepancies between the actual machine and the illustrations and text in this manual.

3 Specifications

Table 1, Frame Nailer Specifications

Overall Width 4975 mm Overall Height 1410 mm Overall Length 1345 mm Working Height 870 mm Weight 765 kg Timber Feed Front Air Supply 6-8 Bar (600-800 kPa) Nail Gun Capacity 273.8 l/min (60 cycles) each

Specifications may change without notice

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4 Installation 4.1 Handling & Transport • Box all additional parts and secure with the machine

• Using a single fork truck, lift the machine package underneath using the forklift spaces provided

• Once on the truck, tightly strap the machine.

• Do not place any loads on top of the machine

• The machine should be kept free from road grime and rain, and should be covered at all times while being transported

The Frame Nailer will be delivered in large component form and will require assembly on site by trained personnel. Due care and attention should be given whilst unpacking the components from their packaging materials. Any damage caused whilst in transit should be noted immediately and Spida Machinery informed. Refer to section 3 specifications for weights of individual components when selecting Manual Handling Equipment required, prior to positioning them on the selected site. 4.2 Installation • It is advisable to forklift the machine package as close to the final assembly point as possible to reduce manual lifting

• The final operating position of the machine must be free from any rubbish or impediments

• There must be good lighting in the installation area to allow proper positioning of the machine

• The ground on which the machine rests must not vary by more than 30mm over a 12m x 5m area

• The Frame Nailer should be leveled using jacking bolts on steel jacking plates. Once level, machine should be bolted to the floor through holes provided.

• Electrical commissioning to be to local standards and be performed by a qualified electrician

The site selected for the Frame Nailer will depend on the ground. The ground chosen should be clean and free of water or possible flooding. The area on which the framework sits must be as even and horizontal as possible. This can be achieved by adjusting the length of the feet. There should be no twist to the framework once the feet have been adjusted to take the ground into account.

The final operating position of the machine should be free of all rubbish or impediments, with general access to all areas of the Frame Nailer for the ease of loading and unloading material of varying sizes.

With the machine in position, a qualified engineer should be used to connect the pneumatic components to the machine and adjust the air pressure to the required setting (refer to 3 Specifications for pressure settings)

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Check all pneumatic hoses and connectors to ensure that the fittings haven’t worked loose during transportation of the machine. Re-tighten all fittings that appear to be leaking. If leaking persists undo the fittings and apply a sealing compound to the joints in question. Re-tighten the fitting. (Any serious leaking problems during the warranty period should be reported to Spida Machinery). Check the air pressure in the system is sufficient to operate the machine (refer to 3 Specifications for pressure settings).

To check the air pressure, turn the compressor on and allow the pressure to build up. When the controls are activated, normal pressure should read 6-8 bar or 600- 800 kPa. All maximum pressures are factory set and should not be changed.

Check that all safety equipment is functioning properly.

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5 Safety This section is provided as a guide only, it is the responsibility of the employer to ensure compliance with the relevant Health and Safety Regulations applicable to them at the time. 5.1 Young Persons No person under the age of 15 should be allowed to operate or assist with the operation of machinery. 5.2 Long Hair and Loose clothing Any long hair or loose clothing must be fully contained to eliminate the risk of entanglement with machinery.

PROTECTIVE SAFETY CLOTHING AND EQUIPMENT MUST BE WORN; INCLUDING:

Eyewear

Hearing protection

Respirator or Dust mask

Protective Clothing

Safety footwear 5.3 Cleaning and Maintenance of Machinery For safe and reliable use, machinery should be regularly cleaned and maintained. During cleaning and maintenance, the Frame Nailer must be isolated from all sources of energy and locked out to prevent unexpected operation. 5.4 Training and Supervision of Frame Nailer Operators No person should be expected or allowed to operate the Frame Nailer until they have been fully trained and authorised to do so. They must be familiar with:

• Actual and potential hazards and appropriate controls. • Correct use and adjustment of guards. • Emergency procedures. • How the Frame Nailer works. • Checks to perform prior to starting. • How to recognise potential faults. • Location of controls and how to Stop and Start the Frame Nailer. 5.5 Responsibilities of Frame Nailer Operators Operators should:

• Check the Frame Nailer prior to use and during operation to ensure it is in sound operating order. • Report immediately any defects noted to their supervisor. • Use any, and all safety equipment provided. • Not operate any machinery if under the influence of drugs or alcohol, consult a physician or pharmacist if unsure of any medication.

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5.6 Operating Speeds and Vibration Machinery should be operated within its designed limitations and for its designed use only, any unfamiliar noise, vibration or failure should be investigated and remedied promptly. 5.7 Machinery Stability and Location The Frame Nailer should be securely fastened to the structure of the building to prevent movement or toppling over. Location should provide access all around for maintenance and cleaning. Lighting must be adequate to allow operator to clearly see controls and work pieces but not glaring or blinding.

Consideration should be given to the operators work area for product flow and to minimise repetitive actions and unnecessary movement.

An exclusion zone around the Frame Nailer should be maintained to prevent persons not directly involved with the operation of the machine from reaching any part of the machine.

Figure 1, Recommended exclusion zone around the Frame Nailer. 5.8 Electrical Safety Electrical wiring must be installed and maintained by a suitably qualified person in accordance with relevant regulations. 5.9 Isolation, hold cards and lock out devices There should be procedures for isolating and locking out the Frame Nailer, for purposes of maintenance and to prevent unintended use should a fault have been identified.

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5.10 Noise control The normal operation noise of some machines will be more than permitted noise exposure levels. Employers must ensure adequate hearing protection is available and is used by all persons in the affected area. 5.11 Manual Handling Manual handling should be avoided where possible, use of mechanical lifting and assisting equipment is recommended. Consider using forklifts, hoists, and trolleys to eliminate lifting and carrying components. 5.12 Recommended Service Interval It is recommended that for optimal performance, the Frame Nailer should be serviced every 6 months. It is also recommended that a service log be kept, as a reminder of when the next service should be due. Spida Machinery performs service runs on a regular basis throughout NZ; however, should the need arise for an early service, or should a service need to be booked in advance, please advise Spida Machinery accordingly.

WARNING! Do not operate the Frame Nailer without having received the proper instruction in operation and safety from this manual.

WARNING! It is recommended that the employers maintain training records demonstrating the competencies of each employee

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6 Safe Operation NOTE: The Frame Nailer is to be operated in accordance with this manual. Deviation from this specified operation may result in incorrect nailing, measuring or injury. 6.1 User Warnings • All moveable parts of the machinery must be set so as not to allow its movement through the cutting/pressing area of adjacent machinery. • All machine and components should be inspected upon delivery and at weekly intervals for looseness, fracture, bends, sharp edges or surfaces and any other condition that may contribute to a human mishap or further deterioration of the machine. We suggest a log be kept for this purpose. • When broken, damaged, or loose parts (or any condition that may represent a hazard) are observed, corrective action should be taken immediately. Inadequate attention to maintain the machine can cause the premature failure of these parts. We suggest this information also be logged. • The electrical boxes should be locked at all times to avoid casual entry by unauthorized persons, as touching live surfaces is hazardous. • Split, broken, warped, twisted or material with excessive wane should be avoided or used with caution because of the greater possibility of the material not being held securely during manufacturing processes. • The machine is not to be used for any other purpose than the nailing of timber components. • Keep hands out of moving parts on the machine. Operators should be instructed not to extend fingers or limbs into or beyond the vicinity of the warning labels. The danger here is obvious – fingers in these areas will risk mutilation. • Be sure the machine is completely free of foreign objects, and that all guards are in place before connection to electrical and/or pneumatic supply. • Any guards removed for maintenance or adjustments must be replaced before the machine is put back into service. • Exceeding the capabilities of the machine will void the warranty and could lead to a serious injury. • All Operators should read and then sign the register of this manual before operating the Frame Nailer to ensure they are thoroughly familiar with the machine capabilities and limitations and to ensure correct operating procedures are adhered to. • Failure to perform the daily and weekly service checks as per the schedule may result in serious machine damage or a severe accident.

WARNING! This machine must only be operated by personnel who have been properly instructed in all aspects of the machine’s safe operation. They must also be wearing the recommended protective clothing and have thoroughly read and understood this operation and service manual.

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6.2 Manual Handling

The following is not a comprehensive list. Manual lifting has the potential to be hazardous; so, for a full description of material handling please refer to lifting standards, techniques, and your own company policies.

• Ensure material supply is via forklift or other support mechanism • Ensure correct lifting techniques are adopted to transfer material to infeed of cutting line • Suggest use of trolleys or bench at required height and location to minimize handling and twisting • Ensure required PPE is worn • Ensure correct and appropriate lifting techniques are used • Suggest the setup of a material supply via gravity roller transfer system • Avoid twisting torso when moving pre-cut members from transfer system to pressing surface of table • Only lift components of weight which you assess to be within your limit • Use machinery (forklift) for material decreed to be too heavy or ask for assistance from another worker

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6.3 General

Table 2, General Hazards

POTENTIAL HAZARDS SAFE WORK PROCEDURE

Safety Ask questions if you have any doubts about doing the work safely. Check and adjust all safety devices daily. Poor Guarding Ensure all guards are fitted correctly and are adequately guarding guns and moving parts. Make sure guards are in position and in good working order. Do not operate machine without guards. Poor Housekeeping Inspect Frame Nailer and surrounding areas for obstructions, hazards, and defects. Remove built-up debris from around machine, electrical leads, pneumatic lines, and power points. Electrical Faults Inspect electrical leads for damage. Inoperable Safety Switches Check that start/stop and emergency stop buttons operate effectively. Incorrect Accessories Use only the accessories designed for each specific application Foreign Objects Check that foreign objects and maintenance tools etc. are removed from the machine before using the machine. Defective/Damaged parts Any identified defects must be reported and actioned prior to use of the Frame Nailer.

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6.4 Operation

Table 3, Operational Hazards

POTENTIAL HAZARDS SAFE WORK PROCEDURE Slip, Trip & Falls Avoid awkward operations and hand positions where a sudden slip could cause your hand or part of your body to move into the nailing line. Electric power cords should be above head level or in the floor in such a way that they are not trip hazards. Floor areas should be level and non-slip. Clean up any spills immediately. Workplace Use good lighting so that the work piece and machine controls can be seen clearly. Position or shade light sources so they do not shine in the operators’ eyes or cause glare and reflections. Ensure that the floor space around the equipment is sufficient to allow the operator to process his work without bumping into other staff or equipment. Keep the work area free of clutter, clean, well swept and well lit. Housekeeping Clean built up debris from around the machine, electrical leads, pneumatic lines, and power points Defects Report all defects to the supervisor Personal Protection Wear safety glasses or a face shield. Wear hearing protection that is suitable for the level and frequency of the noise you are exposed to in the work area. Wear dust masks when required. Do not wear gloves when operating this machine. Do not wear loose clothing, work gloves, neckties, rings, bracelets or other jewellery that can become entangled with moving parts Machine Guarding Make sure all guards are fastened in position. The machine MUST NOT be operated with any of the guards removed. The machine is fitted with steel guards. Improper Use Only use the machine for what it has been designed for. Material Defects Inspect stock for nails or other foreign materials before nailing. Use only material that the machine has been designed to accommodate. Operator Technique Do not impede the movement of the Frame Nailer while in use. Ensure any body parts, clothing, or work tools do not get in the way of moving parts. Only place material once the Frame Nailer is in the home position and has come to a complete halt. Do not move stock from the Nail table until the clamps have been returned to their home position. Hit by projectiles The Frame Nailer must be electrically and pneumatically isolated before attempting to clear blockages or material jams. Any small off cut should be removed using a push stick which has been properly constructed. Do not use fingers to remove items which have become entangled in movable parts.

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6.5 Maintenance

Table 4, Maintenance Hazards

POTENTIAL HAZARDS SAFE WORK PROCEDURE Cleaning and maintenance Turn the air off on the main isolator, and isolate power to the preparation machine before inspecting, changing, cleaning, adjusting or repairing a machine. Do not use compressed air to remove sawdust etc. from machines or clothing. Operational Buttons Make sure that Operational buttons are in good working condition and within easy convenient reach of an operator. Buttons should be protected so that accidental contact will not upset the machine. Emergency Stop Buttons Make sure that Emergency Stop buttons are in good working condition and within easy convenient reach of an operator. Incorrect electrical and Machine must be switched off at the Main Power Switch, and pneumatic isolation of locked out (pneumatically isolated), before maintenance or cleaning machine Incorrect tools Use Correct tools for the job to minimise personal injury and damage to the machine Stalled Clamp Isolate air before attempting to free a stalled clamp Guarding Ensure Guards are fitted correctly, adjusted and in good working order.

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6.6 Recommendations That the operator is trained, on induction of the dangers of accessing the machine operating area.

The electrical system is to be serviced, by a qualified electrician only.

That all operators are walked through the operators’ manual and all potential hazards are identified.

That good housekeeping is maintained at all times to avoid the risk of slips, trips or falls.

That approved eye and hearing protection is used at all times when operating the machine.

That approved dust masks and safety footwear are worn at all times when operating the machine.

That if the machine is not operating as efficiently as specified, the operator notify their supervisor who in turn takes appropriate action and eliminate the problem if possible.

All guards and safety devices are not to be removed.

It is recommended that a visual exclusion zone be marked on the floor on a one metre (1000mm) perimeter surrounding the working area of the machine. To identify the work space to pedestrians.

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7 Operating Controls

7.1 Frame Nailer controls Before attempting to operate the Frame Nailer, familiarise yourself with the location and function of each control.

Figure 2, Frame Nailer controls

WARNING! Do not operate the Frame Nailer without the correct knowledge and function of each of the controls.

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Table 5, Control functions (see Figure 2)

Control Function Description Fire button (Two Hands No Tie Down) Activates clamps/guns when both buttons are pressed at the 1 same time Fire button (Two Hands No Tie Down) Activates clamps/guns when both buttons are pressed at the 2 same time Reset button Resets clamps back to the starting point. Can be activated at 3 any point during operation, up until the guns are fired Emergency Stops Stops the machines operation, and resets everything back to 4 their starting positions. This must be deactivated before operations can recommence Isolation Station switch (Left and Can choose to use only the right station, only the left station, 5 Right stations) or use both Isolation Gun switch – Right (Top and Can choose to use only the top gun, only the bottom gun, or 6 Bottom guns – Right side station) use both. On the right station only Isolation Gun switch – Left (Top and Can choose to use only the top gun, only the bottom gun, or 7 Bottom guns – Left side station) use both. On the left station only 8 Cabinet Door Latch Use to open or lock the control box cabinet 9 Pneumatic Brake Switch Activates/Deactivates the Carriage Clamp 10 Trolley Clamp Switch Activates/Deactivates the Trolley Clamp/s

WARNING! Do not operate the Frame Nailer without the correct knowledge and function of each of the controls.

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7.2 Pneumatic Controls

Figure 3, Frame Nailer pneumatic controls

WARNING! Do not operate the Frame Nailer without the correct knowledge and function of each of the controls.

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Table 6, Pneumatic Control functions (see Figure 3)

Control Qty Function Description Pneumatic 1 3 Trolley Clamp Switch Activates/Deactivates the Trolley Clamps 2 3 Trolley Clamp Locks the trolleys in place 3 2 Horizontal Stud Clamp Locks the stud horizontally against the Stud Pin 4 1 Rack Ram Clamp Locks the plate against the stud horizontally 5 1 Carriage Clamp Locks the wall frame height 6 2 Vertical Stud Clamp Locks the stud vertically 7 2 Plate Clamp Locks the plate vertically 8 2 Stud Pin A guide to push stud against; this drops below the carriage moving plate when the frame is pushed on to the next stud position, and re-appears once the frame is re-positioned Sensors A 2 Plate Sensor Activates when the plate is in position in front of the guns, and is held in place by one of the vertical clamps B 2 Vertical Stud Clamp Activates when there is a stud in position beneath the clamp Sensor once the clamp is activated. If there is no timber in position, the clamp will bottom out and the sensor will not activate C 2 Plate Clamp Sensor Activates when there is a plate in position beneath the clamp once the clamp is activated. If there is no timber in position, the clamp will bottom out and the sensor will not activate

Note: If the sensors are not activated, then the guns will not fire. The sensors ensure that there is timber positioned in front of the guns, and that it is clamped correctly.

WARNING! Do not operate the Frame Nailer without the correct knowledge and function of each of the controls.

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7.3 Pneumatic filter/regulator

Figure 4, Valve/Filter/Regulator/Dump assembly

Table 7, Valve/Filter/Regulator/Dump parts

Control Function A Regulator adjustment B Mounting bracket C Valve on/off D Air in E Pressure relief valve F Air to Nailer G Dump Valve H Pressure gauge I Moisture release

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8 Operation NOTE: The Frame Nailer is to be operated in accordance with this manual. Deviation from this specified operation may result in incorrect nailing or injury. 8.1 Machine Set-up Before operations commence, the operator must ensure that the Wall Extruder has been set-up correctly.

To set-up the machine:

- Ensure that the safety guards are secured and correctly positioned. - Check the nail spacing between the guns on both carriages, and ensure that they are set up at the correct height. - Complete a visual inspection of potential hazards near the proximity of the machine. - Check that there are no obstructions either to any moving parts, within the firing line, or further down the framing line. - Complete all safety checks required

Once the Wall Extruder and the surrounding area are satisfactorily clear, the Wall Extruder can be switched on. 8.2 Operating Computer The operating computer provided with the Wall Extruder operates the progressors to move the frame along when required; ensures that all operating controls work as required when the associated buttons are pushed, e.g. turning the clamps on in the correct order when the red fire buttons are depressed; releases the clamps either automatically when firing is complete, or when the reset button is pushed; moves the stud pins up and down when required; adjusts the specifications of the Wall Extruder to suit different framing requirements as needed; detects errors in the machine, and stops the Wall Extruder from working if necessary; and generally makes sure that the Wall Extruder and Tables are running as they should be.

Before loading the plates for a frame, check that the computer is turned on and that the program has been set-up with the required specifications. The program runs the Wall Extruder based on the manually entered specifications; therefore, if a new frame is to be loaded that has different requirements than the previous, ensure that the computer program has been readjusted accordingly to ensure nailing remains correct. 8.3 Stations Right/Left/or Both If only one of the nailing stations is required, it is possible to isolate the nailing stations individually using the Isolation Station Switch (as shown in Figure 2). If one of the stations is isolated, it is recommended to place a timber block in front of the station that has been isolated as an additional safety measure; on the off-chance there is a malfunction, and nails are still fired.

8.4 Guns Top/Bottom/or Both If only one of the guns on a nailing station is required, it is possible to isolate the guns individually using either the left and/or right station Isolation Gun Switch (as shown in Figure 2).

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If one of the guns is isolated, it is recommended to place a timber block in front of the gun that has been isolated as an additional safety measure; on the off-chance there is a malfunction and nails are still fired. 8.5 Guns in correct position The upper nail gun has two positions but is fixed in relation to the lower nail gun. The upper nail gun can be set to suit either 70mm or 90mm timber and can be offset by 20mm above the lower nail gun. The offset of the upper nail gun is an automatic setting that is controlled by the operating computer. The computer automatically detects the size of the timber being added, and adjusts the gun heights accordingly; however, be sure to check that gun offset has been set correctly for the timber that is being added before firing.

Caution: When processing 70mm wide timber the nail gun is set to the Down Position. 8.6 Trolley and Carriage Clamps

Figure 5, Nog centres adjustment

The position of the Nog Trolleys can be adjusted horizontally as in Figure 5 to achieve different nog centres. By squeezing the Trolley Clamp at the top of the Nog Trolley, the Trolley Clamp is released from the beam and the Unit Rollers are free to move; allowing the Nog Trolley to be adjusted as required. By letting go of the Trolley Clamp, the Trolley Clamp is applied to the beam and the Nog Trolley is horizontally locked. The Nog Trolleys must be locked in place before attempting to fire the guns.

The position of the Floating Carriage assembly can be adjusted to suit different frame sizes. The carriage must be set to the correct framing height required PLUS 5mm or so; this allows the remaining timber components to be added easily. Applying the pneumatic brake switch once the

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required framing height has been set, activates the carriage clamp and locks it into the rack; this stops the floating carriage assembly from moving freely along the beam. Once the components have been loaded and the vertical and horizontal clamps are activated, the rack ram clamp is activated which pushes the floating carriage so that the plates are clamped horizontally, removing any remaining height gap and locking the carriage to the correct framing height. The carriage clamp must be applied before attempting to fire the guns.

Please note that the fixed carriage is not adjustable.

8.7 Loading When the required framing dimensions have been set, ensure the Carriage and Trolley clamps have been applied, and load timber to be nailed. Only the top and bottom plates are to be loaded at this point. Ensure that the timber faces are hard up against guide fences, and pushed back onto the trolleys, to ensure nailing is square. Then tell the computer program that the plates have been loaded; the progressors will then push the plates to the first stud nailing position.

Note: Operator must ensure they are familiar with their companies individual loading/unloading procedures before nailing is commenced. 8.8 Clamping and Firing Operation The clamping and firing operations use a Two Hand No Tie Down (THNTD) pneumatic initiating system, which ensures both hands of the operator are clear of the clamping operation and the guns firing operation.

When the required framing components are correctly in place, the two-step clamping sequence can begin. - The first step is initiated by simultaneously holding both RED firing buttons (shown in Figure 2) down until the plate clamps have been activated. These clamps hold down the outer frame, and lock it in place vertically. - The next step is to load the stud onto the Wall Extruder. Ensure that it is against the Stud Pins, within the range of the horizontal stud clamps, so that the frame will be square. Again, simultaneously hold down both RED firing buttons (shown in Figure 2) down until the remaining clamps have been activated. First the horizontal stud clamps come up from underneath the carriage plates, and lock the studs in place against the pins. Then the vertical stud clamps push down on the studs, locking them against the carriage moving plate. The rack ram clamp then pushes the carriages into the frame, securing the rack to the beam and horizontally clamping the frame. These clamps all come on one after the after in the order described, so that they do not interfere with each other.

The guns will not fire if the clamp sensors are not activated. There are three types of clamp sensors as shown in Figure 3. The first type of sensor is on each of the carriage assemblies, and line up with the gun firing line on the carriage moving plate. These sensors ensure that there are plates on both carriages, and that they are in position. The plates sit over top of these sensors, and when the plates are pushed down by the activation of the plate clamps, the sensors are depressed; triggering their activation. The second type of sensor is located within the vertical stud clamp cylinders, one on each carriage, and ensures that the stud has been loaded and clamped correctly. If either of the clamps bottom out, the sensors will know that there is no stud in place, and will not activate. If either of the clamps

26 Operations Manual – Gen III Fast Framer (Frame Nailer)

do not line up correctly, the sensors will know that the stud is not being clamped correctly, and will not activate. The last type of sensor is located on the side of the Vertical Plate Clamp sensor, one on each carriage, and ensures that the plate has been loaded and clamped correctly. If either of the clamps bottom out, the sensors will know that there is no plate in place, and will not activate. If either of the clamps do not line up correctly, the sensors will know that the plate is not being clamped correctly, and will not activate. Ensure that all three types of sensors are activated, before progressing to the next step. If any problems occur during clamping, or if the set-up is incorrect, simply press the reset button shown in Figure 2 to release the clamps, and begin clamping again.

Note: If the sensors do not activate (because of no wood, or wood positioned incorrectly), or there is another error of some sort, the Wall Extruder will not fire and will send and error to the program. The detail of the error will then be shown on the bottom of the computer display screen.

Once the clamps have been applied and everything is sitting square, the firing sequence can begin. This is initiated by simultaneously holding both RED firing buttons (shown in Figure 2) down, until the guns have fired; nailing the frame as required.

If at any time during the clamping or firing sequences either of the RED firing buttons are released prematurely, the sequence will stop and air pressure will be expelled from the exhaust. The sequence will reset and the operation will commence when both buttons are depressed again.

Note: It is the responsibility of the operator to ensure the firing area is clear of obstructions that may hinder safe firing operation! This includes but is not limited to other personnel working in the immediate area!

Never attempt to fire Nail Guns if the timber is not correctly in place or if there is no timber in the machine.

Always keep hands clear of Clamping

Once the firing sequence is complete, and the firing buttons have been released, the clamps automatically release, the stud pins drop, and the progressors advance the frame to the next stud position where the above sequence starts again. 8.9 Air Dump In an emergency, or when disconnecting the air supply or performing any maintenance, the air must be dumped from the system. Dump any air in the system using the dump valve (see Figure 4, item D). 8.10 Machine Shut-down Once operations are complete, ensure that the Wall Extruder is switched off and any foreign tools/equipment are removed.

27 Operations Manual – Gen III Fast Framer (Frame Nailer)

9 Parts Identification 9.1 Top Level Assembly (2001000)

Figure 6, Frame Nailer with guns.

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Table 8, Parts List – Frame Nailer

ITEM QTY PART NUMBER DESCRIPTION 1 1 1701100 Main Frame Assembly 2 1 1701200 - L LH Carriage Assembly 3 1 1701200 - R RH Carriage Assembly 4 3 1701660 Nog Trolley Assembly 5 40 1711400 Carriage Guide Wheel Assembly - Vertical 6 20 1711500 Carriage Guide Wheel Assembly- Horizontal 7 2 2001200 Plate Clamp Assembly 8 1 2001100 Framer Control & Mount 9 2 SMPGMA02 Gun Mount Assembly with customer supplied Guns 10 2 1804420 Progressor Table 11 2 SMPGPFA6300 Fence Assembly 12 2 1804110 Table Leg Moving Side 13 1 0605000 Computer Monitor Assembly 14 1 EEHW Electrical Enclosure

Depending on customer requirements, the Frame Nailer can be supplied with different guns.

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9.2 Main Frame Assembly (1701100)

Figure 7, Main Frame Assembly

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Table 9, Main Frame Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 6146 Festo Rod Clevis SG-M16x1.5 2 1 1463475 DSBC-63-25-PPSA_(Z) DSBC_Z-Standard cylinder 3 1 1463475 DSBC-63-25_(K) DSBC_K-Standard cylinder 4 1 182A021 Ducting Support 5 1 182C034 Carriage Clamp 6 2 182C038 Frame Leg 7 1 182C047 Laser Cut Rack 8 1 182C080 Cylinder Mount 9 1 536309 ADN-15-P---(Z) ADN-(Z)-Compact cylinder - Z 10 1 536309 ADN-15-P-A_(KS) ADN-(KS)-Compact cylinder - piston rod 11 4 C21022 Horizontal Foot 12 4 C21185 Vertical Foot 13 2 C36582 Frame End Cap 14 1 DIN-439-B - M12x1.25(F) DIN-439 Form B-Hex nut 15 4 EFWM8Z M8 Plain Washer 16 2 HTBOM1220Z Hex Head Bolt M12 x 20 - Zinc 17 6 HTBOM820Z M8 x 20 HT Hex Head Bolt - Zinc 18 4 HTBOM830Z Hex Head Bolt M8 x 30 - Zinc 19 1 M16x1.5(F) Nut Festo Spear Nut M16x1.5(F) 20 1 RHS 250x150x6-4965 Main Beam 21 4 SHCSM616Z M6 X 16 Socket Head Cap Screw 22 4 SHCSM830Z M8 x 30 Socket Head Cap Screw 23 2 SWM12MZ M12 Spring Washer 24 6 SWM8MZ M8 Spring Washer

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9.3 Nog Trolley Assembly (1701660)

Figure 8, Nog Trolley Assembly

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Table 10, Nog Trolley Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 11914 Festo Front Panel Valve SV-5-M5-B 2 1 572711 Festo Compact Cylinder - ADN-63-20-A-PPS-A 3 1 9305 Festo Toggle Switch H-22-SW 4 1 182C300 Nog Trolley Web 5 1 182C301 Side Plate 1, Nog Trolley 6 1 182C302 Side Plate 2, Nog Trolley 7 1 182C303 Nog Trolley Platen 8 1 2001011 Nog Plate Extension 9 8 C09186 Cam 10 8 C35600 Spacer 11 4 C36806 Wheel Mount 12 4 C36809 Axle 13 4 C36810 Spacer (90 Long) 14 1 C36811 Clamp 15 8 C36812 Spacer (30 Long) 16 8 EFWM20Z M20 Plain Washer 17 2 HTBOM616Z M6 x 16 Hex Head Bolt - Zinc 18 4 HTBOM825Z Hex Head Bolt M8 x 25 - Zinc 19 16 M12 PLAIN WASHER Plain Washer 20 8 M12 x 40 SHCS Hexagon Socket Head Cap Screw 21 4 M8 x 25 SHCS Hexagon Socket Head Cap Screw 22 8 SHCSM1265Z M12 x 65 Socket Head Cap Screw 23 2 SWM6MZ M6 Spring Washer 24 8 SWM8MZ M8 Spring Washer 25 24 BRG6304DD Bearing - 6304-DDU - 52x20x15

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9.4 Fixed Carriage Assembly (1701200 L or R)

Figure 9, Fixed Carriage Assembly

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Table 11, Fixed Carriage Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 182A014 - Manual Carriage Frame (LH) 2 1 182C014 Carriage Fixing Bracket Pt1 3 1 182C015 Carriage Fixing Bracket Pt2 4 1 182C037 Guide Rod 5 1 2001013 A Cylinder Plate 6 1 2001200 RF - L Plate and stud clamp left assembly - refit 7 1 2001301 Aligning stopper plate 8 1 AT350-138 Air Tank - 5 litre - 350mm x 138mm 9 2 C21014 Spacer 10 4 C21043 Axle Shaft 11 4 C21044 Retainer 12 1 HNM20Z M20 Hex Nut CL8.8 - Zinc 13 4 HTBOM1240Z Hex Head Bolt M12 x 40 - Zinc 14 1 HTBOM2055Z Hex Head Bolt M20 x 55 - Zinc 15 4 HTBOM820Z M8 x 20 HT Hex Head Bolt - Zinc 16 3 HWCSM1040 Hex Socket Head Cap Screw M10x40 17 4 HWCSM630CS Countersunk Cap Screw M6x30 18 4 HWCSM835CS Hex Socket CSK Cap Screw M8x35 19 3 HWNHM10 Hex nut M10 20 4 M12 PLAIN WASHER Plain Washer 21 1 RSDQA40-60-DCQ9179Q RSQ-Stopper Cylinder/Fixed Mounting Height 22 1 SWM16MZ M20 Spring Washer

35 Operations Manual – Gen III Fast Framer (Frame Nailer)

9.4.1 Exploded Horizontal Stud Clamp Assembly (1701130)

Figure 10, Exploded Horizontal Stud Clamp Assembly

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Table 12, Exploded Horizontal Stud Clamp Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 174392 Festo Swivel Flange SNCB-50 2 1 9263 Festo Rod Eye SGS-M16x1.5 3 2 182C026 Slider Block 4 2 182C028 Rod Eye Spacer 5 2 182C031 Positioner Side Plate 6 1 182C032 - Manual Pusher Post 7 1 182C033 - Manual Slave Plate 8 1 182C035 Pivot Pin 9 1 182C036 Cylinder Rod Pin - Stud Clamp 10 1 182C037 Guide Rod 11 1 182C048 Stop Pin 12 1 182C049 Rear Clevis Pin - Stud Clamp 13 1 2098975 Festo Standard Cylinder DSBC-50-300-PPVA-N3 14 4 CSCSM516Z M5 x 16 CSK Cap Screw - Zinc 15 4 CSCSM620Z M6 x 20 CSK Cap Screw - Zinc 16 6 D1400-0120APP Circlip 12mm External 17 2 D1400-0160APP Circlip 16mm External 18 2 HTBOM1030Z Hex Head Bolt M10 x 30- Zinc 19 8 SHCSM620Z M6 x 20 Socket Head Cap Screw 20 4 SMF2412 Self-Lubricating Bush (Blackwoods) 21 2 SMF3230 Self-Lubricating Bronze Bush 20x26x30lg - Flanged 22 2 SWM10MZ M10 Spring Washer

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9.5 Floating Carriage Assembly (1701200 L or R)

Figure 11, Floating Carriage Assembly

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Table 13, Floating Carriage Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 1711213 - Manual Switch Valve Bracket 2 1 182A012 - Manual Carriage Frame (RH) 3 1 182C034 Carriage Clamp 4 1 182C080 Cylinder Mount 5 1 2001301 Aligning stopper plate 6 1 536309 ADN-15-P---(Z) ADN-(Z)-Compact cylinder - Z 7 1 AT350-138 Air Tank - 5 litre - 350mm x 138mm 8 1 AVVZM550-01-08 VZM500-5 Port Mechanical Valve 9 2 C21014 Spacer 10 2 HTBOM1220Z Hex Head Bolt M12 x 20 - Zinc 11 4 HTBOM1240Z Hex Head Bolt M12 x 40 - Zinc 12 2 HTBOM820Z M8 x 20 HT Hex Head Bolt - Zinc 13 3 HWCSM1040 Hex Socket Head Cap Screw M10x40 14 2 HWCSM616 Hex Socket Head Cap Screw M6x16 15 4 HWCSM630CS Countersunk Cap Screw M6x30 16 4 HWCSM835CS Hex Socket CSK Cap Screw M8x35 17 3 HWNHM10 Hex nut M10 18 4 M12 PLAIN WASHER Plain Washer 19 1 RSDQA40-60-DCQ9179Q RSQ-Stopper Cylinder/Fixed Mounting Height 20 2 SWM12MZ M12 Spring Washer 21 2 SWM8MZ M8 Spring Washer

39 Operations Manual – Gen III Fast Framer (Frame Nailer)

9.6 Plate Clamp Assembly (2001200 L or R - B)

Figure 12, Plate Clamp Assembly

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Table 14, Plate Clamp Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 2001201 L Plate Clamp (LHS) 2 2 2001202 Clamp Pivot Linkage 3 1 2001203 L Stud Clamp (LHS) 4 1 2001204 Cylinder Spacing Plate 5 1 2001206 UHMWPE Spacer 6 1 ACCP96SD32-125 CP96S/CP96SD-ISO Cylinder 7 1 ACGKM10-20 CP96/C96_GKM-Rod Clevis 8 1 ACMGPM40-150Z MGP-Z-Compact Guide Cylinder/Standard type 9 1 BRG6800DD Bearing 19x10x5 10 1 BRGSCE 20 Housing with ball bush, shaft Ø 20 mm 11 4 HWCSM555 Hex Socket Head Cap Screw M5x55 12 1 HWCSM620 Hex Socket Head Cap Screw M6x20 13 4 HWCSM625CS Hex Socket CSK Head Screw M6x25 14 4 HWCSM825 Hex Socket Head Cap Screw M8x25 15 4 HWCSM835 Hex Socket Head Cap Screw M8x35 16 4 HWNHM5 Hex nut M5 17 4 HWNHM6 Hex nut M6 18 1 HWWFM632 Washer M6x32

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9.7 Gun Mount Assembly (SMPGMA02)

Figure 13, Gun Mount Assembly

Note: The guns to be supplied for this machine are customer sourced. Therefore, as the details of the guns for each machine will be different, the guns have been omitted from this drawing.

For more information on the guns please refer to the manufacturers handbook.

42 Operations Manual – Gen III Fast Framer (Frame Nailer)

Table 15, Gun Mount Assembly parts list

ITEM QTY PART NUMBER DESCRIPTION 1 1 1711212 Gun Mount Cover 2 1 ACCD85N25-20-B Air Cylinder 25 bore 20 stroke 3 1 BRGLB-INA KWVE 20W-G3-V2 Linear bearing block 4 1 BRGLR-INA TKVD 20W-140-40/60/40 Linear bearing track 140mm Long 5 2 GMP-PF350S Gun Mount Plates - Customer Supplied Guns 6 6 HWCSM425 Hex Socket Head Cap Screw M4x25 7 4 HWCSM610 Hex Socket Head Cap Screw M6x10 8 4 HWCSM630 Hex Socket Head Cap Screw M6x30 9 8 HWCSM675 Hex Socket Head Cap Screw M6x75 10 6 HWCSM816 Hex Socket Head Cap Screw M8x16 11 4 HWCSM825 Hex Socket Head Cap Screw M8x25 12 4 HWCSM845 Hex Socket Head Cap Screw M8x45 13 6 HWNHM4 Hex nut M4 14 8 HWNHM8 Hex nut M8 15 1 SMPGMB02 Gun mount bracket ram rod - profile and fold (6mm MS) 16 1 SMPGMB04 Gun mount bracket assembly 17 1 SMPGMB05 Gun mount bracket ram fixed - profile and fold (5mm MS) 18 1 SMPGMP01 Gun mount backing plate

43 Operations Manual – Gen III Fast Framer (Frame Nailer)

9.8 Computer Monitor and Electrical Enclosure Assemblies (0605000 and EEHW)

Figure 14, Computer Monitor and Electrical Enclosure Assemblies

Table 16, Computer Monitor and Electrical Enclosure Assemblies Parts List

ITEM QTY PART NUMBER DESCRIPTION 1 1 0605000 SPIDA - Monitor Box 2 1 0605211 Monitor mount bracket 3 1 0605212 Monitor Locator 100x105 4 1 EEHW Electrical enclosure Hole and Window 5 1 HWQCM8 Quick Clamp Handle - M8 6 2 SMPBKT13 Computer box bracket

44 Operations Manual – Gen III Fast Framer (Frame Nailer)

9.9 Progressor Tables (1804420)

Figure 15, Progressor Table Assembly

45 Operations Manual – Gen III Fast Framer (Frame Nailer)

Table 17, Progressor Table Assembly Parts List

ITEM QTY PART NUMBER DESCRIPTION 1 4 1703110 Wheel Assembly 2 2 1804110 Table Leg - Rapid Framer 3 2 1804120 Table leg fixed side 4 6 1804125 Table foot assembly 5 64 HWCSM820BH Button Head Screw M8x20 6 40 HWCSM830CS Hex Socket CSK Cap Screw M8x30 7 104 MT21-1351 M8 Sq Nut - Posn Fixing 8 4 SMPBT3100-285-18-P Bench top 3100x285x18 9 16 SMPFB225 Fence Bracket 10 24800 mm SMPGP9045 Guide Profile 11 2 SMPGPFA6300 Fence assembly 12 2 SMPGPGK2 Gearbox Kit 2 13 2 SMPGPTK2 Guide profile trolley kit

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9.9.1 Fence Assembly (SMPGPFA6300)

Figure 16, Fence Assembly

47 Operations Manual – Gen III Fast Framer (Frame Nailer)

Table 18, Fence Assembly Parts List

ITEM QTY PART NUMBER DESCRIPTION 1 4 BRG6005DD Bearing 47x25x12 2 8 HWCSM635 Hex Socket Head Cap Screw M6x35 3 4 HWCSM675 Hex Socket Head Cap Screw M6x75 4 3 HWCSM835CS Hex Socket CSK Cap Screw M8x35 5 2 HWSSM825 Hex socket set screw M8x25 6 1 IME12-04BPSZCOS SICK, Proximity Sensor 7 4 MT21-1018 Power Lock Fasteners 8 3 MT21-1351 M8 Sq Nut - Posn Fixing 9 6300 mm SMPGP9045 Guide Profile 10 2 SMPGPPBa Pulley Block part 1 11 2 SMPGPPBb Pulley Block part 2 12 2 SMPGPTB - 01 Belt tensioner body Part of 13 2 SMPGPTB - 03 Tension block slider Assembly SMPGPTB 14 2 SMPGPTB-02 Tension block insert 15 1 SMPGPTC Tensioner connector 16 2 TRTIB-AT10-32 Timing Belt AT 10/32 17 1 TRTIB-AT10/32 Timing Belt AT10/32 18 2 TRTIP19AT1032F-BF A 19 Tth Pulley AT10 x 32mm belt 16mm Bore bearings inset 19 2 SMPGPPB45 Pulley Block assembled

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9.9.2 Gearbox Kit 2 (SMPGPGK2)

Figure 17, Gearbox Motor Assembly

Table 19, Gearbox Motor Assembly Parts List

ITEM QTY PART NUMBER DESCRIPTION 1 1 EMBLY343160V5K BLY3473D Brushless 5000RPM 160VDC 440W Motor Complete 2 4 HWCSM516CS Hex Socket CSK Cap Screw M5x16 3 2 HWCSM835 Hex Socket Head Cap Screw M8x35 4 2 MT21-1351 M8 Sq Nut - Posn Fixing 5 1 SMPPLT22 Mount Plate Profile to Angle Gearbox 6 1 VRAM060-S-L2-20-12-73.03 Gearbox 20:1

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9.9.3 Guide Profile Trolley Kit (SMPGPTK2)

Figure 18, Guide Profile Trolley Assembly

Table 20, Guide Profile Trolley Assembly Parts List

ITEM QTY PART DESCRIPTION NUMBER 1 1 1802251 Pivot Bush 2 1 1802253 Pusher Pad 3 1 1802254 Rapid Framer Gravity Stop - 6mm S/S profile 4 10 HWCSM812BH Hex Socket BH cap Screw M8x12 5 1 HWCSM820 Hex Socket Head Cap Screw M8x20 6 2 HWCSM825CS Hex Socket CSK Cap Screw M8x25 7 8 HWWFM6 Flat Washer M6 8 1 HWWFM8 Flat Washer M8 9 8 MT21-1351 M8 Sq Nut - Posn Fixing 10 26200 mm SMPGP9045 Guide Profile 11 400 mm SMPGPDS Slider for GP 12 1 SMPGPEP Guide profile end cap

50 Operations Manual – Gen III Fast Framer (Frame Nailer)

10 Maintenance If a part is damaged substantially, or if anything covered in this maintenance section cannot be fixed by general maintenance; then do not use the Frame Nailer and contact a supervisor, maintenance engineer, or Spida Machinery.

Table 21, Maintenance intervals

Check Day Week Month ½ Year Guards in place x Oil level in lubricators x Work area is clear x Clamp operation x Clamp sensor x Clean Frame Nailer of any build up x Noises or Vibrations x Emergency stop working x Drain moisture from air reservoir x Air supply pressure x Pneumatic Filter x Nog Trolley assemblies in good condition x Carriage assemblies in good condition x For loose or damaged bolts x Floor bolts for tightness x Guide Trolley Slides x Bench Top x Brake material on Floating carriage and Nog Trolleys x Inspect the Frame Nailer x Maintain Nail Guns x

(or as required)

Failure to perform these checks as per schedule indicated in Table 21 may result in severe damage or a serious accident.

WARNING! Electrical power and Pneumatic Air supply must be isolated from machinery and appropriate danger tagging in place whenever any maintenance is being performed on machinery. Any defects, which are found on inspection should be rectified immediately and reported to the supervisor for appropriate action.

51 Operations Manual – Gen III Fast Framer (Frame Nailer)

10.1 Maintenance Items 10.1.1 Guards Check Guards are in place, and they are tight, with no loose bolts. Guards should always be operational. 10.1.2 Air Line Lubrication To enable the Nail guns to operate effectively and accurately they require compressed and lubricated air between 600-800 kPa. The machine is fitted with an automatic lubricator with a Filter and Pressure Regulator. The Competent Operator is required to check the level of the oil prior to commencement of work and top up with the air tool oil. Pneumatic control valves and cylinders do not require lubricated air.

10.1.3 Keep work area clear Ensure that the area surrounding the Frame Nailer is free of trip hazards, unnecessary tools, or other debris. There should be no reason for passers-by to approach or pass near the Frame Nailer while it is in use. 10.1.4 Inspect Clamps The clamps should slide freely, clamp evenly, and there should be no excessive wear visible on shafts. If necessary, the linear bearings can be lubricated with a Teflon or silicon spray. Check for loose fastenings or damage to the air cylinder.

Test the plate (vertical) clamps, vertical stud clamps, and horizontal stud clamp, for tightness before work commences each day. Using a spare piece of wood, activate the clamps and test the rigidity of the wood to ensure that the clamps are still holding as required. Check the rack ram clamp for tightness once the first frame for the shift has been loaded. Do not use the Frame Nailer if, during any of these tests, the timber/clamp is loose, or the clamp is not activating properly.

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10.1.5 Plate Sensor

Figure 19, Plate Sensor locations

Check plate sensors (see Figure 19) are free and clear of any build-up of dust and securely fastened; sensor malfunctions will prevent the guns from firing.

Note that as the other clamp sensors are located within the clamp cylinders, they do not require regular cleaning or maintenance. 10.1.6 Clean Frame Nailer of any build up Keep the Frame Nailer free of any build-up of debris. Moving parts should not be obstructed, and the Frame Nailer should be usable without any hindrance. Remove and replace components as required to clean out any built-up debris or dust; ensure that any components removed are then replaced correctly.

Ensure there are no bent or jammed nails blocking the nail guns, and that there are no bent or jammed nails in the nail feeds that could possibly jam the nail guns at a later stage.

10.1.7 Noises or vibrations Take note of any unusual noises or vibrations. Do not operate the Frame Nailer if the cause of any vibrations or unusual noises cannot be found. 10.1.8 Emergency Stop Buttons Check emergency stops are working and that they stop the machine when activated. This test should be performed before using the machine, at least once a day.

Check operational controls are working, and that they function as designed. Inspect these other controls at regular intervals.

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10.1.9 Dry Air Supply For best results, clean dry air is essential. A drain valve is provided on the air reservoir and this should be opened weekly to drain any condensation; or when moisture is seen in the reservoir prior to commencing work.

10.1.10 Air Supply Air pressure should be maintained at 600-800 kPa; this can be checked at the filter regulator located on the rear of the Frame Nailer (see Figure 4). Take measures to ensure air quality; such as by installing an aftercooler, air dryer, or water separator. Do not use compressed air that contains chemicals; synthetic oils, including organic solvents; or salt or corrosive gases, etc., as it can cause either damage or a malfunction. If synthetic oil is used for the compressor oil, depending on the type of synthetic oil used, or on the conditions of use, there may be adverse effects on the resin of the pneumatic equipment or on the seals if the oil is flowed out to the outlet side; so, the mounting of a main line filter is recommended. 10.1.11 Check Filter/Regulator Periodically check the filter and regulator for any cracks or damage. If condensation in the drain bowl is not emptied on a regular basis, the bowl will overflow and allow the condensation to enter the compressed air lines. Water can cause malfunction of pneumatic equipment. The filter and regulator are located on the rear of the Frame Nailer. See Figure 4 for regulator parts

Also, be sure to check the pneumatic lines at the same time for possible kinks, air leaks, or other damage. 10.1.12 Nog Trolley Assemblies The nog trolley assemblies should move easily along the main beam when adjusting, and should not move when locked. The nog trolley assemblies should be generally maintained every month to: - Check on the condition of the guide wheel assemblies - Check on the condition of the locking mechanisms - Ensure all plates are still square. All assembly components should also be checked to ensure there is no damage or wear that will affect the performance of the assemblies. Ensure that there are no loose, damaged, or missing bolts, and replace or tighten as necessary.

Do not use the Frame Nailer if any of the assemblies are not adjusting correctly and/or still allow movement when locked; if the Trolley clamp switch and/or the Trolley clamp are not activating correctly; or if any timber added does not fit onto an assembly/does not sit square; and if any of the above cannot be fixed by general maintenance.

10.1.13 Carriage Assemblies The floating carriage should move easily along the beam before the carriage clamp is applied. Once the carriage clamp is applied, the carriage should not be able to move freely along the beam. Once the Rack Ram clamp has been activated before the firing sequence, the timber frame should be held at the correct height and there should be no movement of the floating carriage assembly.

Both carriage assemblies should be generally maintained every month to: - Check on the condition of the guide wheel assemblies - Check on the condition of the locking mechanisms - Ensure all plates and guides are still square

54 Operations Manual – Gen III Fast Framer (Frame Nailer)

- Ensure that the gun mounts on the carriage assemblies are still correctly positioned. The rack ram cylinder and rack should also be generally maintained every month to check on the condition of the cylinder and the clamping mechanism. All assembly components should also be checked to ensure there is no damage or wear that will affect the performance of the assemblies. Ensure that there are no loose, damaged, or missing bolts, and replace or tighten as necessary.

Do not use the Frame Nailer if the floating carriage assembly is not adjusting correctly and/or still allows movement when locked; if the Pneumatic brake switch and/or the carriage clamp are not activating correctly; if any of the gun mounts on either of the carriage assemblies is not firing straight/is blocked; or if any timber added does not fit onto an assembly/does not sit square; and if any of the above cannot be fixed by general maintenance.

10.1.14 Loose Fasteners and Fixings Check for loose, missing, or damaged bolts especially on guards, cover and floor fixing. Tighten or replace where necessary. 10.1.15 Guide Trolley Slides The sliders on the Guide Trolleys should allow the trolleys to move up and down the Fence smoothly and easily. Check the slides for excessive play and/or wear, and tighten/replace if necessary. Use the guide in section 10.2 to replace the sliders, or alternatively contact Spida Machinery. 10.1.16 Bench Top Check the table bench tops for excessive wear or damage, and replace if necessary. This should be checked every six months. 10.1.17 Maintain Brake Materials Check brake materials for wear, and replace as necessary.

- On the Nog trolleys, check the clamp pad on the end of each cylinder. - On the floating carriage, check the carriage clamp and rack connections.

10.1.18 Maintain Frame Nailer Check all major operating components for wear, fatigue, and fixing. Adjust, tighten, or replace components as required.

Do not use the Frame Nailer if it is damaged significantly or if it is not working correctly, and all other mentioned maintenance is not applicable. 10.1.19 Nail Guns Nail guns have been fitted to the Frame Nailer to provide accurate and reliable nailing. All maintenance/servicing that is required, should be carried out as specified by the gun supplier’s handbook.

Periodically check the distances between guns, on each carriage assembly, to ensure that the correct nailing distance is maintained. If any shift has occurred, then adjust guns as required.

Also, be sure to check the gun mount assemblies for potential damage. If any damage is apparent then do not use the Frame Nailer, and contact a supervisor, supplier, or maintenance engineer.

55 Operations Manual – Gen III Fast Framer (Frame Nailer)

10.2 Replacing Guide Trolley Slides

Figure 20, Trolley slide replacement

Tools required: Set of Allan keys

• Disconnect power. • Disconnect lead and remove home sensor. • Disconnect leads from and remove motor. • Undo 16 cap screws holding fence assy. • Turn upside down, and release belt tension. (Grub screw in centre of tensioner) • Remove tensioners, (outside screws.) • Undo pulley blocks from each end, grub screw top and bottom. • Slide trolley out at one end. • Undo grub screws either side of slides, remove, replace. • Blow out the aluminium extrusion, and pulley blocks. • Reassemble, tension belt (put most tension at the front, leaving adjustment at rear if more tension is needed later. • Bolt fence back up. • Fit motor and leads. • Fit home sensor and lead. • Start up, enable home trolley. • Check home position is correct, if not alter in set up screen. • Reset enable home trolley. • Send out to 6 mtrs, and check. • If incorrect recalibrate trolley as normal.

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10.2.1 Reference Distances for Guide Trolley sliders

Figure 21, Stop Slider distances

The above figure shows the required distances in mm between the sliders, and between the slider and the end of the Stop. Use these distances when the sliders need to be removed for maintenance.

57 Operations Manual – Gen III Fast Framer (Frame Nailer)

11 Foreseeable Misuse Through experience, Spida Machinery’s technical staff have listed (in order of occurrence) the most common misuses of the machinery by operators, the symptoms that result and the rectification required to address the misuse and return the machine to optimal working order.

Table 22, Common misuse issues

MISUSE SYMPTOM RECTIFICATION REQUIRED Lack of cleaning Clamps not retracting - Clean Frame Nailer, especially framing surfaces and underneath Frames being assembled nail guns. incorrectly - Remove any large pieces of debris, Machine overheating and clean out any dirt. Nail gun failing to fire - Clean air lines, and service guns as per operation manuals. Clamps failing - Check all pneumatic cylinders and linear bearing rails, clean and service as required. Lack of lubrication Excessive wear of moving parts - Lubricate all moving parts, and replace any excessively worn parts Unusual amount of noise while as required. parts are moving Clamps not moving

Lack of care Carriages and trolleys not - Repair or replace any damaged, moving correctly loose, or missing parts. Foreign objects in Main - Remove any loose or unnecessary Assembly objects. Misaligned clamps, fences, and - Re-calibrate parts as required. plates - Note, if possible, how each part was Bent or stuck stopper pins mistreated, and train operators to prevent additional misuse of these Guns firing incorrectly and other parts. Parts not working as designed - Contact Spida Machinery in the event of a major crash No operation or loss of control data

Any other misuse and resultant damage of the machine is deemed non-foreseeable as its occurrence is not consistent.

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12 Trouble Shooting Table 23, Trouble shooting

Trouble Probable Causes Correction Guns not firing Triggers not activating Pneumatic trigger may be faulty – replace if necessary No air to gun Check air supply to gun Trigger jammed Contact gun supplier Plate sensor not activating Check sensor clear and free of debris, or is being activated correctly. Otherwise replace Plate clamp sensor or Vertical Remove clamp cylinder cover and check stud clamp sensor not on condition of sensors, ensure that activating sensor is being activated correctly. Otherwise replace Guns firing incorrectly Each gun is supplied by Clean air lines and ensure regulated different air pressures pressure to each gun is the same.

Damaged air lines Check for bent or leaking air lines, and replace as required.

Guns incorrectly angled/have Adjust angle between nail guns as mismatching angles required, and ensure they are locked into position.

Guns not isolating correctly Check switches have turned correctly. when required Check connection between switches and guns, and replace lines as required.

Clamps not coming on Air supply Replace any broken air lines

Damaged linear bearing rails Replace linear rails

Obstruction Clear obstruction Clamps ineffective/inadequately Lack of lubrication Lubricate moving parts clamping Damaged air lines Check for bent or leaking air lines, and replace as required Loose, damaged, or missing Inspect clamp parts. Repair or replace parts items as required Nails being punched too far into Excessive air pressure Adjust the regulator to the correct the timber pressure Nail heads protruding from the Low air pressure Adjust the regulator to the correct timber pressure

If any of the above corrections do not solve the issue, then do not use the Frame Nailer and contact a supervisor, maintenance engineer, or Spida Machinery.

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13 Distributor & Repairer Contacts

13.1 Agent/Distributor Company Name: ______

Address: ______

Contact Person: ______

Ph.: ______Fax: ______

Mobile: ______Email: ______

13.2 Automation Repairs Company Name: ______

Address: ______

Contact Person: ______

Ph.: ______Fax: ______

Mobile: ______Email: ______

13.3 Mechanical Repairs Company Name: ______

Address: ______

Contact Person: ______

Ph.: ______Fax: ______

Mobile: ______Email: ______

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14 Warranty SM2012 Ltd, SPIDA Machinery, Tauranga, New Zealand, warrants the equipment listed below to the initial purchaser of the equipment only against defective workmanship and materials only, for a period of twelve (12) months from the date of shipment from SPIDA's factory, subject to the following conditions:

1. SPIDA extends the original manufacturer’s warranty to SPIDA on buy-in items such as motors, saw blades and air cylinders or other such buy-in items but does not add its warranty herein described to such items. 2. This warranty only applies if: a. The attached copy of this warranty is signed by the initial purchaser and returned to SPIDA's address shown above within 14 days of shipment of the goods from SPIDA's factory. b. The equipment is installed by SPIDA or its licensed installer. c. Regular routine maintenance has been carried out on equipment in accordance with instructions in manual provided by SPIDA and proper housing and shelter provided for the equipment. d. The equipment is operated by competent personnel in accordance with the operating instructions set out in the manual provided by SPIDA and not otherwise. The equipment has not been subjected to alterations or repairs or dismantling without prior written approval of SPIDA. Any parts returned to SPIDA either for repair or consideration of a warranty claim consequent to an authorisation to dismantle must be shipped prepaid.

. SPIDA may, at its option, either repair or replace the defective part upon inspection at the site of the equipment where originally installed. The warranty does not cover the cost of freight, Labour or traveling for the removal or replacement of the defective parts, g. This warranty does not apply to any deterioration due to average wear and tear or normal use or exposure. h. In all warranty matters, including any question of whether this warranty applies to any claim, the decision of SPIDA is final,

This warranty is the only warranty made by SPIDA as the manufacturer and is expressly in lieu of and excludes all other warranties, conditions, representations and terms expressed or implied, statutory or otherwise, except any implied by law and which by law cannot be excluded. Neither SPIDA or its agents or servants will be liable in any way for any consequential loss, damage or injury including any loss of use, profits or contracts.

The law applicable to this warranty shall be the law of New Zealand and the parties hereto submit to the exclusive jurisdiction of the Courts of New Zealand.

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Machinery/Equipment

The item bearing the following serial plate:

______

Date of Shipment: ______

Signed by: ______

Name: ______

Position: ______

Acceptance of Warranty

I acknowledge and accept the contents of this warranty.

Signed by: ______

Name: ______

Company: ______

Position: ______

Date: ______

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15 Pneumatic Drawings

Figure 22, Pneumatic diagram

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16 Training Certificate – Fast Framer Instructor: ______

Company: ______

I declare that: • I have trained the person names below (“the trainee”) in the safe operation of the machinery/equipment detailed in the training manual. • The trainee has demonstrated an understanding of the safe operation of the machinery/equipment. • The trainee has indicated the he/she has read and understood this training manual.

Signed: ______

Date: ______

Trainee: ______

Company: ______

Position: ______

I declare that: • I have received instruction from the person named above (“the instructor”) for the safe operation of the machinery/equipment detailed in this training manual. • All information in this training manual was demonstrated and explained by the instructor. • I have thoroughly read and understood this training manual.

Signed: ______

Date: ______

Witnessed by:

Name: ______

Company: ______

Signed: ______

Date: ______

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17 Frame Nailer Training Check List

Machine Operators Checklist

All operators are required to be shown and advised as below Checklist is to be filled in at machine with all operators

STANDARD FRAMER COMPONENTS Checked Shown location of Main framer body Shown location of Plate fences Shown location of the stud stops Shown location of height adjustment for nail guns Shown location of the safety air blow off valve Shown location of clamping button Shown location of clamping release button Shown location of firing button Shown location of nail gun trigger switches Shown location of all machine E-Stops

PNEUMATICS MATERIAL CLAMPS Checked Advised on correct air pressure setting Advised on air supply cleanliness Shown location of pneumatic supply point Shown location of pneumatic supply regulator Shown location of pneumatic control panel Shown location of remote control clamp releases

Shown location of pneumatic supply lines Shown location of gun oiler and regulators Shown location of moisture trap

Shown location of pneumatic material clamps Shown location of clamp sensors Shown how to operate pneumatic material clamps Advised on the safe use of pneumatic clamps Advised on correct hand placement when using pneumatic clamps Has been advised to keep hands clear of moving clamps at all times Understands that severe crushing can occur if caught in clamp

NAIL GUNS Checked Shown location of nail guns Shown location of nail gun trigger switches Shown location of pneumatic clamps Shown the location and operation of isolator switches Shown nail fire trigger sensors Has been advised to keep both hands on buttons until the nailing cycle is complete Shown clamping process and is aware to keep hands clear while nailing cycle is in progress Understands that severe damage can occur if caught in clamping/nailing cycle

MACHINE OPERATION Checked Has been shown how to operate the pneumatic clamping from the control box Has been shown how to set and lock wall panel height Has been shown how to set and lock stud nailing position Has been advised on suitable / unsuitable materials Has been shown location of individual gun isolator switches Has been shown to operate the machine from the control screen

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Understands to keep body parts well clear of all moving parts on the machine Has been advised to be conscious of the number of frames on the outfeed rollers

SAFEKEEPING PRACTICES Checked Has been advised only the operator is permitted within the workspace while machine is operating Has been advised to keep hands and body parts well clear of clamps while operating Has been advised to keep hands and body parts well clear of guns while operating Main supply of air and electricity to be off before commencing any routine maintenance Air pressure to be drained before routine maintenance Advised to keep working area clean and clear of trip and slip hazards Shown where to access and clean off-cut, waste and dust build up points Check any electrical leads to the machine regularly for deterioration Ensure working area has adequate lighting Has been advised on minimum PPE requirements for machine operation Has been advised to report machinery defects as soon as noticed Shown heavy waste build up areas Advised on correct cleaning and repair procedures Shown danger and warning decals Has been advised to use safe work practices while lifting timber and framing components

VERIFICATION: Training officer to fill in this section Training Officer Name: Signature: Date: I the undersigned declare that I have been shown and instructed in the all of the above listed matters. I declare that all the information in this document was shown and demonstrated to me by the instructor. I further declare that I have read and understand the Operation and Maintenance Manual Operator Name: Signature: Date: Witnessed by Name: Signature: Date: A copy of this document is to be kept in each employee file on site.

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