Trademaster GECKO User manual

BEFORE USE, ENSURE EVERYONE USING THIS MACHINE READS AND UNDERSTANDS

ALL SAFETY AND OPERATING INSTRUCTIONS IN THIS MANUAL .

Serial #............................................ Date of Purchase............................

OPERATOR’S MANUAL

GECKO

WELDING CARRIAGE

TRADEMASTER GECKO WELDING CARRIAGE

IMPORTED & DISTRIBUTED BY

INDUSTRIAL TOOL & MACHINERY SALES

18 BUSINESS ST

YATALA QLD 4207 AUSTRALIA

07 3287 1114

07 3287 1115

[email protected]

www.industrialtool.com.au

INDUSTRIAL TOOL

WARRANTY TERMS

In addition to any warranties or conditions implied by applicable Statute or Regulations, Industrial Tool & Machinery

Sales warrants all of it’s products against defective workmanship and faulty materials for a period of twelve (12)

months from the date of purchase, unless otherwise stated. At our option we will repair or replace, free of charge,

any item on the condition that:

• The complete machine or tool is returned, freight prepaid to ITM or one of it’s authorised service agents as

directed by ITM, and is found to have a material or constructional defect.

• The machine or tool has not been subject to misuse, neglect or damage by accident.

• The fault is not a result of normal “wear and tear”.

• Written permission has been received from ITM prior to commencement of repair.

• Repairs, tampering or modification carried out by unauthorised personnel will void all warranty.

• Consumable items such as cutting tools, pilot pins, saw blades, grinding wheels etc. are NOT covered by

warranty.

Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled

to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage.

You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the

failure does not amount to a major failure.

TABLE OF CONTENTS

General Information 2

Technical Data 3

Design 4 - 5

Saftey Precautions 6 - 7

Startup and Operation 8 - 11

Wiring Diagram 12

Parts Lists & Exploded Views

General Assembly 13 - 14

Drive System Assembly 15

Drive System 16 - 17

Controller Housing Complete 18

Panel Assembly 19

Torch Holding & Low Torch Holding Assembly 20

GENERAL INFORMATION

1. GENERAL INFORMATION

1.1. Application

The GECKO Welding Carriage produces continuous welds using MIG/MAG welding torches with

handle diameter in 16–22 mm range (0.63–0.87’’). The machine can work in PA, PB, PC, and PF

welding positions. It is fixed by permanent magnets and contains a four wheel drive with speed

adjustment.

1.2. Technical data

TECHNICAL DATA

Welding position ~ 115–230 V, 50–60 Hz

Power 20 W

Welding position horizontal PA (flat), PB (horizontal vertical), PC

(horizontal)

vertical PF (vertical up)

Minimum path convex radius 1000 mm (40’’)

Minimum path concave radius 1250 mm (50’’)

Torch type MIG/MAG

Torch diameter 16–22 mm (0.63–0.87’’)

Maximum torch reach 70 mm (2.76’’)

Maximum weight

of cables horizontal work 8 kg (17.7 lbs)

vertical work 13.3 lbs)

Welding material thickness minimum 4 mm (0.16’’)

Ground clearance 4 mm (0.16’’)

Pulling force horizontal work 150 N

vertical work 100 N

Torch adjustment range 35 mm (1.38’’, up-down, left-right)

Follower arm adjustment range 100 mm (3.93’’)

Horizontal speed 0–110 cm/min (0–43.3’’/min)

Vertical speed 0–100 cm/min (0–39.4’’/min)

Dimensions 240 mm (L) × 258 mm (W) × 277 mm (H)

9.5’’ (L) × 10.2’’ (W) × 10.9’’ (H)

Weight 8 kg (17.7 lbs)

1.3. Design

The GECKO Welding Carriage contains a drive system with controller, cross slides, two follower

arms, and torch holder. The drive system comprises a gear motor that drives four rubber wheels

of high thermal resistance.

The magnetic unit with powerful permanent magnets fitted at the carriage bottom ensures

properadhesiontoferromagneticsurfaces.Togglingthemagneticunitlever(Figure1)toposition

“0” reduces the intensity of the magnetic field, what helps moving the welding carriage during

positioning. The cross slides enable precise control of the torch holder position in both horizontal

and vertical axis. Additionally, the machine can ignite an arc through the arc ignition socket when

choosing a travel direction.

Figure 1. GECKO Operator’s Manual

Cross Slides

Follower Arm

Torch Holder

Power Switch

Power Supply Socket

Saftey Line Lug

Arc Ignition Socket

Magnetic Unit Lever

Drive System

Control Panel

DESIGN

1.4. Equipment included

The GECKO Welding Carriage is supplied with complete standard equipment in a foam filled

cardboard box. The included equipment consists of:

• welding carriage – 1 unit

• foam filled cardboard box – 1 unit

• power cord – 1 unit

• arc ignition cable – 1 unit

• torch holder – 1 unit

• 4 mm Allen key – 1 unit

• Operator’s Manual – 1 unit

DESIGN

LED Display

Speed Adjusting Knob Arc Ignition Switch (TEST / 0 / 1)

Travel Direction Switch (left / 0 / right)

Figure 2. Control Panel Design

1. Before start, read Operator’s Manual and complete proper occupational safety and

health training.

2. Machine must be used only in applications stated in Operator’s Manual.

3. Machine must be complete and all parts must be genuine.

4. Power supply specifications must conform to those stated on rating plate.

5. Power supply socket must be equipped with grounding pin.

6. Never carry machine by cord or yank it to disconnect plug from socket. It may cause

power cord to break and result in electric shock.

7. Bystanders must not be present in immediate vicinity of machine.

8. Before start, check condition of machine and electrical installation, including power

cord, plug, control panel, and wheels.

9. Keep machine dry. Exposing it to rain, snow, or frost is prohibited.

10. Ensure proper lighting at worksite.

11. Neverusemachineinvicinityofflammablefluidsorgases,orinexplosiveenvironments.

12. Make sure that rubber of driving wheels is clean and not damaged.

13. Never disassemble driving wheels cover.

14. Remove objects attracted to chassis by magnetic unit.

15. Transport and position machine using carrying handle, with magnetic unit lever set to

position “0”.

16. Place machine on ferromagnetic material in such a way that wheels always touch

surface and there is no contact between surface and chassis.

17. Do not stay underneath machine placed at heights.

18. Plug power cord into mains only when power switch is set to position “0”.

19. Keep power socket clean. Do not use compressed air for cleaning purposes.

20. Mounting torches other than MIG/MAG type or torches with handle diameter outside

16–22 mm range (0.63–0.87’’) is prohibited.

21. Maximum torch reach must not exceed 70 mm (2.76’’).

22. Keep torch cables from touching surface (they must be suspended to reduce carriage

load). Use only cables which maximum weight is 8 kg (17.7 lbs) for horizontal work

and 6 kg (13.3 lbs) for vertical work.

23. Operating in welding positions: PD (horizontal overhead), PE (overhead), and PG

(vertical down), as well as on curvatures with convex (concave) radius lower than

1000 mm (1250 mm) is prohibited.

24. When operating at heights, use safety line to protect machine from falling down.

25. Always use eye protection (welding helmet, shield, and screen), hearing protection,

gloves, and protective clothing during operation. Do not wear loose clothing.

26. Before every use, inspect machine to ensure it is not damaged. Check whether any

part is cracked or improperly fitted. Make sure to maintain proper conditions that may

affect machine operation.

27. Never try to manually stop motion of machine. For this purpose set travel direction

switch to position “0”.

2. SAFETY PRECAUTIONS

SAFTEY PRECAUTIONS

WARNING! Safety rules must be closely observed.

SAFTEY PRECAUTIONS

28. Perform all maintenance work only with power cord unplugged from power socket.

29. Perform all repairs only in service center appointed by seller.

30. If machine falls on hard surface, from height, is wet, or has other damage that could

affect technical state of machine, stop operation and immediately send machine to

service center for inspection.

31. Never leave machine unattended during operation.

32. Remove from worksite and store in safe and dry location when not in use.

3. STARTUP AND OPERATION

3.1. Preparation

Use carrying handle (Figure 3) for transportation and positioning at the worksite. Set all levers

to position “0”: power switch, magnetic unit lever, travel direction switch, and arc ignition switch.

WARNING! Read safety precautions before starting.

Plug the cord into machine power supply socket, put a torch into torch holder, and secure with

knob. If the machine is to be used to control the welding device, plug supplied arc ignition cable

into the arc ignition socket. The cable works as a welding gun switch and comprises two wire

pairs of a different color. Connecting each pair enables to control arc ignition of one welder.

Figure 3. Control units

Precise Torch Adjusting Knobs

Carrying Handle

Bolt Securing Follower Arms Knob Securing Torch Into Holder

Levers Securing Torch

Position and Angle

STARTUP AND OPERATION

To continuously track the travel geometry, set the first follower arm 10 mm (0.4’’) closer to the

machine than the second one (Figure 4). For this purpose, use 4 mm Allen key to unscrew the

bolt that secures the follower arms and screw the bolt after the setting has been made.

Toggle the magnetic unit lever from left (“0”) to right position (“1”), what changes the machine

adhesion to work surface from the minimum to maximum. Loosen the levers (Figure 3) and adjust

the position and angle of the torch. Set the torch position precisely using the two knobs located at

the cross slides. If the work is to be done along the vertical axis, perform welding upward (position

PF according to the EN ISO 6947). When operating at heights, attach a safety line to the lug. The

safety line is not included in the standard equipment.

3.2. Operation

Plug the power cord into the mains and turn on the power by toggling power switch to position

“I”, which will indicated by the illuminating all the segments of the display (“888”). After a while,

the indication changes to “EUr” if the unit of speed is set to centimeters per minute, or to “USA”

– for inches per minute. Then, you will see the carriage speed, which you adjust by rotating the

knob located on the panel. If the machine is to be used to control the torch, toggle the arc ignition

switch to position “I”. To check whether the arc ignition cable is connected correctly, toggle the

switch to position “TEST”.

Figure 4. Proper follower arms position

STARTUP AND OPERATION

Travel Direction

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