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Koike Sanso Kogyo WEL-HANDY MINI Operation Manual

Portable automatic welding carriage for fillet welding
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Summary of Contents for Koike Sanso Kogyo WEL-HANDY MINI

  • Page 1 2SHUDWLRQ 0DQXDO BOEKNAAM %HGLHQLQJVKDQGOHLGLQJ %HWULHEVDQOHLWXQJ :(/+$1'< 0,1, 3257$%/( $8720$7,& :(/',1* &$55,$*( )25 ),//(7 :(/',1* For every person who will be engaged in operation and maintenance supervision, it is recommended to read through this manual before any operations, so as to permit optimum operation of this machine .2,.( 6$162 .2*<2 &2/7'...
  • Page 2 *XDUDQWHH WHUPV BOEKNAAM KOIKE Europe B.V. in Zaandam The Netherlands provides a 1 year guarantee on the devices, from the day of delivery. In case the buyer also agreed on an installation contract, the guarantee starts on the date the products are supplied.
  • Page 3 (QJOLVK BOEKNAAM The guarantee expires in case: repairs, replacements or expansions regarding the devices have been conducted by others than Koike Europe b.v. without its consent; the devices were neglected or applied, treated and/or maintained carelessly and/or unprofessionally according Koike Europe b.v.; type numbers and/or serial numbers are damaged, removed and/or altered;...

  • Page 4: Table Of Contents

    WEL-HANDY MULTI CONTENTS 1 Safety information ..................5 1.1 Introduction .................... 5 1.2 General machine safety precautions ............. 6 1.2.1 Machine safety ................6 1.2.2 Safety clothing ................6 1.2.3 Electrical system precautions ............7 1.3 General Welding safety precautions ............8 1.3.1 Rotary section precautions ............
  • Page 5 WEL-HANDY MULTI...
  • Page 6 WEL-HANDY MULTI PREFACE Introduction Thank you very much for purchasing this product. This manual is intended for operators and maintenance personnel. Read the operation manual thoroughly to ensure correct, safe and effective use of the machine. Make sure you read, understand and take all the necessary safety precautions.
  • Page 7 WEL-HANDY MULTI Explanation of symbols In this manual safety signs (symbols) are used to indicate safety messages and signal words to indicate the degree or level of hazard. The safety indicators are explained in the table below. Symbol Title Meaning Safety alert symbol This symbol is applied to indicate general caution, warning and danger messages.

  • Page 8: Safety Information

    WEL-HANDY MULTI 1 Safety information 1.1 Introduction Operation, inspection, and maintenance that disregard the basic safety rules cause many accidents. Carefully read, understand, and master the safety measures and precautions described in this operation manual and on the machine before operating, inspecting, and maintaining the machine.

  • Page 9: General Machine Safety Precautions

    WEL-HANDY MULTI General machine safety precautions 1.2.1 Machine safety Warning Strictly obeserve the following to prevent accidents resulting in serious injury or death. • Keep people out of the space around the welding machine and working area. • The welding machine generates a magnetic field around itself. Such a magnetic field affects certain types of sensors and clocks.

  • Page 10: Electrical System Precautions

    WEL-HANDY MULTI 3 Noise can cause hearing difficulties. 4 Wear light-shielding goggles or hand shield, which blocks light sufficiently, for welding operation or monitoring welding. 5 Wear protective goggles to protect your eyes from spatters and slugs. 6 Install a protective curtain around the welding site so that arc light will not reach the eyes of people around the site.

  • Page 11: General Welding Safety Precautions

    WEL-HANDY MULTI 6 DO not use cables with Insufflcient capacity or damaged cables whose conductors are exposed. 7 Firmly tighten and insulate cable connections. 8 Firmly connect the welding cable on the base metal side at a location as close as possible to the base metal. 9 Do not use the machine with the welding machine case or coser removed.

  • Page 12: Rotary Section Precautions

    WEL-HANDY MULTI 1.3.1 Rotary section precautions Caution Strictly observe the following to prevent injury due to rotary section 1 Do not bring your hands, hair, or clothes close to the cooling fan of the welding power supply or the feeder roller of the wire feeder; otherwise you can be caught in them.

  • Page 13: High Pressure Gas Cylinder Safety Precautions

    WEL-HANDY MULTI 1.3.4 High pressure gas cylinder safety precautions Caution Strictly observe the following to prevent gas cylinders from falling or bursting. 1 Never use broken cylinders or cylinders from which gas is leaking. 2 Install cylinders upright and take measures to prevent them from falling.
  • Page 14 WEL-HANDY MULTI 7 Do not bring hot base metal right after welding close to inflammables. 8 Welding on ceilings, floors, an walls may cause fire on the hidden side. Remove inflammables from the hidden side. 9 Firmly tighten cable connections, and firmly connect the welding cable on the base metal side at a location as close as possible to the base metal.
  • Page 15 WEL-HANDY MULTI...

  • Page 16: Locations Of Safety Labels

    WEL-HANDY MULTI 2 Locations of safety labels Safety labels and other labels for correct operation are affixed to the machine. Carefully read the labels and follow the instructions on them when operating the machine. Never remove the labels. Keep them clean and legible at all times. WARNING WARNING WARNING...
  • Page 17 WEL-HANDY MULTI...

  • Page 18: Outline Of Machine

    WEL-HANDY MULTI 3 Outline of machine 3.1 Features of machine The WEL-HANDY MULTI has been developed to allow even unskilled operators to successfully do horizontal fillet welding (bottom steel plate traveling type) in a simple manner. Major features are as follows: Compact, Light weight, Durable and Low gravity.

  • Page 19: Name And Function Of Each Section

    WEL-HANDY MULTI 3.2 Name and function of each section 3.2.1 Main unit of welding carriage figure 3 - 1 1. Slide unit assembly 7. Metal socket 2. Torch holder 8. Driving wheel (Rubber roller) 3. Guide roller and arm 9. Torch angle adjusting bolt 4.
  • Page 20 WEL-HANDY MULTI Warning Secure the insulated section of the torch before mounting it. When the conductive section is secured, a short circuit and/or electric shock can result. 2 Torch holder Insert the exclusive use torch mounting section into the torch holder to secure it.
  • Page 21 WEL-HANDY MULTI Warning Never fail to ground the clip. The grounded clip prevents short circuits or electric shock which results from a short circuit in the carriage, etc. 8 Driving wheel (Rubber roller) 9 Torch angle adjusting bolt Used to set the torch angle. Loosen the bolt and swing the torch for setting within the range of 40°...

  • Page 22: Operation Panel

    WEL-HANDY MULTI 3.2.2 Operation panel Warning Strictly observe the following to prevent electric shock. • Pull out the input power plug from the outlet and turn off the control power before inspection, disassembly, and repair. If it is necessary to inspect the machine while the power is being supplied, leave the operation to an engineer who has through knowledge and about electricity and skill to prevent a short circuit and electric shock.
  • Page 23 WEL-HANDY MULTI 3 Traveling speed control knob Turn it clockwise for acceleration and counterclockwise for deceleration. The speed corresponding to the graduations of the speed setting dial is as follows. This setting is a tentative rough standard and changes by the situation of the load.

  • Page 24: Specifications

    WEL-HANDY MULTI 3.3 Specifications Type: WEL-HANDY MULTI Weight of machine: 6.8 kg 4 rubber wheel drive (Permanent Driving method: magnet suction type.) Pulling power: 30 kg Traveling speed: 150 - 1,500 mm/min. Tracing method: Guide roller The height of guide roller: Changeable to three positions Torch adjusting range: Torch angle 40°...
  • Page 25 WEL-HANDY MULTI...

  • Page 26: Preparation And Procedure For Operation

    WEL-HANDY MULTI 4 Preparation and procedure for operation Warning Strictly observe the following to prevent burns Never directly touch the torch nozzle, tip, orifice, insulation cylinder, and the surface of the carriage which are very hot right after welding. Caution Set the welding power switch in the “No Self-Holding (or No Crater Treatment)”...

  • Page 27: Preparation And Procedure For Welding

    WEL-HANDY MULTI 4.2 Preparation and procedure for welding Conduct welding in the following manner, while referring to the Fig. 5 "System connection diagram" and the operation procedure in item 5.1. Warning Strictly observe the following to prevent electric shock. Turn OFF the control power and welding power, and then conduct operations from (1) to (4) shown below.
  • Page 28 WEL-HANDY MULTI Caution When inserting the wire, do not bring your head near the wire that comes out of the tip. Your eyes can be damaged. 6 Press the tracing roller against the vertical plate, and set the carriage in the welding position. 7 For attraction by the magnet, incline the magnet lever as shown in Fig.3.

  • Page 29: System Connection Diagram

    WEL-HANDY MULTI 4.3 System connection diagram figure 4 - 1 System connection diagram 1. Welding torch 2. Signal cable* (Do not connect the signal cable on the torch to the wire feeder) 3. Connector, 2-pins 4. Wire feeder 5. Convenience outlet 6.

  • Page 30: Operational Precautions

    WEL-HANDY MULTI 4.5 Operational precautions 1 Make sure that the operating voltage is as specified, If the difference exceeds plus or minus 10% of the input power, trouble can occur. 2 Clean the traveling surface to remove remaining bars, slugs, spatters, etc.
  • Page 31 WEL-HANDY MULTI...

  • Page 32: Maintenance

    WEL-HANDY MULTI 5 Maintenance For correct operation of the machine for an extended period of time without trouble, the daily maintenance is indispensable. (Refer to 6.1 "Maintenance and inspection.") When trouble occurs, refer to 6.3 "Trouble and corrective measures." Warning As for the attachment, removal of the drive wheel, please use 2 spanners without fail.

  • Page 33: Recommended Spare Parts

    WEL-HANDY MULTI 5.2 Recommended spare parts 1 Fuse 2 Guide roller 3 Rubber wheel 4 Auto stop switch 5 Printed circuit board...

  • Page 34: Troubleshooting

    WEL-HANDY MULTI 6 Troubleshooting Repairs are only to be conducted by a qualified professional. 1 Tracing is incorrect Possible cause The tracing rollers are not running The cable is caught, preventing traveling The traveling surface is not flat, and the wheels are not in contact with the surface The wheels are loose 2 The auto stop switch is invalid and welding will not stop Possible cause...
  • Page 35 WEL-HANDY MULTI When the stop Replace. switch is invalid, the printed circuit board is defective. 3 The control power cannot be turned ON (The indication lamp will not come ON) Possible cause Action The fuse is blown out. (1A) Warning Strictly observe the following to prevent a short circuit or electric shock.
  • Page 36 WEL-HANDY MULTI When the welding Replace. does not start even if the start switch is pressed: - Detective start switch - Detective printed circuit board Disconnection of Replace. motor 5 The traveling speed will not change Possible cause Action The variable resistor for speed control is defective Warning...
  • Page 37 WEL-HANDY MULTI When the machine Check if the torch switch metal plug is not connected travels: Check if the metal plug pins (1) and (2) are short-circuited. - The welding power sypply is not turned ON - The metal plug pins are short circuited, the welding power...

  • Page 38: Wiring Diagram

    WEL-HANDY MULTI 7 Wiring diagram 100V 5 -1A (120V) (220V) (230V) (240V) (42V) figure 7 - 1 1. Arc on 9. PCB 2. Test arc 10. Transformer 3. Arc ON/OFF 11. Motor 24 VDC 5000 rpm 4. Power ON/OFF 12. Connector 1 5.
  • Page 39 WEL-HANDY MULTI...

  • Page 40: 8Parts List

    WEL-HANDY MULTI 8 Parts list 8.1 Main body and inside parts...
  • Page 41 WEL-HANDY MULTI Main body and inside parts Item Description Q’ty Stock no. Remarks Main body case 61000567 Bearing retainer 61000571 Base plate 61000573 Drive wheel 61000579 Key for drive wheel 61000607 Collar for drive wheel 61000608 Adjusting washer No.1 61000620 t=0.2 mm Adjusting washer No.2 61000621...
  • Page 42 WEL-HANDY MULTI Main body and inside parts Item Description Q’ty Stock no. Remarks 18-2 Water proof cap 64000024 AT-4043 18-3 Nylon connector 6N080004 For wiring of limit switch Transformer 61000479 Thrust washer 61000587 Magnet lever 61000641 DU bush with brim 64000015 Screw 222.004.765 SF-6x14...

  • Page 43: Outside Parts

    WEL-HANDY MULTI 8.2 Outside parts...
  • Page 44 WEL-HANDY MULTI Outside parts Item Description Q’ty Stock no. Remarks Wheel cover 61000590 Screw 222.004.720 SR-5x10 Hexagon bolt 222.004.204 BC-5x25 Washer 222.004.530 WF-5 Spring washer 222.004.501 WS-5 Guide roller assembly 61000644 Bracket 61000594 Fixing holder 61000597 Hexagon bolt 222.004.230 BC-5x12 Washer 222.004.530 WF-5 Spring washer...
  • Page 45 WEL-HANDY MULTI Outside parts Item Description Q’ty Stock no. Remarks 22-7 Toggle switch 6N110009 M-2029 L/B 22-8 Dust proof nut 60032480 Machine connection cable 60039755 25-2A 23-1 Plug 60038197 ME2538 23-2 Plug 60035563 23-3 Rubber plug 60030280...
  • Page 46 .2,.( ,17(51$7,21$/ *5283 Total system supplier of welding and cutting .2,.( $521621 ,1& 635 West Main Street, Arcade, NY14009, USA. Tel: 716-492-2400 Fax: 716-457-3517 www.koike.com .2,.( (8523( %9 Grote Tocht 19, 1507 CG Zaandam, Holland. Tel: 075-6127227 Fax: 075-6702271 www.koike.nl .2,.( .25($ (1*,1((5,1* &2/7' 1318-26, Daekwang-Dong,...

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