Itm 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
ul. Elewatorska 23/1, 15-620 Białystok, Poland
Phone: [phone], Fax: [phone]
www.promotech.eu e-mail: [e-mail]
OPERATOR’S MANUAL
G
GE EC CK KO O ( (H HS S) )
WELDING CARRIAGE
Ver: 2.01 05/07/2021

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LIMITED WARRANTY
Industrial Tool & Machinery Sales (hereinafter referred to as ITMS) will, within twelve (12) months from the
original date of purchase, repair or replace any goods found to be defective in materials or workmanship.
This warranty is void if the item has been damaged by accident, neglect, improper service or other causes not
arising out of defects in materials or workmanship. This warranty does not apply to machines and/or components
which have been altered, changed, or modified in any way, or subjected to overloading or use beyond
recommended capacities and specifications. Worn componentry due to normal wear and tear is not a warranty
claim. Goods returned defective shall be returned prepaid freight to ITMS or agreed repair agent, which shall
be the buyer’s sole and exclusive remedy for defective goods. ITMS accepts no additional liability pursuant to
this guarantee for the costs of travelling or transportation of the product or parts to and from ITMS or the service
agent or dealer, such costs are not included in this 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.
THE MANUFACTURER RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND
MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE.
PRODUCTS IMPORTED AND DISTRIBUTED NATIONALLY BY:
INDUSTRIAL TOOL & MACHINERY SALES
18 BUSINESS ST, YATALA QLD 4207
T: 07 3287 1114 E: [email protected]
F: 07 3287 1115 W: www.industrialtool.com.au

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Contents
1. GENERAL INFORMATION ............................................................................................... 3
1.1. Application ................................................................................................................. 3
1.2. Technical data............................................................................................................ 3
1.3. Equipment included ................................................................................................... 4
1.4. Dimensions ................................................................................................................ 5
1.5. Design ....................................................................................................................... 6
2. SAFETY PRECAUTIONS.................................................................................................. 7
3. STARTUP AND OPERATION ........................................................................................... 9
3.1. Preparing ................................................................................................................... 9
3.2. Connecting to the welding circuits.............................................................................10
3.3. Positioning at the worksite ........................................................................................11
3.4. Operating ..................................................................................................................12
3.5. Changing the unit of speed .......................................................................................13
3.6. Troubleshooting ........................................................................................................14
4. MAINTENANCE ...............................................................................................................15
5. ACCESSORIES ...............................................................................................................16
5.1. Torch clamps ............................................................................................................16
5.2. Rods .........................................................................................................................17
5.3. Torch holders............................................................................................................18
5.4. Torch extension arm .................................................................................................20
5.5. Guide arms ...............................................................................................................21
5.6. Dual torch mount.......................................................................................................26
5.7. Auxiliary magnet blocks ............................................................................................27
5.8. Flexible guide set ......................................................................................................28
5.9. Guide adjustment tool ...............................................................................................30
5.10. Flexible trackway set...............................................................................................31
5.11. Magnetic units for flexible trackway .........................................................................34
5.12. Support for trackway with magnetic units ................................................................38
5.13. Vacuum unit ............................................................................................................39
5.14. Vacuum track system..............................................................................................40
5.15. Support for trackway with vacuum units ..................................................................41
5.16. 76 mm cross slide ...................................................................................................42
5.17. Cable anchor...........................................................................................................43
5.18. Display protection shield .........................................................................................43
5.19. Fall arrester.............................................................................................................44
5.20. Stainless steel wheels.............................................................................................45
6. 115–230 V WIRING DIAGRAM ........................................................................................46
7. 115–230 V HS WIRING DIAGRAM ..................................................................................47
8. 42 V WIRING DIAGRAM..................................................................................................48
9. 42 V HS WIRING DIAGRAM ............................................................................................49
10. DECLARATION OF CONFORMITY ...............................................................................50
11. WARRANTY CARD........................................................................................................51
1. GENERAL INFORMATION............................................................................................... 4
1.1. Application...................................................................................................................... 4
1.2. Technical data ................................................................................................................ 4
1.3. Equipment included........................................................................................................ 5
1.4. Dimensions..................................................................................................................... 6
1.5. Design ............................................................................................................................ 7
2. SAFETY PRECAUTIONS................................................................................................. 8
3. STARTUP AND OPERATION .......................................................................................... 10
3.1. Preparing........................................................................................................................ 10
3.2. Connecting to the welding circuits.................................................................................. 11
3.3. Positioning at the worksite.............................................................................................. 12
3.4. Operating........................................................................................................................ 13
3.5. Changing the unit of speed............................................................................................. 14
3.6. Troubleshooting.............................................................................................................. 15
4. MAINTENANCE................................................................................................................ 15
5. ACCESSORIES................................................................................................................ 16
5.1. Torch clamps.................................................................................................................. 16
5.2. Rods ............................................................................................................................... 17
5.3. Torch holders.................................................................................................................. 18
5.4. Torch extension arm....................................................................................................... 20
5.5. Guide arms..................................................................................................................... 21
5.6. Dual torch mount ............................................................................................................ 26
5.7. Auxiliary magnet blocks.................................................................................................. 27
5.8. Flexible guide set............................................................................................................ 28
5.9. Guide adjustment tool..................................................................................................... 30
5.10. Flexible trackway set .................................................................................................... 31
5.11. Magnetic units for flexible trackway.............................................................................. 34
5.12. Support for trackway with magnetic units..................................................................... 38
5.13. Vacuum unit.................................................................................................................. 39
5.14. Vacuum track system ................................................................................................... 40
5.15. Support for trackway with vacuum units....................................................................... 40
5.16. 76 mm cross slide......................................................................................................... 41
5.17. Cable anchor ................................................................................................................ 42
5.18. Display protection shield............................................................................................... 42
5.20. Stainless steel wheels .................................................................................................. 43
115–230 V WIRING DIAGRAM............................................................................................. 44
115–230 V HS WIRING DIAGRAM....................................................................................... 45
42 V WIRING DIAGRAM....................................................................................................... 46
42 V HS WIRING DIAGRAM................................................................................................. 47
PARTS LIST.......................................................................................................................... 48
PARTS LIST - ASSEMBLY PANEL....................................................................................... 54
PARTS LIST - TORCH HOLDING ASSEMBLY & LOW TORCH HOLDING ASSEMBLY.... 55

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GECKO (HS)
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1. GENERAL INFORMATION
1.1. Application
The GECKO (HS) is a welding carriage designed to make continuous butt and fillet
welds. The carriage allows MIG/MAG torches and is clamped with permanent magnets.
Accessories allow using torches with a larger diameter and using two torches at
the same time. They also allow the carriage to move along outside edges, lap joints
and templates, walls that are low or have holes, and on ceilings, pipes, and tanks.
Using an optional flexible trackway set allows the carriage to move on a flexible
rail. You can clamp the rail to the surface by using magnetic units or by using vacu-
um units and a vacuum track system.
1.2. Technical data
GECKO
GECKO HS
Voltage
1~ 115–230 V, 50–60 Hz
1~ 42 V, 50–60 Hz (60 V DC)
1~ 115–230 V, 50–60 Hz
1~ 42 V, 50–60 Hz (60 V DC)
Power 20 W 20 W
Welding position
(according to
EN ISO 6947
and AWS/ASME)
Horizontal
PA/1F/1G
PB/2F
PC/2G
PD/4F
PE/4G
PA/1F/1G
PB/2F
PC/2G
PD/4F
PE/4G
Vertical
PF/3G
N/A
Minimum path curve radius 1000 mm (3.5 ft) 1000 mm (3.5 ft)
Torch type
MIG/MAG
MIG/MAG
Torch diameter
16–22 mm (0.63–0.87″)
16–22 mm (0.63–0.87″)
Maximum torch reach
70 mm (2.76″)
70 mm (2.76″)
Maximum allowed
cable weight
Horizontal work
8 kg
8 kg
Vertical work 6 kg N/A
Minimum workpiece thickness
4 mm (0.16″)
4 mm (0.16″)
Ground clearance 4 mm (0.16″) 4 mm (0.16″)
Horizontal pulling force 150 N 150 N
Vertical pulling force
100 N
N/A
Cross slide adjustment range
0–35 mm (0–1.38″)
up-down, left-right
0–35 mm (0–1.38″)
up-down, left-right
Guide arm adjustment range
0–100 mm (0–3.93″)
0–100 mm (0–3.93″)
Horizontal speed
0–110 cm/min
(0–43.3 in/min)
5–220 cm/min
(1.5–86.6 in/min)
Vertical speed
0–100 cm/min
(0–39.4 in/min)
N/A
Weight
8 kg (18 lbs)
8 kg (18 lbs)

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1.3. Equipment included
1
Carriage
1 unit
2
Cardboard box
1 unit
3
Long rod torch holder with clamp
1 unit
4
3 m (10 ft) power cord
1 unit
5
6.5 m (21 ft) arc ignition cable
1 unit
6
4mm hex wrench
1 unit
–
Operator’s Manual
1 unit
1
2
3
4
6
5

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1.4. Dimensions
320 mm (12.6″)
277 mm (10.9″)
366 mm (14.4″)

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1.5. Design
Lug for fall arrester
Cross slide
Guide arm
Power switch
Arc ignition socket
Magnet ON/OFF lever
Control panel
LED display
Travel direction switch (Left / O / Right)
Arc ignition switch (TEST / O / I)
Speed adjustment knob

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2. SAFETY PRECAUTIONS
1. Before use, read this Operator’s Manual and complete a training in occupational
safety and health.
2. Use only in applications specified in this Operator’s Manual.
3. Make sure that the carriage has all parts and they are genuine and not damaged.
4. Make sure that the specifications of the power source are the same as those spec-
ified on the rating plate.
5. Connect the carriage to a correctly grounded power source.
6. Do not carry the carriage by the cords or arc ignition cable, and do not pull them.
This can cause damage and electric shock.
7. Keep untrained bystanders away from the carriage.
8. Before each use, ensure the correct condition of the carriage, power source,
cords, arc ignition cable, plugs, control panel, and wheels.
9. Before each use, make sure that no part is cracked or loose. Make sure to main-
tain correct conditions that can have an effect on the operation of the carriage.
10. Keep the carriage dry. Do not expose the carriage to rain, snow, or frost.
11. Keep the work area well lit, clean, and free of obstacles.
12. Do not use near flammable materials, or in explosive environments.
13. Make sure that the rubber of the wheels is clean and not damaged.
14. Do not remove the cover of the wheels.
15. Remove objects attracted to the chassis by the magnet.
16. Transport and position the carriage by using the carrying handle and only after
you set the magnet ON/OFF lever to ‘O’.
17. Put the carriage so that four wheels are on the surface. Make sure that no con-
tact is between the surface and chassis.
18. Do not stay below the carriage that is put at heights.
19. Connect the cords and arc ignition cable only after you set the power switch to
‘O’.
20. Keep the sockets clean. Do not use high pressure during cleaning.
21. Install only MIG/MAG torches whose diameter matches the diameter of the torch
holder.
22. Do not put the torch more than 70 mm (2.76″) outward from the left or right side
of the carriage.

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23. Keep the torch cables away from the surface. Hang them to decrease the load
applied on the carriage. Use only cables whose weight is not more than 8 kg
(18 lbs) for horizontal work and 6 kg (13 lbs) for vertical work.
24. Do not work on curves with convex or concave radius less than 1000 mm (3.5 ft).
25. Use the HS version of the carriage in horizontal positions only.
26. At heights, use a fall arrester not to let the carriage fall.
27. Use eye protection (helmet, shield, and screen), ear protection, gloves, and pro-
tective clothing. Do not use loose clothing.
28. Do not stop the carriage by hand. To stop, set the travel direction switch to ‘O’.
29. Do the maintenance only after you unplug the carriage from the power source.
30. Repair only in a service center appointed by the seller.
31. If the carriage falls, is wet, or has any damage, stop the work and promptly send
the carriage to the service center for check and repair.
32. Do not leave the carriage unattended during work.
33. If you are not going to use the carriage, remove it from the worksite and keep in a
safe and dry place.

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3. STARTUP AND OPERATION
3.1. Preparing
Use the carrying handle to transport the carriage to the worksite. Then, set to ‘O’ all
switches (power, travel direction, and arc ignition switch) and the magnet lever. Next,
connect the carriage to the power source, and then put the torch into the torch holder
and tighten with the knob.
Fig. 1. View from the back side
Knobs for precise torch adjustment
Levers that secure
the torch position and angle
Knob that secures the torch in the holder
Screw that secures the guide arm
Carrying handle

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3.2. Connecting to the welding circuits
The carriage can control two torches by using the arc ignition cable plugged into the
arc ignition socket. To do this, refer to the diagram from Fig. 2 and connect one blue-
jacketed wire to one terminal of the welding circuit. Then, connect the other blue-
jacketed wire to the other terminal of the same circuit. To control the second torch,
connect the green-jacketed wires to the terminals of the second welding circuit.
Fig. 2. Connecting the arc ignition cable to welding circuits
Make sure that the arc ignition cable is connected correctly. To do this, turn on the
power of the carriage, and then set the arc ignition switch to TEST. This should ena-
ble the arc for a while.
Blue
Blue
Welding circuit 1
Green
Green
Welding circuit 2

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3.3. Positioning at the worksite
Put the guide arms so that the carriage is in constant contact with the workpiece. You
can set them by a constant step (interval adjustment), or continuously after you swap
them (continuous adjustment). To set them correctly when the carriage moves to the
left, use the 4 mm hex wrench to loosen the screw that secures the right guide arm.
Next, move out the right arm about 10 mm (0.4″) or one groove more than the
left arm (Fig. 3), and then tighten the screw again.
Fig. 3. Correct positioning of the guide arms
Lug for fall arrester
Travel direction
Continuous adjustment
Interval adjustment
Swap the guide arms
to change between
methods of adjustment
Grooves
Moving out the right arm
by one groove
You can install the roller assemblies at the
other end of the guide arms

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To put the carriage closer to the workpiece, use the 4 mm hex wrench to remove
the roller assemblies. Next, install them at the other end of the guide arms, and then
swap the guide arms (Fig. 3).
Switch the magnet ON/OFF lever from left (‘O’) to right (‘I’). This will change the
clamping force from minimum to maximum. Loosen the levers to adjust the position
and angle of the torch. Use two knobs at the cross slide to precisely set the torch
position.
At heights, attach a fall arrester (not included) to a lug (Fig. 3) to prevent fall of
the carriage. This will avoid possible injury to the operator in case the carriage loses
the clamping. Do not stay below the carriage that is put at heights.
3.4. Operating
Set the power switch to ‘I’ to turn on the power. Then, the display comes on ( ).
Next, if the unit of speed is set to centimeters per minute, shows. If the unit is
set to inches per minute, shows. Next, the carriage speed shows. Use the speed
knob to set the required speed. To control the torch through the carriage, set the arc
ignition switch to ‘I’.
If the arc ignition switch is set to ‘I’, the torch starts welding promptly
after you select a travel direction.
Use the travel direction switch to select a direction of travel. Then, the travel
starts with the speed that is shown. You can adjust the speed at any time.
To stop the travel, set the travel direction switch to ‘O’.
After the work is finished, use the power switch to turn off the carriage. Then,
unplug the carriage from the power source.

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3.5. Changing the unit of speed
To change the unit of speed between centimeters per minute and inches per minute,
unplug the carriage from the power source and follow the steps shown in Fig. 4.
Fig. 4. Changing the unit of speed
After you change the unit and supply the power to the carriage, the current unit of
measure shows. When the jumper cap connects the left and center pin, the display
shows and the speed is shown in centimeters per minute. When the jumper cap
connects the center and right pin, the display shows and the speed is shown in
inches per minute.
Put the jumper cap in the position
that matches the required unit.
cm
inch
Use the 2.5 mm hex wrench (not included)
to loosen the screws and get access to the
back side of the control panel.

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3.6. Troubleshooting
Message
Problem
Solution
Display not fully on after powering. Contact service center for check
and repair.
Speed shown in centimeters per
minute instead of inches per minute.
Refer to the section “Changing the
unit of speed.”
Speed shown in inches per minute
instead of centimeters per minute.
Refer to the section “Changing the
unit of speed.”
Travel direction switch not set to ‘O’
when powering.
Set the travel direction switch to ‘O’. If
the message still shows, contact
service center for check and repair.
Shown during travel indicates
a malfunction.
Contact service center for check and
repair.
Motor overload. The carriage stops. Use the welding cables whose weight
is not more than the maximum weight
specified in the technical data.
Adjust the position of the cables so
that they do not block the carriage.
Remove other objects that block the
carriage or its wheels.
If this message still shows, contact
service center for check and repair.
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4. MAINTENANCE
Each day:
1. Clean the chassis and wheels.
2. Clean the rollers of the guide arms. Make sure that the rollers rotate freely.
3. Clean the torch nozzle and replace if damaged.
Each month:
1. Make sure that the knob and the switches work as intended. Replace if they are
loose or damaged.
2. Examine cables and cords, and replace if damaged.
3. Tighten screws if loose.

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5. ACCESSORIES
5.1. Torch clamps
5.1.1. 16–22 mm torch clamp
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″).
5.1.2. 16–22 mm torch clip
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex
wrench to tighten the torch in the clip.
5.1.3. 22–35 mm torch clamp
Allows using a torch with the diameter of 22–35 mm (0.87–1.38″).
Part number:
WAP-L4040
Part number:
WAP-G2090
Part number:
WAP-G2160

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5.2. Rods
5.2.1. Short rod
Provides a 120 mm (4.72″) reach.
5.2.2. Long rod
Provides a 240 mm (9.45″) reach.
Part number:
WAP-G2050
Part number:
WAP-L4030

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5.3. Torch holders
5.3.1. Short rod torch holder with clamp
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″).
5.3.2. Short rod torch holder with clip
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex
wrench to tighten the torch in the clip.
5.3.3. Short rod low torch holder with clip
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex
wrench to tighten the torch in the clip.
Part number:
WAP-RB2340
Part number:
UCW-0476-27-00-00-0
Part number:
WAP-L4090

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5.3.4. Long rod torch holder with clamp
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″).
5.3.5. Long rod torch holder with clip
Allows using a torch with the diameter of 16–22 mm (0.63–0.87″). Use the 4 mm hex
wrench to tighten the torch in the clip.
Part number:
WAP-L4035
Part number:
UCW-0466-22-00-00-0

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M5x16
M5x10
Part number:
WAP-G2020
5.4. Torch extension arm
Increases the reach of the torch. Use the 4 mm hex wrench to remove the M5x10
screws that attach the cross slide. Next, use the same screws to attach the cross
slide at the end of the arm as shown in the figure. Then, use M5x16 screws to attach
the arm to the carriage.