Koike IK-72T W2 User manual

Portable Automatic Welding Carriage for fillet welding
T89002425
IK-72T W2
OPERATION
MANUAL
KOIKE ENGINEERING TANGSHAN CO.,LTD.
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.

IK-72T W2
INTRODUCTION
Thank you very much for purchasing this product. Read this instruction
manual thoroughly to ensure correct, safe and effective use of the machine.
Read the manual first to understand how to operate and maintain the machine.
Cooperation between colleagues in the workplace is essential for safe,
smooth operation.
Make sure you read, understand and take all the necessary safety
precautions.
SAFETY PRECAUTIONS
This product is designed to be safe, but it can cause serious accidents if not operated
correctly. Those who operate and repair this machine must read this manual
thoroughly before operating, inspecting and maintaining the machine. Keep the
manual near the machine so that anyone who operates the machine can refer to it if
necessary.
■Do not use the machine carelessly without following the instructions in the manual.
■Do not use the machine until you have thoroughly understood the explanations in the manual.
■For safety, leave the installation, maintenance, inspection, and repair of the machine to a trained person
who has thorough knowledge about welding machines or to a qualified operator.
■For safety, leave the operation of the machine to a person with complete knowledge of the instruction
manual and sufficient skill.
■For safety education, make use of respective lecture meetings sponsored by the Welding Society and
Welding Association, as well as by headquarters and branches of related scientific societies and
associations. Make use of qualification tests for welding engineers and welding technicians as well.
■After reading the manual, keep It together with the warranty within reach of people concerned. Read the
manual again as necessary.
■Contact our dealers or our branch office, sales office, or local office for any obscure points.
■When this manual is lost or damaged, place an order promptly with our dealer for another copy.
■When transferring the machine, be sure to attach the instruction manual to the machine to transfer it to
the nest owner.
QUALIFICATIONS FOR MACHINE OPERATOR
Operators and repair staff of this machine must completely understand the contents
of the instruction manual and they must be qualified and educated to handle this
equipment.

IK-72T W2
Symbol
Title
Meaning
General
General caution, warning, and danger.
Be careful not to get your
fingers caught.
Possible injury to fingers if caught in the insertion
part.
Caution: Electric shock!
Possible electric shock under special conditions.
Ground this equipment.
Operators must ground the equipment using the
safety grounding terminal.
Pull out the power plug
from the outlet.
Operators must unplug the power plug from the
outlet when a failure occurs or when there is a
danger of lightning.
Caution against bursting
Possible bursting under certain conditions.
General
General warning.
Caution: Hot!
Possible injury due to high temperature under
certain conditions.
Caution: Ignition!
Possible ignition under certain conditions.
Caution: Magnet
Generating a magnetic field and magnetic waves.
Wear light shielding
goggles.
Be sure to wear light shielding goggle when
looking at welding arcs.
Wear dust/gas mask.
Wear a mask when dust, smoke, or gas is to be
generated during work.
Do not lift.
Lifting the carriage is prohibited to prevent an
accident due to falling.

- 1 -
CONTENTS
1 Safety information...................................................................................................................................- 2 -
2 Safety precautions..................................................................................................................................- 3 -
3 Equipment outline................................................................................................................................... - 8 -
4 Features and specifications.............................................................................................................. - 9 -
4.1 Features...................................................................................................................................................... - 9 -
4.2 Configuration............................................................................................................................................. - 9 -
4.3 Specifications........................................................................................................................................... - 10 -
5 Method of operation.............................................................................................................................- 11 -
5.1 Operation panel........................................................................................................................................ - 12 -
5.1.1 Explanation about operation Unit functions.................................................................................- 13 -
5.1.2 Regarding SELECT SWITCH......................................................................................................- 15 -
5.1.3 Metric, Inch switch over method.................................................................................................. - 22 -
5.1.4 Weaving tack/stitch running motion pattern diagram...................................................................- 22 -
5.1.5 Weaving movement time chart..................................................................................................... - 25 -
5.1.6 tack/stitch running motion Time chart..........................................................................................- 26 -
6 Preparation Operation........................................................................................................................ - 28 -
6.1 Contents of package..............................................................................................................................- 28 -
6.2 Machine Assembly...................................................................................................................................- 28 -
6.3 Trouble and corrective measures............................................................................................................. - 29 -
7 Welding operation..................................................................................................................................- 31 -
7.1 Preparation and procedure for welding....................................................................................................- 31 -
7.2 System connection diagram.................................................................................................................. - 32 -
7.3 Applicable welding machine and signal adaptor.................................................................................. - 33 -
7.4 Operational precautions........................................................................................................................ - 33 -
8 Maintenance.............................................................................................................................................- 33 -
8.1 Maintenance and inspection.....................................................................................................................- 34 -
8.1.2 Monthly inspection....................................................................................................................... - 34 -
8.2 Recommended spare parts....................................................................................................................... - 35 -
8.3 Maintenance and inspection.....................................................................................................................- 35 -
8.4 Warranty................................................................................................................................................... - 38 -
9 Wiring diagram........................................................................................................................................- 39 -
10 Assembly drawing of IK-72T W2................................................................................................ - 40 -
11、Part List....................................................................................................................................................- 41 -
11.1 Main and Driving units.......................................................................................................................... - 41 -
11.2 Torch holder........................................................................................................................................... - 43 -
11.3 Limiting device...................................................................................................................................... - 45 -

- 2 -
1 Safety information
Most accidents are caused by negligence of basic safety regulations during operation, inspection,
and maintenance. Carefully read, understand, and master the safety precautions and preventive
measures written in this manual or on the machine before operation, inspection, and maintenance
of the machine.
■Carefully read thin manual before use.
■Conduct installation of motive power source on the primary side, select the location of installation,
store high-pressure gas. install pipes, store products after welding, and dispose of waste in
conformity with laws and your in-house regulations.
■Precautions are provided In this manual for safe operation of the machine and prevention of injury
to you or other people or other damage.
■Improper handling of the machine will cause injury or damage at various levels. The levels are
classified into three categories, which are represented by respective caution symbols and signal
terms to call people's attention. These symbols and terms are used in the same way on the
warning labels stuck to the machine.
Caution symbol
Signal terms
Definition of terms
DANGER
Improper handling Is very likely to cause death or serious
injury.
WARNING
Improper handling can cause death or serious injury.
CAUTION
Improper handling can cause injury or physical damage.
It is also used to point out dangerous habitual action.
Notice sign
The notice sign notifies machine operators and maintenance
men of precautions as to parts of the machine or peripheral
equipment that will lead to breakdown.
The serious injury mentioned above refers to loss of eyesight, injury, burns (high/medium
temperature), electric shock, bone fracture, poisoning which leave an aftereffect or require
hospitalization or regular treatment at a hospital far an extended period of time. The injury refers to a
wound, burn, or electric shock which do not need hospitalization or regular treatment at a hospital
for an extended period of time. The physical damage refers to damage to assets and extensive loss
due to damage to the machine.

IK-72T W2
- 3 -
2 Safety precautions
WARNING
Strictly observe the following to prevent accidents resulting in serious injury or death.
■This welding machine is designed and manufactured by taking safety into
consideration. However, never fail to observe the warning and precautions
described in this instruction manual, otherwise accidents leading to serious
injuly or death can result.
■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. For the same reason, any
person who have a pacemaker in his heart shall not approach the welding
machine in operation or the welding space unless he has obtained doctor's
permission.
■For safety, leave the installation, maintenance, inspection, and repair of the
machine to a person who has thorough knowledge about welding machines or
to a quafified operator.
■For safety, leave the operation of the machine to a person with complete
knowledge of the instruction manual end sufficient skill.
■Do not use this machine for any purpose other than arc welding described in the
instruction manual.
■Do not remodel the machine.
■Check the safety around the machine before operation to prevent accidents.
■Be sure to hold the handle when carrying the machine.
■Wear leather gauntlets when touching the machine during welding or right after
operation.
Do not touch the welded surface antil it has cooled.
WARNING
Strictly observe the following to prevent electric shock.
■Do not touch the charged section; otherwise fatal electric shock or burns can
result. When the power on the input side is turned on, the Input circuit and the
inside of the welding machine are charged. Even if the input power is turned off,
the capacitor may have been charged. When the welding power is output, the
electrode and base metal, as well as the metal portion in contact with these, are
charged.
■Never touch charged sections.
■The welding power supply case and base metal, as well as jigs electrically
connected to them, shall be grounded in conformity with the law (Technical
Standard for Electric Equipment) by a qualified electric engineer.
■Turn off all power supplies on the input side by means of switches in the switch
boxes before installation, maintenance, and inspection. The capacitor will not
discharge completely right after the input power is turned off. Check that no
vohage is remaining before maintenance or inspection.
■Periodically conduct maintenance and inspection. Repair damaged parts before

IK-72T W2
- 4 -
resuming operation.
■Do not use cables with Insufflcient capacity or damaged cables whose
conductors are exposed.
■firmly tighten and insulate cable connections.
■Firmly connect the welding cable on the base metal side at a location as close as
possible to the base metal.
■Do not use the machine with the welding machine case or coser removed.
■Be sure to cover the input and output terminals before use.
■Do not use broken or wet gauntlets.
■Never fail to use a life-line when working in high places.
■Turn oft power switches of all devices and input-side power supply when the
machine is not used.
■Do not wear wet clothes.
■Do not stand on or touch the wet floor.
■Do not use the machine outdoors when it is raining.
■Do not leave the machine outdoors after use.
■Be sure to install a fuse or breaker on the input power supply side.
■Check the supply voltage of the machine before use.
The tolerance for the input supply voltage is plus or minus 10% of the rating.
Use of the machine out of the folerance is prohibited.
■The metal receptacle (plug) on the tough-rubber sheath cable is threaded.
Tighten it firmly.
■Be sure to ground the tough-rubber sheath cable of the machine.
■Turn off the power and stop operation in the following cases, and ask an
engineer with special knowledge of electricity to repair.
*Broken or worn-out cables
*Damage due to water leakage or other liquid
*Malfunction of the machine inspire of operation in conformity with the
instruction manual.
*Breakdown of the machine.
*Abnormal performance of the machine which requires tune-up.
■Ask an engineer with expertise to maintain, inspect, or repair the machire.
■Please make sure that any foreign material does not attach to the connector of
the machine nor to the plug of the power cable when the plug of the power
cable is connected to the machine.
Foreign materials can cause short-circuits or melt the connector.
■In case if you get connected WU-5R, make sure to Turn Off the Power.
Caution: When the power is on if it gets connected there is a possibility of failure.

IK-72T W2
- 5 -
CAUTION
Use protective gear to protect you and others from arc light, scattered spatters/slugs,
and noise.
■The arc light includes harmful ultraviolet rays and infrared rays, causing
Inflammation of eyes or burns.
■Scattered spatters and slugs can damage your eyes and cause burns.
■Noise can cause hearing difficulties.
■Wear light-shielding goggles or hand shield, which blocks light sufficiently, for
welding operation or monitoring welding.
■Wear protective goggles to protect your eyes from spatters and slugs.
■Install a protective curtain around the welding site so that arc light will not reach
the eyes of people around the site.
■Wear protective gear such as leather gauntlets. clothes with long-sleeves, leg
cover, leather apron, helmet, and safety shoes.
■When the noise level is high, wear a noise-proofing protector.
CAUTION
Use protective gear to protect you and others from fumes and gas generated by
welding.
■Welding generates fumes and gas. Inhalation of such fumes and gas can
damage your health.
■Welding operation in a smell space causes deficiency of oxygen, which is very
likely to cause suffocation.
■To prevent gas poisoning and suffocation, use the local waste disposal facilities
stipulated by the law (lndustriat Safety and Health Law snd Regulations to
Prevent Damage due to Dust) or use an effective inhaler.
■When the welding space is small, ventilate the space sufficiently or wear an
inhaler. Have a trained watchman monitor welding.
■Welding operafion near places where degreasing, washing, or opraying is
conducted may lead to generation of harmful gas. Do not conduct welding near
such places.
■Welding zinc plated steel sheets or other coated steel sheets will generate
harmful fumes. Remove the coating before welding, or wear an inhaler before
operation.
■Noise is less than 70 dB.

IK-72T W2
- 6 -
CAUTION
Strictly observe the following to prevent gas cylinders from falling or bursting.
■Gas cylinders, when they fall, can cause accidents leading to death or injury.
■High-pressure gas is contained in gas cylinders. Improper handling of gas
cylinders can cause a burst or emission of high-pressure gas, causing accidents
that lead to death or injury.
■Handle gas cylinders in conformity with the law (High Pressure Gas Control
Law).
■Do not expose gas cylinders to high temperatures.
■Set gas cylinders in a special cylinder stands to prevent the gas cylinders from
falling.
■Never generate arcs on gas cylinders. Do not hook the welding torch on gas
cylinders, or do not allow electrode to touch gas cylinders.
■Do not bring your head close to the discharge port when opening the valve on
the gas cylinder.
■Attach a protective cap to gas cylinders when they are kept unused.
■Use a gas flow rate contgear made or recommended by a welding machine
manufacture.
■Read the instruction manual for the gas flow rate contgear before use, and
strictry observe the precautions.
■Never use a gas cylinder from which gas is leaking or a broken gas cylinder.
■Use gas cylinders only for specified purposes.
■DO not apply oil or grease to the valve on gas cylinders.
■When the valve on gas cylinders is hard to open, contact the dealer.
CAUTION
Strictly observe the following to prevent injury due to rotary section.
■Do not bring your hands, hair, or clothes close to the cooling fan of the welding
power supply or the feeder gear of the wire feeder; otherwise you can be caught
in them.
■Do not bring your head near the end of the welding torch during wire inching;
otherwise the wire may stick in your eyes.
■When the spool of wire is released, you can get hurt.
■Do not use the welding machine with its case or cover removed.
■Ask a trained person who has thorough knowledge of welding machines or a
qualified person to remove the case for maintenance, inspection, or repair.
Install a protective fence around the welding machine to prevent people from
getting near carelessly.
■DO not bring your hand, fingers, hair, or clothes close to the rotating cooling fan
or the gear of the feeder.
■Do not bring your head near the end of the welding torch during wire inching.
■Secure the end of the wire with the wire stopper on the spool when storing or
moving the spool of wire or when setting it in the wire feeder.
■When inserting the spool of wire into the wire guide on the wire feeder, firmly
hold the wire so that it will not be released.

IK-72T W2
- 7 -
CAUTION
Strictly observe the following to prevent fire, explosion, or burst.
■Spatters and hot base metal right after welding can cause tire.
■Imperfect connection of cables or imperfect contact on the route of the electric
current on the steel bar and other base metal can cause fire because of heating
due to resistance.
■Arcs generated on the container of gasoline or other inflammables can cause
explosion.
■welding of sealed tanks or pipes can cause bursts.
■Do not do welding in a place where scattered spatters will be in contact with
inflammables.
■Do not do welding in a place near inflammable gas.
■Do not bring hot base metal right after welding close to inflammables.
■Welding on ceilings, floors, an walls may cause fire on the hidden side. Remove
inflammables from the hidden side.
■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.
■Do not weld gas pipes filled with gas.
■Do not weld sealed tanks or pipes.
■Provide a fire extinguisher near the welding place to prepare for the worst.
■Do not weld a container that has inflammables inside.
■Do not have a lighter, matches, or other inflammables with you during welding.