ALL POSITION VARIABLE SPEED TRAVEL CARRIAGE MODEL GK-189-045 PARTS LIST & OPERATING INSTRUCTIONS Distributed by: Website: www.gullco.com GULLCO INTERNATIONAL LIMITED CANADA Phone: 905-953-4140 Fax: 905-953-4138 e-mail: sales@gullco.com GULLCO INTERNATIONAL INC. U.S.A. Phone: 440-439-8333 Fax: 440-439-3634 e-mail: ussales@gullco.com GULLCO INTERNATIONAL [U.K.] LIMITED - EUROPE Phone: +44 1257-253579 Fax: +44 1257-254629 e-mail: sales@gullco.co.uk GULLCO INTERNATIONAL PTY LIMITED - AUSTRALIA Phone: 61 (0) 7 5439-0701 Fax: 61 (0) 7 5439-0704 e-mail: ausales@gullco.com GULLCO INTERNATIONAL LIMITED INDIA Phone: 91-20-65260382 Fax: 91-20-26836656 e-mail: India.lo@gullco.com GULLCO INTERNATIONAL SHANGHAI LIMITED Phone: +8621-50460341 Fax: +8621-50463554 e-mail: gsuntech@sh163.net Revised: October 26, 2007 GD-026.doc
SAFETY INSTRUCTIONS Although the KAT II carriage is manufactured for safe and dependable operation, it is impossible to anticipate those combinations of circumstances which could result in an accident. An operator of the KAT II carriage is cautioned to always practice Safety First during each phase of operation, set-up and maintenance. Read and understand the operation manual before operating or performing service of this equipment. Become familiar with the machines operation, applications and limitations. Keep the operation manual in a clean area and always at a readily available location. This equipment is normally used to automate / semi-automate welding or cutting processes. These processes usually have any combination of the following; bright and hot arcs, flying sparks, fumes, ultra-violet and infra-red radiated energy, hot work-pieces, compressed gases, etc.. The onus is on the operator of this equipment to know, understand and follow all the safety precautions associated with the process being used. A careless operator invites troubles, and failure to follow safety practices may cause serious injury or even death. Important safety precautions are given in the following: Electrical Shock Prevention: Do not use the KAT II carriage in damp or wet locations. Do not expose the KAT II carriage to rain. Never carry the KAT II carriage by the cord or pull the cord to disconnect from the receptacle. Keep the cord from heat, oil and sharp edges. Inspect power cords periodically and replace if damaged. Inspect the security of cords periodically and repair if loose. Disconnect the power cord when not in use. Disconnect the power cord positively to prevent electrical shock before repair and service of the equipment. Bodily Injury Prevention: Do not wear loose clothing, jewelry or loose, long hair which may get caught into automatic systems or moving parts. Keep lifting handle dry, clean and free from oil and grease. Do not operate this equipment if ill or drowsy from medication or fatigue. Always keep the KAT II clean and in good working order. Report any unsafe condition for immediate correction. Important: Ensure that an adequate and well maintained weld return path is provided with good electrical contact. Failure to do so may result in the welding current passing through the carriage and damaging the wiring and electrical components. 1
Safety Instructions Cont... This label is attached to the KAT II carriage and its intent is to instruct all those concerned to read the manual before turning the unit on and before performing service, as well as to positively disconnect the unit from all power supplies before servicing. ALL THE SAFE PRACTICES AND PRECAUTIONS MAY NOT BE GIVEN IN WRITING. SOME ARE BASED ON COMMON SENSE, BUT OTHERS MAY REQUIRE TECHNICAL BACKGROUND TO EXPLAIN. 2
KAT II ALL POSITION VARIABLE SPEED TRAVEL CARRIAGE This parts list covers the operation and maintenance requirements of the Gullco All Position Variable Speed Travel Carriage, model number: GK-189-045 SPECIFICATIONS Speed Range: Weight of KAT II Carriage: Vertical Load Capacity: Motor: Supply Voltage: Complies with: 1-46 in/min [2.5-116.8 cm/min] No Load Horizontal 1.5-36.5 in/min [2.5-92.7 cm/min] Full Load Vertical 13.2 lbs. [6 kg] 50 lbs. [23 kg] 24 VDC permanent magnet gear motor Either 42, 115 or 230 VAC, single phase, 50/60 Hz. CE Certification GENERAL DIMENSIONS 3
GENERAL DESCRIPTION The Gullco KAT II variable speed travel carriage is the major component of an automated torch cutting system designed to improve cutting quality and to reduce the cost of cutting operations. Safety is greatly enhanced by the use of Gullco s low voltage (24 VDC), highly advanced control/power supply system that is available in three line voltage inputs...42, 115, and 230 VAC, single phase, 50/60 Hz. The motor and control are protected by slow-blow fuses. The carriage consists of a 24 VDC permanent magnet gear motor which engages the track through a set of spur gears. A drive engagement lever with its Push to Turn label is located on the side of the carriage. This feature also permits free-wheeling of the carriage for rapid positioning. The carriage is designed to run only on rigid, straight Kat track. ELECTRICAL CONNECTION INSTALLATION WARNING: Ensure proper earth grounding of the KAT II and auxiliary equipment before applying power. Failure to do so may invalidate the Gullco warranty. WARNING: Before connecting the KAT II carriage to a power source (receptacle, outlet etc.) be sure that the voltage supplied is the same as that specified on the nameplate of the carriage. If in doubt, DO NOT PLUG IN THE KAT II CARRIAGE. Copies of the possible nameplates are listed below: 4
As the colours of the wires in the mains lead of this equipment may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: The Green & Yellow or Green wire must be connected to the terminal in the plug which is allocated for Earth / Ground. The Blue or White wire must be connected to the terminal that is allocated for Neutral. The Brown or Black wire must be connected to the terminal that is allocated for Live. MECHANICAL INSTALLATION: The KAT II carriage is equipped with a handle for portability. The weight of the carriage is evenly distributed around the handle, however, if the KAT II carriage has had other equipment attached to it, uneven weight distribution may present a hazard when lifting. Therefore we recommend care and consideration should be given to removing uneven loads and /or any additions that may make the total weight of the equipment too heavy to be comfortably lifted. The drive engagement lever is the lever that extends out of the side of the carriage. This lever engages the drive gear with the rack on the track and must always be disengaged when fitting or removing the "KAT II" carriage from the ends of the track. It also permits free wheeling for rapid positioning. To engage the drive, push the lever in towards the carriage body and turn in an anticlockwise direction. To disengage the drive, push the lever in towards the carriage body and turn in a clockwise direction. WARNING: Never disengage the drive, when there is a possibility that this action may result in the equipment falling to the ground due to load. WARNING: Ensure that the track is well secured when installed in any other position than flat on a surface. The track must have a method of safety backup from falling when suspended, i.e., chained at the ends, welded to work-piece, etc. The KAT II carriage should slide onto the end of the KAT track and the wheel assemblies should fit securely to the sides. The wheel assemblies may require periodic adjustment. For proper operation of the KAT II ensure that the wheel assemblies are positioned properly on the KAT track and are firmly secured. See the following page for instructions. 5
KAT II CARRIAGE WHEEL ADJUSTMENT INSTRUCTIONS REFERENCE:- DRAWING GK-181-004 The KAT II wheel center distance C-D can be adjusted to accommodate minor variations of KAT track width. To ensure proper performance of the KAT II, adjustment can be made as follows:- 1. Positively disconnect/isolate carriage from power source. 2. Remove top cover to expose lower housing. 3. Loosen the 2 hex head screws, item (1) and turn adjustable spacer item (2) in order to increase of decrease the C-D dimension. When properly adjusted, hold bolt head (4) securely and retighten hex head screw (1). 6
OPERATION = STOP - This overrides all other controls and when activated will apply regenerative braking to the motor to bring it to a dead stop, and will disallow any further operation of the motor whenever it is in this state. = RUN - This removes the STOP command and allows the control to assume an operational status. = FORWARD - When the switch is in this position, the control will drive the motor in the Forward direction. = NEUTRAL - When the switch is in this position, the control will not drive the motor in either direction. = REVERSE - When the switch is in this position, the control will drive the motor in the Reverse direction. = VARIABLE SPEED CONTROL - By turning the rotary encoder knob in a clockwise direction, the motor speed will be increased. When rotated in the counter-clockwise direction, the motor speed will decrease. = POWER ON - When the switch is in this position, power is supplied to the carriage control system. = POWER OFF - When the switch is in this position, power is not supplied to the carriage control system. Note: The supply must be isolated elsewhere before removing any covers from this equipment 7
= POWER ON LED - indicates when power is being supplied to the carriage control and the unit is ready for operation. = REVERSE LED - indicates when the carriage is traveling in the reverse direction. = FOWARD LED - indicates when the carriage is traveling in the forward direction. = STOP LED - indicates when a stop command is present from the Run/Stop switch. MAINTENANCE The KAT II carriage is a rugged piece of equipment, and under normal conditions, it will give you years of trouble free service, if it is operated within the limits of its expected use and if the following maintenance points are adhered to: Clean all excess dust and spatter from the KAT II carriage regularly. Pay particular attention to the drive gear and wheel assemblies. Occasionally lubricate the wheel assemblies and the drive gear. A dry lubricant is preferred, but even light machine oil will help. Check wheel assemblies for proper fit with track and adjust as necessary (See page 5. for details). The motor and control are protected by a slow blow fuse, 5 amp for 42 VAC, 2.5 amp for 115 VAC and 1.25 Amp for 230 VAC. It is important that Fuse-tron slow blow or exact equivalent fuses are used. INSPECTION At least once per year, the equipment should be taken out of service, stripped down and all moving parts should be cleaned, greased and inspected for wear and damage. All cables must be inspected for breaks and abrasion and must be well secured. All damaged and worn parts should be replaced. All fastening devices should be inspected for tightness. NOTE: These inspections should be performed with greater frequency if conditions and usage requires. STORAGE The KAT II carriage should be kept in a dry environment with no possibility of impact or damage due to stacking of heavy objects on top of the KAT II. SHIPPING When shipping the KAT II carriage, the drive engagement lever must be in the disengage position and packing placed under the belly of the lower housing, in between the wheel assemblies but not resting on the drive gear. 8
KAT II CONTROL BOARD SCHEMATIC DRAWING NUMBER GK-189-050 REVISION 4 9
KAT II CARRIAGE LOWER HOUSING ASSEMBLY DRAWING NUMBER GK-181-005 10
KAT II CARRIAGE LOWER HOUSING ASSEMBLY REFERENCE:- DRAWING GK-181-005 ITEM PART NUMBER DESCRIPTION QTY 1 GK-181-003 KAT II WHEEL MOUNTING PLATE 1 GS-010-007 GEAR MOTOR WITH PINION (ITEMS 2, 14,15 & 32) 1 2 GK-189-040 24 VDC GEAR MOTOR (INCLUDES ITEM 32) 1 GK-181-006 CAM HOLDER & SUPPORT ASSEMBLY (ITEMS 3-9) 1 3 GK-181-016 CAM SHAFT SUPPORT ANGLE 1 4 GK-181-012 CAM LEVER 1 5 GK-111-051 1/4" I.D. x 5/8" O.D. FLAT WASHER 1 6 GK-116-003 3/8" O.D. x 9/32" I.D x 3/4" LONG SPRING 1 7 GK-117-006 Ø3/32" x 1/2" LONG SPRING PIN 3 8 GK-181-013 CAM 1 9 GK-181-011 CAM HOLDER 1 10 GK-112-054 #10-32 x 1/2"LONG ROUND HEAD SCREW 2 11 GK-181-002 KAT II MOTOR MOUNTING PLATE 1 12 GK-136-059 #8 LOCK WASHER 4 13 GK-112-052 #8-32 x 5/8" LONG ROUND HEAD SCREW 4 14 GS-010-011 14 TEETH PINION 1 15 GK-117-011 Ø3/32" x 5/8" LONG SPRING PIN 1 16 GK-104-051 Ø3/8" x 5/8" SOCKET HEAD SHOULDER SCREW 1 GK-181-018 LOWER GEAR ASSEMBLY (ITEMS 17 & 18) 1 17 GK-181-015 15 TEETH GEAR 1 18 GK-118-055 FLANGE BEARING 1 19 GK-104-070 Ø5/16" x 1/2" SOCKET HEAD SHOULDER SCREW 1 20 GK-108-066 5/16"-18 x 1/2" LONG HEX BOLT 4 21 GK-111-054 5/16" I.D. x 3/4" O.D.FLAT WASHER 6 22 GS-010-018 ADJUSTABLE V-WHEEL SPACER 2 23 GK-109-052 5/16"-18 HEX NUT 2 24 GK-112-084 #10-32 x 1/4" LONG ROUND HEAD SCREW 4 25 GK-108-085 5/16"-18 x 1 3/4" LONG HEX BOLT 2 GS-010-022 V-WHEEL ASSEMBLY (ITEMS 26-28) 4 26 GS-010-015 V-WHEEL 4 27 GS-010-023 BALL BEARING 4 28 GK-119-056 RETAINING RING 4 29 GS-010-017 V-WHEEL SPACER 2 30 GK-141-011 #10-32 x 1/2" LONG FLAT HEAD MACHINE SCREW 4 31 GK-181-014 POST 1 32 GK-156-003 2 TERMINAL MOTOR CONNECTOR (NOT SHOWN) 1 11
KAT II CARRIAGE UPPER HOUSING ASSEMBLY DRAWING NUMBER GK-189-010 12
KAT II CARRIAGE UPPER HOUSING ASSEMBLY REFERENCE:- DRAWING GK-189-010 ITEM PART NUMBER DESCRIPTION QTY 1 GK-181-001 KAT II TOP COVER 1 2 GL-190-019 "PUSH TO TURN " NAMEPLATE 1 3 GK-171-032 POWER CORD 1 4 GK-148-014 STRAIN RELIEF 1 5 GK-156-047 3-TERMINAL CORD CONNECTOR 1 6 GK-153-013 HANDLE (WITH SCREWS) 1 GK-189-049 KAT II CONTROL ASSEMBLY (ITEMS 7-25) 1 7 GK-189-050 CIRCUIT BOARD ASSEMBLY (INCLUDING ITEMS 10 & 12) 1 8 GK-189-048 FACE PLATE 1 9 GK-141-018 #4-40 x 3/8" FLAT HEAD MACHINE SCREW 2 10 GK-191-P-100 FORWARD / REVERSE SWITCH 1 11 GK-191-P-097 SPEED SELECTOR KNOB 1 12 GK-191-P-052 RUN / STOP SWITCH 1 13 GK-165-134 FUSE HOLDER 1 GK-165-098 5 AMP SLOW BLOW FUSE FOR 42 V AC 14 GK-165-099 2.5 AMP SLOW BLOW FUSE FOR 115 V AC 1 GK-165-097 1.25 AMP SLOW BLOW FUSE FOR 230 V AC 15 GK-191-P-022 POWER ON/OFF SWITCH 1 16 GK-191-P-056 NUT 3 17 GK-129-014 INTERNAL LOCK WASHER 3 18 GK-165-133 METAL NUT FOR FUSE HOLDER 1 GK-189-039 ELECTRICAL ASSEMBLY (ITEMS 19-25) 1 19 GK-141-021 #6-32 x 3" FLAT HEAD MACHINE SCREW 1 20 GK-189-046 TRANSFORMER MOUNTING RUBBERS 2 21 GK-191-P-153 TRANSFORMER (SPECIFY 42 V AC, 115 V AC OR 230 V AC SUPPLY) 1 22 GK-189-047 TRANSFORMER MOUNTING PLATE 1 23 GK-191-P-020 BRIDGE RECTIFIER (MDA 2500) 1 24 GK-135-054 #6-32 HEX HEAD LOCK NUT 1 25 GK-189-042 CAPACITOR (4700 µf @ 40 V) 1 26 GK-141-014 #6-32 x 5/16" LONG FLAT HEAD MACHINE SCREW 6 27 GK-141-001 #8-32 x 1/2" LONG FLAT HEAD MACHINE SCREW 1 28 GK-136-059 #8 LOCK WASHER 1 29 GK-135-058 #8-32 LOCK NUT 1 30 GK-191-P-128 LINE CORD INTERFACE HARNESS (NOT SHOWN) 1 13
REVISIONS LIST December, 2000 Title Page Gullco Canada & Gullco India phone and fax numbers changed. Page 1 Added Important note regarding weld grounding. Page 11 Item # 13 was GK-112-051, now GK-112-052 Multiple Re-arranged and re-numbered pages. January, 2002 Page 13 Item # 10 was GK-189-051, now GK-191-P-100. Page 13 Item # 12 was GK-189-052, now GK-191-P-052. December, 2002 Title Page Updated Gullco UK & Gullco Australia s phone and fax numbers. June, 2006 Title Page Page 4 Added Gullco International Shanghai contact details. Updated nameplate labels. October, 2007 Title Page Updated Gullco contact details. ADDITIONAL NOTES Specifications and products are subject to change without notice. KAT, Moggy, Sam, KATBAK & KBM are registered trademarks of Gullco International Enterprises Ltd. Only use genuine/authorized replacement parts. 14
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