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Koike Sanso Kogyo AUTO PICLE-S Manual

Remote control gas motorized pipe cutting machine
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AUTO PICLE-S
REMOTE CONTROL GAS MOTORIZED PIPE CUTTING MACHINE
KOIKE SANSO KOGYO CO.,LTD.

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Summary of Contents for Koike Sanso Kogyo AUTO PICLE-S

  • Page 1 AUTO PICLE-S REMOTE CONTROL GAS MOTORIZED PIPE CUTTING MACHINE KOIKE SANSO KOGYO CO.,LTD.

  • Page 2: Table Of Contents

    AUTO PICLE-S CONTENTS 1 Safety information ..................5 1.1 Introduction .................... 5 1.2 General machine safety precautions ............. 5 1.2.1 Machine safety ................5 1.2.2 Safety clothing ................6 1.2.3 Electrical system precautions ............6 1.2.4 Maintenance and inspection precautions ........6 1.3 General Gas cutting safety precautions ..........
  • Page 3 AUTO PICLE-S 5.5 Cutting operation ................. 28 5.5.1 Bevel cutting ................28 5.5.2 Vertical cutting ................29 6 Maintenance and inspection ............... 31 6.1 Disassembly ..................31 6.1.1 Disassembly for maintenance and inspection of electric parts .. 31 6.1.2 Disassembly for maintenance and inspection of the gear case 32 6.2 Daily inspection ...................
  • Page 4 AUTO PICLE-S 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 5 AUTO PICLE-S 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...

  • Page 6: Safety Information

    AUTO PICLE-S 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 7: Safety Clothing

    AUTO PICLE-S no gas leak with a detection liquid. If a gas leak is found, retighten the nut firmly. • Never disassemble the machine other than during maintenance and inspection. Otherwise, malfunction will result. • Never remodel the machine. Remodeling is very dangerous.

  • Page 8: General Gas Cutting Safety Precautions

    AUTO PICLE-S General Gas cutting safety precautions Strictly observe the safety rules and precautions to ensure the safety of gas cutting operations. Operators and supervisors MUST keep safety in mind. 1.3.1 Prevention of explosion 1 Never cut pressurized cylinders or hermetically sealed containers.

  • Page 9: Safety Precautions For Fire

    AUTO PICLE-S 7 Cut hoses to the minimum possible length. Short hoses reduce hose damage and pressure drop, as well as reduce the flow resistance. 1.3.5 Safety precautions for fire Take safety precautions to prevent fire prior to gas cutting.

  • Page 10: Operating And Handling Safety Precautions

    AUTO PICLE-S 1.4 Operating and handling safety precautions 1 Mount and center the machine correctly and confirm correct motion before operation. 2 Check that the power switch is in the OFF position, before supplying power. 3 Prior to operating the machine, check the safety of the surroundings to avoid accidents.
  • Page 11 AUTO PICLE-S...

  • Page 12: Locations Of Safety Labels

    AUTO PICLE-S 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.
  • Page 13 AUTO PICLE-S...

  • Page 14: Outline Of Machine

    The AUTO PICLE-S is a remote control gas motorized pipe cutting machine. AUTO PICLE-S is a compact pipe cutter developed on the basis of the through going examination of the actual conditions of pipeline installation work sites. The machine will exhibit excellent performance in straight and bevel cutting of all sizes of pipes, which accounts for most of pipe cutting work, being habitually used by many users.

  • Page 15: Name And Function Of Each Section

    AUTO PICLE-S 3.2 Name and function of each section 1. Wheel 10. Gas distributor Four wheels permit the machine to Division into preheating oxygen, run stable on pipes. preheating gas and cutting oxygen. 2. Chain 11. Clutch lever The machine attached to the rail Used to run the machine.

  • Page 16: Specifications

    AUTO PICLE-S 3.3 Specifications Weight: 15 kg Machine size: 270 x 230 x 400 Power source: 110/42V +/- 10% Speed control: SCR control with dial operation Cutting speed: 100 - 700 mm/min Cutting thickness: 50 mm Bevel angle: 0° - 45°...
  • Page 17 AUTO PICLE-S Option Guide rail: pipe cutting diameter D-600 ø400 - ø600 D-900 ø600 - ø900 D-1200 ø900 - ø1200 D-1500 ø1200 - ø1500...

  • Page 18: Preparation For Operation

    AUTO PICLE-S Preparation for operation 4.1 Contents of package Carefully take the machine out of the case. First, please check your unit to make sure it is complete. The following is a list of the parts you should receive. Body...

  • Page 19: Machine Assembly

    AUTO PICLE-S 4.2 Machine assembly figure 4 - 1 1 Carefully take the main unit out of its case. 2 Remove the slide spring and stopper attached to the slide bar. 3 Put the slide spring and stopper back to their positions in this order.

  • Page 20: Connecting The Gas Supply Hose

    AUTO PICLE-S 3 Fully tighten the screw-threaded metal plugs so that they will not come loose during operation. 4.3.2 Connecting the gas supply hose Caution Carefully check the jet oxygen (JO), preheating oxygen (PO), preheating gas and respective marking before connecting hoses to the torch and distributor.

  • Page 21: Determining The Number Of Chains

    AUTO PICLE-S 4.3.4 Determining the number of chains The relationship between the pipe Outside Diameter and the number of chains is as follows: y = x + 11 y = the number of chains (Unit: cm; Round off the value in x = Pipe Outside Diameter mm to the next value in cm.)

  • Page 22: Assembling And Mounting The Guide Rail

    AUTO PICLE-S 1-2mm 120% figure 4 - 2 4.3.6 Assembling and mounting the guide rail 1 Assembling the rail a Attach the supporting bases (set) at intervals of 120 mm to the guide rail that matches the pipe diameter. b Change the number of supporting bases (set), taking into...
  • Page 23 AUTO PICLE-S 2 Installation of the guide rail. a Secure the pipe to the cut and mark a line 450-mm away from the cutting position. (4 locations along the periphery). b Wind the guide rail along the marked line. c Set the adjusting shaft (2) (see figure 4 - 3) in alignment with the hole (while the hand clamp is being tightened) d Secure the guide rail by tightening the adjusting nut.

  • Page 24: Trial Operation

    AUTO PICLE-S e Insert the two hand clips alternately into the hole in the overlapping section of the upper and the lower guide rail as shown in figure 4 - 4, in order to prevent lateral misalignment of the guide rails.
  • Page 25 AUTO PICLE-S...

  • Page 26: Safety Measures Prior To Operation

    AUTO PICLE-S 5.1 Safety measures prior to operation Strictly observe the safety rules, precautions and instructions to ensure safety during gas cutting operations. Operators and supervisors MUST keep safety in mind. 5.1.1 Grounding the machine The cable of this machine is equipped with a grounding wire.

  • Page 27: Ignition And Flame Adjustment

    AUTO PICLE-S 1 Operate the power switch for start-stop changeover. 2 Be sure to set it in the stop position unless the machine is to be moved. 5.2 Ignition and flame adjustment Adjust the gas pressure according to the Cutting Data. The data shows the pressure when all the valves are open.

  • Page 28: Cutting And Piercing Method

    AUTO PICLE-S 5.3 Cutting and piercing method • Cut in from the end of steel plate. • Pierce steel plate before cutting. • Drill a hole before cutting. Piercing method 1 Ignite and adjust the flame. 2 Thoroughly preheat the cut-in point until it is white hot.

  • Page 29: Cutting Operation

    AUTO PICLE-S Should flashback occur, find the cause and take appropriate action before using the machine again. 5.5 Cutting operation 1 Attach the chain to the section to cut and align the tip with the cutting start-up point. 2 Bring a flame close to the tip for ignition and ensure sufficient preheating.

  • Page 30: Vertical Cutting

    AUTO PICLE-S 5.5.2 Vertical cutting Vertical cutting is possible for max. 500 dia. pipes. Be sure to firmly set the guide rail at that time. figure 5 - 4...
  • Page 31 AUTO PICLE-S...

  • Page 32: Maintenance And Inspection

    AUTO PICLE-S 6 Maintenance and inspection Refer to the following for inspection and maintenance of the machine and use the machine under the best operating conditions at all times. Maintenance is only to be conducted by a qualified professional. 6.1 Disassembly 6.1.1 Disassembly for maintenance and inspection of electric parts...

  • Page 33: Disassembly For Maintenance And Inspection Of The Gear Case

    AUTO PICLE-S 6.1.2 Disassembly for maintenance and inspection of the gear case Disassemble the gear case in the same manner as the maintenance and inspection of the motor in section 6.1.1. Remove the four round crosshead screws (M6x16) (8) that are securing the casing (9) and apply the notemp grease to the gear case.

  • Page 34: Troubleshooting

    AUTO PICLE-S Troubleshooting Repairs are only to be conducted by a qualified professional. 1 The machine will not move (The motor will not run) Problem Possible cause Solution Power is not Check the power supply. Replace the power supplied Check the connections.
  • Page 35 AUTO PICLE-S 2 Speed cannot be controlled (The motor runs) Problem Possible cause Solution Defective speed Remove the connector of SCR control and apply Replace the control resistor the probes of a tester to resistor terminals 2 and 1, defective resistor.
  • Page 36 AUTO PICLE-S Abrasion of the clutch key. Replace or repair. Excessive play between the shaft and the drive Replace or repair. wheel. Hoses or cabtyre cords hinder smooth running. Pay attention during operation. Flaws on the drive and the drive wheel or adhesion Replace or repair.
  • Page 37 AUTO PICLE-S...

  • Page 38: 8Wiring Diagram And Assembly Drawing

    AUTO PICLE-S 8 Wiring diagram and assembly drawing 8.1 Wiring diagram 10 -1A TR4 TR3 TR2 TR1 figure 8 - 1 1. Body 8. Scr control 2. Motor 15W 5000 RPM 9. Variable resistor 50k (B.1/4W) 3. SW3 switch 10. F Fuse (2A) 4.

  • Page 39: Assembly Drawing

    AUTO PICLE-S 8.2 Assembly drawing figure 8 - 2...

  • Page 40: Parts List

    AUTO PICLE-S 9 Parts list 9.1 Body unit...
  • Page 41 AUTO PICLE-S Body unit Item Description Q’ty Stock no. Remarks Slide body 32412 Slide body cover 32413 Cross feed body 32414 Torch holder bracket 32415 Slide bar 32416 Guide roller base 32417 Guide roller bracket 32418 Guide roller 32419 Slide spring...
  • Page 42 AUTO PICLE-S Body unit Item Description Q’ty Stock no. Remarks Screw 222.004.763 M5x12 222.004.401 M12 with WF NH-12 Spring pin 222.004.856 ø3x20 PR-3x10 Screw 222.104.315 M6 With Nut SS-6x15 Screw 222.004.232 M5x18 BC-5x18 Wing bolt 222.004.685 M4x10 BS-4x10 Wing bolt 222.004.686...

  • Page 43: Driving Unit

    AUTO PICLE-S 9.2 Driving unit...
  • Page 44 AUTO PICLE-S Driving unit Item Description Q’ty Stock no. Remarks Reduction gear box 32400 Casing 61000887 Gear assembly 61001127 Screw 6C520320 Gear (B) 32404 Gear shaft (B) 32405 Collar (B) 32406 Clutch lever 32407 Casing (D) 32408 Pinion 31312 Casing (A)
  • Page 45 AUTO PICLE-S Driving unit Description Q’ty Stock no. Remarks No.2 worm assembly 32469 Double thread Carbon cap 33365 Carbon brush 30752...

  • Page 46: Electrical And Gas Unit

    AUTO PICLE-S 9.3 Electrical and gas unit...

  • Page 47: Screw

    AUTO PICLE-S Electrical and gas unit Item Description Q’ty Stock no. Remarks Motor cover (A) 32422 Motor cover (B) 32423 Control box 61001001 Operation panel 32450 Name plate 32451 Torch 10055 KE only Distributor 31846 Except USA Switch 35226 S-333...

  • Page 48: Nut

    AUTO PICLE-S Electrical and gas unit Item Description Q’ty Stock no. Remarks Terminal 31666 Isolation washer 36374 WP-1 Spacer 36049 SP-5 Srew 222.004.702 M3x5 Screw 222.004.702 M3x5 Controller 69000105 Transformer 6100472 For 100 - 220V Transformer 6100672 For 230 - 240V...

  • Page 49: Guide Rail

    AUTO PICLE-S 9.4 Guide rail...

  • Page 50: Spring Pin

    AUTO PICLE-S Guide rail Item Description Q’ty Stock no. Remarks Guide rail base 32434 Liner 32435 Hand clamp base plate 32436 Hand clamp bracket 32437 Hand clamber 32438 Adjusting shaft (A) 32439 Adjusting nut 32440 Adjusting shaft (B) 32441 Setting shaft for spring plate (A)
  • Page 51 AUTO PICLE-S...

  • Page 52: Cutting Data

    AUTO PICLE-S 10 Cutting Data 102 HC (Standard Speed) for Acetylene Fuel Oxygen pressure Plate Cutting Kerf Tip size thickness speed width (kg/cm pressure (mm) (mm/min) Cutting Preheat (mm) (kg/cm 12.5 0.25 0.25 0.25 0.25 102-D7 (High Speed) for Acetylene...
  • Page 53 AUTO PICLE-S 106 HC (Standard Speed) for Propane Fuel Oxygen pressure Plate Cutting Kerf Tip size thickness speed width (kg/cm pressure (mm) (mm/min) Cutting Preheat (mm) (kg/cm 12.5 0.25 106-D7 (High Speed) for Propane Fuel Oxygen pressure Plate Cutting Kerf...

  • Page 54: Chain

    AUTO PICLE-S is a remote control gas motorized pipe cutting machine. The special rail for torch/tip guidance system provides high cutting accuracy and makes the AUTO PICLE-S particularly suitable for large pipes. Features Designed specially for pipe cutting, it is highly portable and very easy to set up.

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