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Koike Sanso Kogyo EDGE-CUT Operation Manual

Portable automatic gas cutting machine
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Portable Automatic Gas Cutting Machine
BBF00B12
■
OPERATION MANUAL
Read and understand the contents of this
Manual carefully before operating, inspecting
and servicing this product.
KOIKE SANSO KOGYO CO., LTD.

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Summary of Contents for Koike Sanso Kogyo EDGE-CUT

  • Page 1 Portable Automatic Gas Cutting Machine BBF00B12 ■ OPERATION MANUAL Read and understand the contents of this Manual carefully before operating, inspecting and servicing this product. KOIKE SANSO KOGYO CO., LTD.
  • Page 3 INTRODUCTION Thank you very much for purchasing this product. Read this Operation 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.
  • Page 4 Symbol Title Meaning General General caution, warning, and danger. Be careful not to get your Possible injury to fingers if caught in the insertion fingers caught. port. Caution: Electric shock! Possible electric shock under special conditions. Ground this equipment. Operators must ground the equipment using the safety grounding terminal.

  • Page 5: Table Of Contents

    EDGE-CUT CONTENTS 1. Safety Information ■ WARNING ■ CAUTION ■ NOTICE SIGNS 1.1 General machine safety precautions 1.1.1 Machine safety 1.1.2 Safety clothing 1.1.3 Operation and handling safety precautions 1.1.4 Electrical system precautions 1.1.5 Maintenance and inspection precautions 1.2 Gas cutting safety precautions 1.2.1 Prevention of explosion...
  • Page 6 EDGE-CUT 6.5 Yearly or every 2000-hour inspection 7. Troubleshooting 8. Wiring diagram 9. Assembly drawing EDGE-CUT 9.1 Off-center type 9.2 Type 100 10. Parts list 10.1 Drive unit 10.2 Main body and electric components 10.3 Holder and distributing components 10.4 Option 10.4.1 Type 100...

  • Page 7: Safety Information

    EDGE-CUT 1 Safety information Many accidents are caused by operation, inspection, and maintenance which disregard the basic safety rules. Carefully read, understand, and master the safety measures and precautions described in this instruction manual and on the machine before operating, inspecting, and maintaining the machine.

  • Page 8: Operation And Handling Safety Precautions

    EDGE-CUT 1.1.3 Operation and handling safety precautions 1. Read this instruction manual before operating the machine. 2. Mount and center the machine correctly and confirm correct motion before operation. 3. Before connecting the power plug to the outlet, make sure that the power switch is in the OFF position (or the normal/reverse changeover switch is in the stop position).

  • Page 9: Gas Cutting Safety Precautions

    EDGE-CUT 1.2 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. 1.2.1 Prevention of explosion 1. Never cut pressurized cylinders or hermetically sealed containers.

  • Page 10: Safety Precautions For Skin Burns

    EDGE-CUT 1.2.6 Safety precautions for skin burns Observe the safety precautions to prevent skin burns. Ignoring heat, spatter, and sparks during operation could cause a fire or burned skin. 1. Do not perform cutting near flammables. (Move flammables well away from the sparks.) 2.

  • Page 11: Locations Of Safety Labels

    EDGE-CUT 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 12: Outline Of The Machine

    Outline of the machine Features of the machine The EDGE-CUT achieves high-quality cutting of the X-shaped grooves only by one unit although it has conventionally been done by two portable cutting machines. By copying the sheet steel edge with a roller, high-quality groove cutting is possible. This machine has originally been developed as a result of intensive research of the field work in users’...
  • Page 13 EDGE-CUT Cross feed handle A’ssy Positional regulation of the torch in horizontal position Vertical handle A’ssy Positional regulation of the torch in vertical position Off-center torch Cuts a maximum length of 50 mm of grooves NOTE) A type 100 torch is also available...

  • Page 14: Specifications

    EDGE-CUT Specifications Item Specifications Model EDGE-CUT Overall length 402 mm Overall weight Off-center type: 11.5 kg, Type 100: 12.5 kg Cutting thickness Up to 50 mm in groove cutting length Groove angle 0 ~ 45º Cutting speed 100 ~ 1000 mm/min...

  • Page 15: Preparation For Operation

    EDGE-CUT Preparation for operation Contents of package The standard package includes the following items. Check the contents before assembling. Construction Off-center type Type 100 〇 〇 Main unit 〇 〇 Valve with preset function Torch 300-type Type 100 × 〇...

  • Page 16: Assembly Of The Machine

    EDGE-CUT Assembly of the machine 1. Take out the main unit from the package. 2. Mount the weight on the horizontal bar (only for the type 100 specification) 3. Connect the primary hose to the valve with a preset function.

  • Page 17: Use Of Valve With Preset Function

    EDGE-CUT 4.3.4 Use of valve with preset function (1) = Close Shuts off gas flow even when an adjusting valve is opened (2) = Ignite Supplies preheating oxygen and fuel gas Once the flame is adjusted, setting the lever to this position and igniting achieve an appropriate preheating flame at all times.

  • Page 18: Cutting Operation

    EDGE-CUT Cutting operation Safety measures to take before operation 5.1.1 Grounding of earth cable As safety measures for operators, check first that the input current and voltage are appropriate and the power connection is correct. ■ Grounding of Earth Cable ・The ground pin is attached to the rubber plug of a cabtyre cord.

  • Page 19: Ignition And Flame Adjustment

    EDGE-CUT Ignition and flame adjustment  Before ignition, adjust the gas pressure, referring to the Tip Nozzle Capacity Standard Table. The pressure listed in the table indicates a value when all valves are opened. After ignition, correct and adjust the pressure as required. (Refer to Page 29.) ■...

  • Page 20: Groove Cutting

    EDGE-CUT 5.3.1 Groove cutting When cutting in the inclined direction to make a groove, fix the blow pipe at a desired angle referring to the angle scale (5º/scale) on the blow pipe support. Since dimension L shown below is used as plate thickness in calculation, select the tip nozzle based on this dimension.

  • Page 21: Maintenance And Inspection

    EDGE-CUT Maintenance and inspection Inspect and take care of the machine, referring to the procedure below, in order to use the machine in the best conditions. Disassembly of the machine 1. Dismount the handle (1) from the main unit. 2. Dismount the holder (3) of the following torch from the horizontal bar (2), and disconnect the distribution hose from each twin valve (4) with a preset function.

  • Page 22: Disassembly For Maintenance And Inspection Of The Gear Box

    EDGE-CUT Disassembly for maintenance and inspection of the gear box 1. Loosen the set screw (2) of the clutch joint (A) (1) inside the gear box, and dismount the clutch shaft (3) and the clutch joint (A) from the gear box.

  • Page 23: Semi-Yearly Every 1000-Hour Inspection

    EDGE-CUT Semi-yearly or every 1000-hour inspection 1. Remove dust from the control board and transformer attached to the case. 2. Check if there is sufficient grease in the gear box. If not, supply it. Yearly or every 2000-hour inspection 1. Disassemble and clean the gear box, and supply a moderate amount of grease.

  • Page 24: Troubleshooting

    EDGE-CUT Troubleshooting 1. The machine does not operate. (The motor does not rotate.) Cause Check Point Measures 1) Power is not Check the power supply and power supplied. cord connection. 2) The power cord is Check the cord for continuity using a Repair the disconnection disconnected.
  • Page 25 EDGE-CUT 2. The machine does not operate. (The motor is rotating.) Cause Check Point Measures 1) The machine Dismount the cover from the gear box, Disassemble to clean and malfunctions. and check the clutch for operation. repair. 2) The reduction gears The motor rotates even when the drive Replace the gear head.

  • Page 26: Wiring Diagram

    EDGE-CUT 8 Wiring diagram SPECIFICATION OF TRANSFORMER SUPPLY TERMINAL TERMINAL VOL TAGE (PRIMARY) (SECONDARY) 100V 110V 120V 200V 220V 230V 240V －20－...

  • Page 27: Assembly Drawing Edge-Cut

    EDGE-CUT 9 Assembly drawing of EDGE-CUT 9.1 Off-center type －21－...

  • Page 28: Type 100

    EDGE-CUT 9.2 Type 100 （521） （35） （402） －22－...

  • Page 29: Parts List

    EDGE-CUT 10 Parts list 10.1 Drive unit －23－...
  • Page 30 EDGE-CUT Drive unit Q’ty Item No. Part name Stock No. Remarks Gear box 61003558 Idle wheel A’ssy 60036804 Collar 60036806 Gear box cover 61003561 Drive wheel 61003549 Drive shaft A’ssy 61005717 with key Clutch (A) 60036404 Worm gear 60036406 Teflon packing...

  • Page 31: Main Body And Electric Components

    EDGE-CUT 10.2 Main body and electric components To the Motor －25－...
  • Page 32 EDGE-CUT Main body and electric components Q’ty Item No. Part name Stock No. Remarks Lower casing 61003559 Grip 61003560 Cover 60036813 Clutch lever 60036825 Clutch joint A’ssy (A) 60036827 Clutch joint A’ssy (B) 60036828 Base plate mounting brackets 60036908 Lever shaft...

  • Page 33: Holder And Distributing Components

    EDGE-CUT 10.3 Holder and distributing components －27－...
  • Page 34 EDGE-CUT older and distributing components Item No. Part name Q’ty Stock No. Remarks Cross feed table A’ssy 60036848 Cross bar 60036849 Support base 60030566 Holder support 60030567 Square thread 60030565 40 handle 60030223 φ 14 pinion 60030557 φ 60030558 Cross feed pinion...
  • Page 35 EDGE-CUT 10.4 Option 10.4.1 Typ100 －29－...

  • Page 36: Type 100

    EDGE-CUT Type 100 Item No. Part name Q’ty Stock No. Remarks Cross bar (300L) A’ssy 61003672 Type 100 Support base 60030566 Holder support 61003727 Square thread 60030565 60030223 φ40 handle Handle 60031628 Pinion 60031627 Calibration collar 60030906 with screw Hexagon bolt...

  • Page 37: Cutting Data

    EDGE-CUT 11 Cutting data 11.1 Tip nozzle (Type 300) 301-302 For Acetylene PRESSURE (MPa)/(kg/c ㎡) TIP SIZE Flux (nl/h) PLATE CUTTING THICKNESS SPEED CUTTING PREHEAT (mm) (mm/min) (301) (302) (00) 0.18/1.8 1,000 0.20/2.0 0.020/0.20 1,500 0.25/2.5 1,800 0.30/3.0 0.025/0.25 2,900 0.35/3.5...

  • Page 38: Tip Nozzle (Type 100)

    EDGE-CUT 11.2 Tip nozzle (Type 100) 102(STANDARD SPEED) For Acetylene OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF (Mpa) / (kg/c ㎡) PRESSURE THICKNESS SPEED WIDTH SIZE (Mpa) / (kg/c ㎡) (mm) (mm/min) (mm) CUTTING PREHEAT 0.15 / 1.5 0.15 / 1.5 0.02 / 0.2...
  • Page 39 EDGE-CUT 106(STANDARD SPEED) For Propane OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF (Mpa) / (kg/c ㎡) PRESSURE THICKNESS SPEED WIDTH SIZE (Mpa) / (kg/c ㎡) (mm) (mm/min) (mm) CUTTING PREHEAT 0.15 / 1.5 0.15 / 1.5 0.02 / 0.2 0.2 / 2.0 0.2 / 2.0...
  • Page 40 EDGE-CUT OPERACTION MANUAL Date of issue: Oct.2005 Dec.2005 Mar.2006 Sep.2006 Jun.2007 Mar.2008 Jul.2008 Nov.2011 Jan.2013 10th May.2016 11th Dec.2016 12th Feb.2018 13th Feb.2023 KOIKE SANSO KOGYO CO., LTD. Printed in Japan...

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