Koike Sanso Kogyo IK-70 Operation Manual

Portable automatic gas cutter

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Portable Automatic Gas Cutter

Small Circle Cutter

OPERATION MANUAL

For every person who will be engaged in

operation and maintenance supervision, It is

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Summary of Contents for Koike Sanso Kogyo IK-70

Page 1 Portable Automatic Gas Cutter BFB00B19 Small Circle Cutter OPERATION MANUAL For every person who will be engaged in operation and maintenance supervision, It is recommended to read through this manual before operations, permit optimum operation of this machine. KOIKE SANSO KOGYO CO.,LTD.
Page 3 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.
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
IK-70 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 Operations 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 2) The speed cannot be controlled. (The motor is running.) 3) The machine will not move.(The motor runs.) 4) The machine moves but the operation is not normal. 8. Wiring diagram 9. Assembly drawing of IK-70 10. Parts list 10.1 Gear unit 10.2 Rotary distributor unit 10.3 Speed adjusting unit...
Page 7: Safety Information
IK-70 Safety information Many accidents are caused by operation, inspetion, 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: Operations And Handling Safety Precautions
IK-70 2.Avoid operating the machine with wet clothes or hands in order to prevent electric shock. 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.
Page 9: Gas Cutting Safety Precautions
IK-70 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
IK-70 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.Do not cut containers filled with flammables.
Page 11: 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 t he machine. Never remove the labels. Keep them clean and legible at all times. IK-70 Model 600 －5－...
Page 12: Outline Of Machine
Therefore, it exhibits excellent functions in hole making operations in the shipbuilding industry. IK-70 (Small Circle Cutter) has been designed on the basis of a variety of circle cutters developed in the past, pursuing the operability from the human engineering stand point. Designed and manufactured...
Page 13: Specifications
IK-70 3.3 Specifications Model 600 Weight: 24 kg Body: 17kg Stand: 7 kg ±10% Power source: Speed control: control with dial operation Torch rotation speed: 0.2-6 rpm Cutting thickness: 5～50 mm ※There is a range that cannot be cut depending on the relationship between cutting thickness and cutting diameter.
Page 14: Preparation For Operation
IK-70 4 Preparation for operation 4.1 contents of package The contents of the standard package are shown below. Check them carefully before assembling the machine.  Body: 1 set  Gas distributor: 1 set  Torch holder: 1 set ...
Page 15: Preparation For Operation
IK-70 4.3 Preparation for operation 4.3.1 Connecting the power cable 1. Connect the power cable to the body. 2. Before plugging the metal plug on the power cord side into the socket on the machine side, check there is no dust inside.
Page 16 IK-70 2. Set the clutch lever in the N (neutral) position, turn the graduated pipe by hand, and adjust the leg opening angle and the horizontal arm length so that the torch and hoses will not touch the legs and shaft column.
Page 17 IK-70 Relationship between the cutting plate thickness and cutting diameter (Model 1000) L (low-speed) range Thickness(mm) 5-10 10-15 15-30 30-40 40-50 Cut speed(mm/min) 550-660 490-550 400-490 350-400 320-350 200-320 Cut diameter φ150 0.42 Not use Not use Not use Not use...
Page 18: Cutting Operation
IK-70 5 Cutting operation 5.1 Safety measures prior to operation 5.1.1 Grounding the machine The cable of this machine is equipped with a grounding wire. For safety, be sure to ground the wire as follows, in addition to checking the connection of the power cable.
Page 19: Cutting And Piercing Method
IK-70 4. Appropriate distance between the tip end and cutting surface: ・Acetylene gas 8-10 mm ・LPG gas 5-8 mm Neutral flame ensures good quality cut surfaces. (Oxygen flame may be used for bevel cutting.) Oxygen flame causes short cutting-oxygen current, allowing slugs to adhere, melting the upper edge of the cutting surface, and causing adverse effects on the cut surface.
Page 20: Safety Measures Against Backfire And Flashback
IK-70 5.5 Safety measures against backfire and flashback 5.5.1 Prevention of backfire Backfires may cause serious accidents or fires. Be careful to prevent such disaster. When a backfire occurs, find the cause and inspect and maintain the machine correctly before using the machine again.
Page 21: Cutting Operation
IK-70 5.6 Cutting operation 5.6.1 Bevel cutting For bevel cutting, use the angle graduation (45 degrees to the right and left from the 0 degrees; 1 division = 5 degrees) on the torch holder to fix the torch at the desired angle.
Page 22: Maintenance And Inspection
IK-70 6 Maintenance and inspection Inspect and maintain the machine as shown below in order to use the machine under the best conditions. 6.1 Disassembly of the machine Disassemble the machine as follows: 1. Remove the torch. 2. Remove the arc rotation unit from the base shaft.
Page 23: Troubleshooting
IK-70 7 Troubleshooting 1) The machine will not move. (The motor will not run.) Cause Inspection point Correction 1)Power is not supplied. Check the power supply. Replace the power supply Check the connections. if it is defective 2)Fuse blown Check the 1A fuse in the control box to Replace the blown fuse.
Page 24: The Machine Will Not Move.(The Motor Runs.)
IK-70 3) The machine will not move. (The motor runs.) Cause Point to be checked Correction (A) Reduction gear slips. 1) Gear table and reducer Remove the reducer box and run the Repair or replace. box slip motor. When the 8th gear will not turn, overhaul the gear table.
Page 25: Wiring Diagram
IK-70 8 Wiring diagram 9 Assembly drawing of IK-70 Model 600 Model 1000 －19－...
Page 26: Parts List
IK-70 10 Parts List 10.1 Gas unit - 20 -...
Page 27 IK-70 Gas unit Item Part name Q’ty Stock No. Remarks Torch holder assembly 60030992 Torch holder 60031351 Graduation collar 60030906 Pinion assembly 60030908 Handle 60030223 Diameter 40 mm ※1 Pinion metal (A) 60030909 Pinion (A) 60030910 ※1 Torch holder bracket...
Page 28: Rotary Distributor Unit
IK-70 10.2 Rotary distributor unit - 22 -...
Page 29 IK-70 Rotary distributor unit Item No. Part name Q’ty Stock No. Remarks Distributor assembly 60030919 Except USA Distributor assembly 60030978 USA only Distributor cover 60032107 Except USA Distributor cover 60032136 USA only Nut for Oxygen 60015001 Nut for Oxygen 60015056...
Page 30: Speed Adjusting Unit
IK-70 10.3 Speed adjusting unit - 24 -...
Page 31 IK-70 Speed adjusting unit Item No. Part name Q’ty Stock No. Remarks Gear box assembly 60032150 With screw Ring 60032137 Worm wheel 60032118 ※1 8th gear shaft 60032123 ※1 Collar F 60030930 8th gear 60032122 ※1 Worm shaft assembly 60032132...
Page 32: Control Panel
IK-70 10.4 Control panel - 26 -...
Page 33 IK-70 Control panel Item No. Part name Q’ty Stock No. Remarks Control box 60032152 Control panel 60030936 Variable resistor 60030745 50 KΩ Speed adjuster 60030980 Switch 60031458 S-43 Nut for dust protector 60032480 Cap for dust protector 60032431 Fuse holder 64000019 ★...
Page 34: Vertical-Horizontal Adjusting Holder
IK-70 10.5 Vertical-horizontal adjusting holder - 28 -...
Page 35 IK-70 Vertical-horizontal adjusting holder Item No. Parts Name Q’ty Stock No. Remarks Positioner holder assembly 60030989 Positioner holder 60030982 G-gear 60030945 G-gear shaft 60030946 G-collar 60030947 Crank handle 60032211 M8x25 Up/Down feed assembly 60032133 Handle 60032529 ※1 G-pinion 60030948 ※1...
Page 36: Carriage
IK-70 10.6 Carriage Model 600 Model 1000 Item No. Part name Q’ty Stock No. Remarks Leg assembly 60032131 Caster 60032134 Carriage assembly 60030708 Idle wheel unit 30030709 Weight 60030903 Wing bolt 60032156 3/8x25 ★ Hexagon bolt 6C011045 BH-10x45 Hexagon nut...
Page 37: Cutting Data
IK-70 11 Cutting data 102 (STANDARD SPEED) for Acetylene OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF (kg/c ㎡) / (Mpa) PRESSURE THICKNESS SPEED WIDTH SIZE (kg/c ㎡) / (Mpa) (mm) (mm/min) (mm) CUTTING PREHEAT 1.5 / 0.15 1.5 / 0.15 0.2 / 0.02...
Page 38: 106 (Standard Speed) For Propane
IK-70 106 (STANDARD SPEED) for Propane OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF (kg/c ㎡) / (Mpa) PRESSURE THICKNESS SPEED WIDTH SIZE (kg/c ㎡) / (Mpa) (mm) (mm/min) (mm) CUTTING PREHEAT 1.5 / 0.15 1.5 / 0.15 0.2 / 0.02 2.0 / 0.2...
Page 40 IK-70 (Small Circle Cutter) OPERATION MANUAL Date of issue: Feb.1996 Jun.2005 Sep.2005 May.2007 Mar.2008 Nov.2008 Dec.2008 Feb.2009 Sep.2010 10th Dec.2010 11th Jun.2011 12th Dec.2011 13th Nov.2012 14th Aug.2013 15th Jan.2015 16th Nob.2016 17th Jul.2017 18th Aug.2018 19th Mar.2020 20th Nov.2020 KOIKE SANSO KOGYO CO.,LTD.