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Koike Sanso Kogyo KHC-600D Operation Manual

Portable automatic gas cutter
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Portable Automatic Gas Cutter
BFC00A01
KHC-600D
Pipe hole Cutter
OPERATION MANUAL
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.
KOIKE SANSO KOGYO CO.,LTD.

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  • Page 1 Portable Automatic Gas Cutter BFC00A01 KHC-600D Pipe hole 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 2 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 3 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 4: Table Of Contents

    KHC-600D 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 5 1) The machine will not move. (The motor will not run.) 2) The speed can not be controlled. (The motor runs.) 3) The machine will not move. (The motor runs.) 8. Wiring diagram 9. Assembly drawing of KHC-600D 10. Parts list 10.1 Distribution unit 10.2 Drive unit 10.3 Torch unit...

  • Page 6: Safety Information

    KHC-600D 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 7: Operations And Handling Safety Precautions

    KHC-600D 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 8: Gas Cutting Safety Precautions

    KHC-600D 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 9: Safety Precautions For Skin Burns

    KHC-600D 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 10: Locations Of Safety Labels

    KHC-600D 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 11: Outline Of Machine

    KHC-600D 3 Outline of Machine 3.1 Features of machine The hole cutter KHC-6000 is used to make circular holes to mount nozzles that are at right angles to a steel pipe of a high-pressure vessel or heat exchanger. The machine can cut flat circles as well.

  • Page 12: Specifications

    KHC-600D 3.3 Specifications Weight: 26 kg (with leg) Machine size: 1050 x 500 x 760mm Power: ±10% Speed control: Control with dial operation Torch rotation speed: 0.12- 1.2rpm Cutting thickness: 5- 50mm Bevel angle: 0 – 45° Cutting diameter: φ80 – φ600 (Bevel cut φ80 – φ500)

  • Page 13: Preparation For Operation

    KHC-600D 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 Distributor 1 set Torch holder 1 set Torch 1 pc Hose Distributor hose (3pcs: 600L)

  • Page 14: Connecting The Tip

    KHC-600D 4.3.3 Connecting the tip 1. Select a proper tip according to the thickness of the steel plate and attach it to the torch. (To select a tip, refer to the table of cutting data.) • When fixing a tip to the torch, tighten the nut with the two wrenches attached.

  • Page 15: Cutting Speed Setting

    KHC-600D 4.3.5 Cutting speed setting ・Adjust the setting of cut speed to become a specified turn number in the light of a list shown below. A number of turn r.p.m. Plate thickness 5～10 10～15 15～30 30～40 40～50 50～ (mm) Cutting speed ～660...

  • Page 16: Cutting Operation

    KHC-600D 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 17: Cutting And Piercing Method

    KHC-600D 5. 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. Similar defects will result when the cutting oxygen pressure is too high.

  • Page 18: Safety Measures Against Backfire And Flashback

    KHC-600D 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 19: Method Of Mount Overhang Stand

    KHC-600D 5.6.2 Method to mount overhang stand 1. Parts assembling dimensions 1) Assemble the overhang stand by according to item 1, 1)-3), "Method to mount the fixture for small-diameter pipe.' 2) Attach the main unit to the overhang stand. 2. Setting 1) Determine the chain length according to the pipe diameter.

  • Page 20: Maintenance And Inspection

    KHC-600D 6 Maintenance and inspection Refer to the following points for maintaining and inspecting the machine in order to use the machine under the best conditions. 6.1 Daily inspection 1. Wipe the outside of the machine with a clean cloth.

  • Page 21: The Speed Can Not Be Controlled. (The Motor Runs)

    KHC-600D 8)Defective motor If all the above items are normal, the Repair or replace the motor is defective. motor with a new one. 9)Defective controller If all the above items are normal, the Replace the defective controller is defective. controller.

  • Page 22: Wiring Diagram

    8 Wiring diagram Clamp Filter Terminal (2P) NCS-253-R(3P) Controller adjust TRANSFORMER Connection TR1:SPEED MAX SUPPLY PRIMARY SECONDARY TR3:SPEED MINI VOLTAGE ※V 100V 100V 110V 120V 120V 120V 200V 220V NCS-254-R(4P) 220V 220V 230V 230V 240V 240V 9 Assembly drawing of KHC-600D －17－...

  • Page 23: Parts List

    KHC-600D 10 Parts List 10.1 Distributor unit －18－...
  • Page 24 KHC-600D Distributor units Item No. Part name Q’ty Stock No. Remarks Gear case 60033550 Body case 60033551 Drive gear 60033552 Distributor cover 60033553 Distributor 60033554 Set shaft 60033555 Lever shaft 60033556 Scale 60033557 Bearing retainer 60033558 Washer 60033559 Collar 60033560...

  • Page 25: Drive Unit

    KHC-600D 10.2 Drive unit －20－...
  • Page 26 KHC-600D Drive units Item No. Part name Q’ty Stock No. Remarks Reduction gear box 60032400 Casing 20547089-Y Gear Ass’y 61001127 Screw 6C520323 SP-3x23 with WS Gear (B) 60032404 Gear shaft (B) 60032405 Collar (B) 60032406 Clutch lever 60032407 ※1 Casing (D)

  • Page 27: Torch Unit

    KHC-600D 10.3 Torch unit －22－...
  • Page 28 KHC-600D Torch unit Item No. Parts Name Stock No. Remarks Torch holder 60033568 ※1 Shaft 60033569 ※1 Center holder 60033570 Stopper 60033571 Holder bar assembly 60032762 With rack Joint 60032764 ※1 Cross bar 60032765 ※1 Cross feed holder 60032767 ※1...

  • Page 29: Stand Unit

    KHC-600D 10.4 Stand unit - 24 -...
  • Page 30 KHC-600D Stand unit Item No. Part name Q’ty Stock No. Remarks Leg (A) 60033573 Leg (B) 60033574 Support bar 60033575 Support plate 60033576 Square pipe (B) 60032823 Square pipe (A) 60033577 Supplementary plate (A) 60032824 Supplementary plate (B) 60032825 Trim...

  • Page 31: Electric Unit

    KHC-600D 10.5 Electric unit Motor wire －26－...
  • Page 32 KHC-600D Electric unit Item No. Part name Q’ty Stock No. Remarks 6N100061 NCS-253-R Metal socket (For 42V、100V–120V) 6N100062 NCS-254-R Metal socket (For 220V – 240V) 64000019 F-7150 Fuse holder 60030707 Fuse 60031458 S-43 Switch Variable resistor 60030745 RV24YNB50k ohm Controller...

  • Page 33: Small Diameter Kit

    KHC-600D 10.6 Small diameter kit Item No. Parts Name Stock No. Remarks Set plate 60033590 Chain shaft 60033591 Set plate 60033592 Hook 60033593 Handle 60033594 Chain 60033596 Bolt with rubber 60033597 Hexagon bolt 6C030615 BC-6x15 Washer 6D510060 WS-6 Washer 6D500060...

  • Page 34: Over-Hang (Option)

    KHC-600D 10.7 Over-hang (option) 11 13 - 29 -...
  • Page 35 KHC-600D Item No. Parts Name Stock No. Remarks 60033598 Supplementary plate (C) 60033599 Supplementary plate (D) 60033600 Leg (A) 60033573 Leg (B) 60033574 Square pipe (B) 60032823 Supplementary plate (A) 60032824 Supplementary plate (B) 60032825 Trim 64000490 NB-8 Wing nut...

  • Page 36: Cutting Data

    KHC-600D 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 37: 106 (Standard Speed) For Propane

    KHC-600D 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 KHC-600D (Pipe hole Cutter) OPERATION MANUAL Date of issue : Nov.2023 Dec.2023 KOIKE SANSO KOGYO CO.,LTD. Printed in Japan...

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