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Koike IK-72T Operation Manual

Portable automatic gas cutter
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Portable Automatic Gas Cutter
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.
Operation Manual – Version T89001713

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Summary of Contents for Koike IK-72T

  • Page 1 Portable Automatic Gas Cutter 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. Operation Manual – Version T89001713...
  • 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

    IK-72T CONTENTS 1. Safety Information ......................... 1 1.1 General machine safety precautions................1 1.2 Gas cutting safety precautions..................3 2. Locations of safety labels....................... 5 3. Outline of machine......................... 6 3.1 Features of machine ..................... 6 3.2 Name and function of each section ................6 3.3 Specifications........................

  • Page 5: Safety Information

    IK-72T 1 Safety information 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 instruction manual and on the machine before operating, inspecting, and maintaining the machine.
  • Page 6 IK-72T 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 7: Gas Cutting Safety Precautions

    IK-72T 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 8 IK-72T 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. Do not perform cutting near flammables. (Move flammables well away from the sparks.) Do not cut containers filled with flammables.

  • Page 9: Locations Of Safety Labels

    IK-72T 2 Location 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 10: Outline Of Machine

    Outline of machine 3.1 Features of machine The IK-72T (three-dimensional cutter) is a portable automatic gas cutter designed and manufactured to ensure high-precision cutting of three-dimensional structures (especially three-dimensional curves) which are conventionally cut by mechanical cutters. Three kinds of rails – 1D, 2D, and 3D – increase the range of operation and greatly help to rationalize and reduce the cutting work.

  • Page 11: Specifications

    IK-72T 3.3 Specifications Weight : 11 Kg (incl. rail) Body: 4.5 Kg Rail: 6.5 Kg Machine size : 190 x 195 x 140 mm Rail size : 30H x 42W x 1500L (mm, extendable rail) ・1D (straight AL rail with 4 magnets) 30H x 42W x 1000L ・2D (two-dimensional rubber rail with 5 magnets)

  • Page 12: Preparation For Operation

    IK-72T 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 Torch 1 pc Hose...
  • Page 13 IK-72T difficult to remove the tip. ・ In addition, avoid damaging the taper of the tip since this may cause backfire. 4.3.4 Attaching the rail 1. Attach the rail to the steel plate. 2. Be careful not to get your hands caught between the magnet removal lever and the steel plate when attaching the rail to the steel plate.
  • Page 14 IK-72T ■ Selecting the rail There are three kinds of rails. Select the appropriate one according to the shape of the cutting sections. ・1D rail (straight AL rail) Used for cutting straight surfaces. e.g. Straight cutting of ceilings or walls ・2D rail (two-dimensional rubber rail)
  • Page 15 IK-72T ■Rail connection method ・1D rail (straight AL rail) 1.Turn OFF the magnet on the connection rail. 2.Align the connecting direction as shown in the figure. 3.Insert the fixed rail. 4.After positioning, fix the rail with the magnet. ・2D rail (two-dimensional rubber rail) ・3D rail (three-dimensional rubber rail)

  • Page 16: Cutting Operation

    IK-72T 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

    IK-72T 5.3 Cutting and piercing method 1. Cut in from the end of steel plate. 2. Pierce steel plate before cutting. 3. 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 18: Cutting Operation

    IK-72T 5.6 Cutting operation 1. Attach the rail to the cutting position, and align the tip with the cutting start point. 2. Bring a flame close to the tip for ignition and ensure sufficient preheating. 3. Simultaneously with opening the cutting oxygen valve, turn on the switch to start cutting.

  • Page 19: Maintenance And Inspection

    IK-72T 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. 6.1 Daily inspection 1. Clean the outside of the machine and sliding sections.

  • Page 20: Troubleshooting

    IK-72T 7 Troubleshooting (1) The machine will not move. (The motor will not run.) Cause Inspection point Correction 1) Power is not supplied Check power supply. Check the connections. 2) Fuse blown Check the 1A fuse in the control box Replace the blown fuse.
  • Page 21 IK-72T (3) The machine will not move. (The motor runs) Cause Inspection point Correction 1) Malfunction Remove the speed reducer box to Disassemble and clean. check the clutch operation. 2) Idle rotation of The reduction gear is rotating idly Replacement of gears (set).

  • Page 22: Wiring Diagram

    IK-72T 8 Wiring diagram   9 Assembly drawing - 18 -...

  • Page 23: Parts List

    IK-72T Parts list Complete IK·72T set...
  • Page 24 COMPLETE IK-27T SET IK-72T CS-15 ITEM PART PART NUMBER DESCRIPTION QUANTITIY NUMBER REMARKS CABTYRE 61004264 CORD ASSEMBLY SPANNER ZS30309 SCREW DRIVER ZS30310 TIP CLEANER ZS30311 FUSE 9938728000 JET OXYGEN ZM30303 HOSE PREHEAT ZM30303 OXYGEN HOSE GAS HOSE ZM30307 METAL PLUG...

  • Page 25: Distribution And Holder Units

    IK-72T Main unit 1...
  • Page 26 MAIN UNIT IK72-T CS-15 ITEM PART QUANTITY NUMBER PART DESCRIPTION NUMBER REMARKS MACHINE BASE ZS31674 DRIVE SHAFT ZS31606 ASSEMBLY CLUTCH SHAFT ZS31607 ECCENTRIC ROLLER ZS31608 STOPPER ZS31609 With Screw CLUTCH HOLDER ZS31610 ASSEMBLY SIDE ROLLER ZS31611 ASSEMBLY SIDE ROLLER SHAFT ZS31612 SIDE ROLLER SHAFT ZS31613...

  • Page 27: Rail Unit

    MAIN UNIT IK72-T CS-15 ITEM PART NUMBER PART DESCRIPTION QUANTITY NUMBER REMARKS SPRING PIN 9968202000 PR-2X12 BEARING 1138358800 628ZZ ROLL PIN 9968204300 PR-2.5X16 SCREW 9968174500 SP-4X4 SET SCREW 9968273500 SS-5X5 SCREW 9968177400 SP-5X14 w/washer SCREW 9968172600 SP-3x6 w/washer WASHER 9968148800 WF-6 HEX NUT 9968123300...
  • Page 28 IK-72T Main unit 2...
  • Page 29 MAIN UNIT 2 IK-72T CS-15 ITEM PART PART NUMBER DESCRIPTION QUANTITY NUMBER REMARKS CROSS FEED BASE ZS31623 VERTICAL SLIDE ZS31665 BASE TORCH HOLDER ZS31624 BASE VERTICAL BAR ZS31625 WITH RACK CROSS FEED BAR ZS31626 WITH RACK PINION ZS31627 HANDLE ZS31628...
  • Page 30 MAIN UNIT 2 IK-72T CS-15 PART ITEM NUMBER PART DESCRIPTION QUANTITY NUMBER REMARKS VERTICAL SLIDE ZS32789 HOLDER ASSEMBLY CROSS FEED ZS31632 HOLDER ASSEMBLY...
  • Page 31 IK-72T Operation box assembly 8 103...
  • Page 32 OPERATION BOX ASSEMBLY IK-72T CS-15 ITEM PART PART NUMBER DESCRIPTION QUANTITY NUMBER REMARKS CONTROLLER 69000130 FUSE HOLDER ZS30749 SWITCH ZS30283 HANDLE ZS31249 VARIABLE 6N310008 50 KW RESISTOR TERMINAL ZS31666 SCREW 9968172300 SP-3X6 CAP FOR DUST ZS32431 PROTECTOR DUST ZS32480 PROTECTOR...
  • Page 33 IK-72T Rail unit (straight rail and 2,3 dimension rail)
  • Page 34 RAIL UNIT IK-72T CS-15 ITEM PART PART NUMBER DESCRIPTION QUANTITY NUMBER REMARKS STRAIGHT RAIL ZS31648 RAIL ONLY SCREW 9968177400 SP-5X14 CONNECTOR 60031694 HOOK BOLT ZS31654 SCREW 9968180100 SP-6x18 2-D RAIL ZS31655 3-D RAIL ZS31656 MAGNET ZS31657 HOLDER(A) MAGNET ZS31658 2D,3D...

  • Page 35: Cutting Data

    IK-72T   11 Cutting data 102(STANDARD SPEED) For Acetylene OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF PRESSURE THICKNESS SPEED WIDTH (kg/c ㎡) / (Mpa) SIZE (mm) (mm/min) (kg/c ㎡) / (Mpa) (mm) CUTTING PREHEAT 1.5 / 0.15 1.5 / 0.15 0.2 / 0.02...
  • Page 36 IK-72T   106(STANDARD SPEED) For Propane OXYGEN PRESSURE FUEL GAS PLATE CUTTING KERF PRESSURE THICKNESS SPEED WIDTH (kg/c ㎡) / (Mpa) SIZE (mm) (mm/min) (kg/c ㎡) / (Mpa) (mm) CUTTING PREHEAT 1.5 / 0.15 1.5 / 0.15 0.2 / 0.02 2.0 / 0.2...
  • Page 37 IK-72T Operation Manual - Version T89001713 2015-04-03...

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