Koike Sanso Kogyo AUTO PICLE-S User manual

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

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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 ................................................ 7
1.3.1 Prevention of explosion ............................................................... 7
1.3.2 Pressure regulator safety precautions ......................................... 7
1.3.3 High pressure gas cylinder safety precautions ............................ 7
1.3.4 Safety precautions for hoses .......................................................7
1.3.5 Safety precautions for fire ........................................................... 8
1.3.6 Safety precautions for skin burns ................................................ 8
1.4 Operating and handling safety precautions ...........................................9
2 Locations of safety labels ............................................................................ 11
3 Outline of machine ...................................................................................... 13
3.1 Features of machine ............................................................................ 13
3.2 Name and function of each section ..................................................... 14
3.3 Specifications ...................................................................................... 15
4 Preparation for operation ............................................................................ 17
4.1 Contents of package ............................................................................17
4.2 Machine assembly ...............................................................................18
4.3 Preparation for operation ..................................................................... 18
4.3.1 Connecting the power cable ...................................................... 18
4.3.2 Connecting the gas supply hose ...............................................19
4.3.3 Connecting the tip ..................................................................... 19
4.3.4 Determining the number of chains ............................................ 20
4.3.5 Securing machine to pipe .......................................................... 20
4.3.6 Assembling and mounting the guide rail ................................... 21
4.3.7 Trial operation ........................................................................... 23
5.1 Safety measures prior to operation .....................................................25
5.1.1 Grounding the machine ............................................................. 25
5.1.2 Selection of tip ........................................................................... 25
5.1.3 Operation of running direction changeover switch .................... 25
5.2 Ignition and flame adjustment .............................................................. 26
5.3 Cutting and piercing method ................................................................ 27
5.4 Safety measures against backfire and flashback ................................ 27
5.4.1 Prevention of backfire ................................................................ 27
5.4.2 Prevention of flashback ............................................................. 27
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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 ...................................................................................32
6.3 3-Month or 1000-hour inspection ......................................................... 32
6.4 6-Month inspection ..............................................................................32
7 Troubleshooting ..........................................................................................33
8Wiring diagram and assembly drawing ..........................................................37
8.1 Wiring diagram ....................................................................................37
8.2 Assembly drawing ...............................................................................38
9 Parts list ......................................................................................................39
9.1 Body unit ...........................................................................................39
9.2 Driving unit ........................................................................................... 42
9.3 Electrical and gas unit ....................................................................... 45
9.4 Guide rail .............................................................................................48
10 Cutting Data ................................................................................................51
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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.
Safety precautions
This product is designed to be safe, but it can cause serious accidents if
not operated correctly. Those who operate and repair this machine must
read this manual thoroughly before operating, inspecting and maintaining
the machine. Keep the manual near the machine so that anyone who
operates, inspects or maintains the machine can refer to it if necessary.
• Do not use the machine carelessly without following the instructions
in the manual.
• Use the machine only after you completely understood the contents
of the manual.
• If an explanation in the manual is difficult to understand, contact our
company or sales service office.
• Keep the manual near by at all times and read it as many times as
necessary for a complete understanding.
• If the manual becomes lost or damaged, place an order with our
company or sales service office for a new one.
• When transferring the machine to a new owner, be sure to hand over
this instruction manual as well.
Qualifications for machine operator
Operators and repair staff of this machine must completely understand
the contents of the instruction manual and they must be qualified and
educated to handle this equipment.
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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.
table 2 - 1
Symbol Title Meaning
Safety alert symbol This symbol is applied to indicate general
caution, warning and danger messages.
Be careful not to get your fingers
caught. Possible injury to fingers if caught in the insertion point.
Caution: Electric shock! Possible electric shock under special
conditions.
Ground this equipment. Operators must ground the equipment using
the safety grounding terminal.
Caution against bursting. Possible bursting under certain conditions.
Caution: Hot! Possible injury due to high temperature under
certain conditions.
Caution: Ignition! Possible ignition under certain conditions.
Pull out the power plug from the outlet. Operators must unplug the power plug from
the outlet when a failure occurs or when there
is a danger of lightning.
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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.
The safety messages used in this manual are classified as indicated on
the machine safety labels.
Danger
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury. The safety label on the machine
is positioned at places that can cause injury or serious accident.
Warning
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury. The safety label on the
machine is positioned at places that could cause injury or serious
accident.
Caution
Indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury or machine damage.
Note:
Indicates an additional explanation for an element of information.
1.2 General machine safety precautions
1.2.1 Machine safety
• The machine casing is mainly made of aluminum alloy to reduce
weight. For this reason, be careful not to drop a heavy item on the
machine, or not to drop the machine when carrying it, since the alloy
is not designed to withstand such impact.
• When mounting hoses to the torch and distributor, tighten the nut
with the attached wrench. After mounting, be sure to check there is
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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.
• Always turn the power off when not used.
• Never use the machine outdoors when the weather is wet. This will
cause failure of the machine and could cause a fatal accident by an
electric shock.
1.2.2 Safety clothing
• Be sure to wear protective gauntlets, goggles, helmet, and safety
shoes during operation.
• Avoid operating the machine with wet clothes or hands in order to
prevent electric shock.
1.2.3 Electrical system precautions
1 Be sure to check the input power voltage of the machine before
operation. The input power voltage should be in the range of ± 10%
of the rated voltage. The machine should not be operated out of this
range.
2 The metal plugs are screw-threaded, therefore, fully tighten them so
that they will not come loose during operation.
3 Stop operation and turn off the power in the following cases, and
ask a qualified electrician to repair the machine.
a Broken or abraded cables.
b When the machine has been in contact with water, or in case of
liquid damage to the machine.
c Abnormal machine operation despite operating the machine
according to the instruction manual.
d Machine breakdown.
e Poor machine performance that requires repair.
4 Periodically inspect the electrical system.
1.2.4 Maintenance and inspection precautions
1 Ask a qualified electrician to perform repair and inspection service.
2 Disconnect the power plug before inspecting and repairing the
machine.
3 Maintain the machine periodically.
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1.3 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.
2 Ensure sufficient ventilation for gas cutting to prevent the air from
becoming stale.
1.3.2 Pressure regulator safety precautions
1 Before starting operation, check that all pressure regulators are
operating correctly.
2 Ask a skilled repair engineer to perform maintenance and inspection
service.
3 Do not use pressure regulators from which gas is leaking, nor
malfunctioning pressure regulators.
4 Do not use pressure regulators smeared with oil or grease.
1.3.3 High pressure gas cylinder safety precautions
1 Never use broken cylinders or cylinders from which gas is leaking.
2 Install cylinders upright and take measures to prevent them from
falling.
3 Use cylinders only for specified purposes.
4 Do not smear container valves with oil or grease.
5 Install cylinders in a place free from heat, sparks, slag, and open
flame.
6 Contact the distributor if the container valves will not open. Never
use a hammer, wrench, or other tools to forcibly open container
valves.
1.3.4 Safety precautions for hoses
1 Use the oxygen hose for the oxygen gas only.
2 Replace cracked hoses or other hoses damaged by sparks, heat,
unshielded fire, etc.
3 Install hoses without twisting.
4 To prevent breakage of hoses, take great care during operation and
transportation.
5 Do not hold the hoses when moving the machine.
6 Periodically check the hoses for damage, leakage, fatigue, loose
joints, etc. to ensure safety.
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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.
Ignoring hot metal, sparks, and slag could cause a fire.
1 Keep a fire extinguisher, fire extinguish sand, bucket full of water,
etc. ready on the site where gas cutting is performed.
2 Keep flammables away from the cutting area to avoid exposure to
sparks.
3 Always cool down steel plates that have become hot after cutting,
as well as hot cut parts or scrap, before bringing them close to
flammables.
4 Never cut containers to which flammable materials are stuck.
1.3.6 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.
3 Do not keep lighters, matches and other flammables nearby.
4 Flames from the torch will burn the skin. Keep your body away from
the torch and tip and check the safety before operating the switches
and valves.
5 Wear the correct protectors to protect your eyes and body.
6 Correctly tighten the tip to prevent backfire (see paragraph 5.5)
7 Check with soapsuds for any leakage from gas from the connection
part of the distributor, hose and torch.
Never use oil or grease on the connection of the oxygen pipe to
avoid backfire which may lead to explosion.
8 Be sure to check the following when igniting:
a Always wear the required protectors (gauntlets, helmet, goggles,
etc.)
b Check for any obstacles, dangerous materials and flammables
near or in the direction of cutting. Determine the gas pressure.
c The gas pressure must be within the appropriate range. (For the
gas pressure, refer to the Cutting Data).
9 The torch, tip and heat shield are heated to a very high temperature.
Always wear gauntlets when handling them. Also the surface after
cutting is very hot so do not touch it even while wearing gauntlets.
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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.
4 Never move the machine while the preheat flame is on.
5 Take great care of spatters and dross when operating the machine at
a high position. They may injure people below.
6 Do not hit any object against the surface of the wheel to be in touch
with pipes or drop the wheel so, as not to scratch the surface;
otherwise knocking will result.
7 Weak chain tension will make the machine slip. Give an appropriate
tension to the chain.
8 Be careful not to get your hand caught between the upper plate and
the slide brackets.
9 When stretching the chain, be careful not to get your hand caught in
the wing bolt.
10 Do not insert your hand into rotary sections (sprocket and wheel).
11 Be careful not to drop the machine when changing the chain.
12 Do not use deformed or rusted chains; otherwise the chain may be
disengaged.
13 Do not mistake the top and bottom sides of the chain.
14 The number of chains must match the pipes.
15 Do not place the machine on pipes when it is unused.
16 Be careful not to damage the wheel.
17 The planer deflection due to a worn wheel causes curved cutting
surfaces and discrepancy between the first and last cutting
positions.
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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.
figure 2 - 1
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3 Outline of machine
3.1 Features 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. The guide rail will permit pipe
cutting in vertical position.
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3.2 Name and function of each section
1. Wheel
Four wheels permit the machine to
run stable on pipes.
2. Chain
The machine attached to the rail
runs along the chain.
3. Torch up/down handle
Changes the torch height.
4. Cross-feed handle
Changes the horizontal position of
the torch.
5. Torch
Cutting thickness: 5~50 mm.
6. Gear box
Voltage control by means of a
speed-controlling resistor permits
staples speed change.
7. Hose
Installed between the gas
distributor and the torch. Two hoses
for oxygen and gas are combined
as a set.
8. Motor switch
Power switch for the motor.
9. Tightening handle
Tightens the handle to secure the
machine and pipes.
10. Gas distributor
Division into preheating oxygen,
preheating gas and cutting oxygen.
11. Clutch lever
Used to run the machine.
12. Main unit
13. Shaft column
14. Sprocket
15. Slide bracket
16. Motor
15 W; 5000 r.p.m.
17. Control box
Permits remote control.
18. Speed control knob
For controlling the cutting speed
from 100 to 700 mm/min.
19. Guide rail
There are four kinds of rails for
respective effective pipe cutting
diameters.
20. Directional changeover switch
For switching forward and
backward travelling.
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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°
Tip: 102 HC (for acetylene) 106 HC
(for propane) #0, 1, 2
Gas: oxygen, acetylene gas or LPG gas
Pipe cutting diameter: ø150 - ø400 mm without guide rail
ø400 - ø1500 mm with guide rail
Accessories
Tip 102 HC (for acetylene) or
106 HC (for propane, #0, 1, 2: one each
Tip cleaner: 1 set
Spanner (A, B, C) 1 set
Lighter: 1 pc
Fuse (2A): 2 pcs
Chain (80 pcs.): 1 set
Control box: 1 set
Slide bar: 1 pc
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Option
Guide rail: pipe cutting diameter
D-600 ø400 - ø600
D-900 ø600 - ø900
D-1200 ø900 - ø1200
D-1500 ø1200 - ø1500
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4 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 1 set
Gas distributor 1 set
Torch holder 1 set
Torch 1 pc
Hose
Distribution hose (3 pcs set: 900L) 1 set
Slide bar 1 pc
Control box 1 set
Tip 102 HC (for acetylene) 106 HC
(for propane) #0, 1, 2 one each
Tip cleaner 1 set
Screw driver 1 pc
Spanner (A, B, C) 1 set
Fuse (2A) 2 pcs
Chain (80 pcs.) 1 set
Lighter 1 pc
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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.
4 Insert the slide bar into the slide cover and cross feed bar.
5 Tighten the wing bolts (M4x10 and M4x15).
4.3 Preparation for operation
4.3.1 Connecting the power cable
Warning
Never forget to ground the machine
1 Insert the metal plug (5p) of the control box into the metal socket
(5p) of the machine.
2 Connect the rubber plug on the power supply side.
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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.
1 Connect the respective gas supply hoses to the primary hose.
2 Securely tighten the joints.
3 Check that there is no gas leakage.
4.3.3 Connecting the tip
Warning
Avoid damaging the taper of the tip since this may cause backfire.
1 Select a proper tip according to the thickness of the steel plate.
(To select a tip, refer to the table of Cutting Data).
2 Attach the tip to the torch.
3 Tighten the nut with the two attached wrenches to fix the tip to the
torch.
Note:
Tightening the tip excessively will make it difficult to remove the tip, since
it will be heated during cutting and tightened still more.
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