Koike Sanso Kogyo AUTO PICLE-S User manual

Portable Automatic Gas Cutter
BGB01B17
OPERATION MANUAL
KOIKE SANSO KOGYO CO.,LTD.
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.

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. Make sure you read, understand and take all 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 operates the machine can refer to it as
necessary.
■Do not use the machine carelessly without following the instructions in the manual.
■Use the machine only after you have 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 to hand at all times and read it as many times as is 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 have either of the following qualifications:
1. Gas welding foremen’s license
2. Completion of gas welding training course
3. Approval by the Minister of Labor

Symbol
Title
Meaning
General
General caution, warning, and danger.
Be careful not to get your
fingers caught.
Possible injury to fingers if caught in the insertion
port.
Caution: Electric shock!
Possible electric shock under special conditions.
Ground this equipment.
Operators must ground the equipment using the
safety grounding terminal.
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 damage.
Caution against bursting
Possible bursting under certain conditions.
General
General warning.
Caution: Hot!
Possible injury due to high temperature under
certain conditions.
Caution: Ignition!
Possible ignition under certain conditions.

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 part 6
3.3 Specifications 7
4. Preparation for operation 8
4.1 Contents of package 8
4.2 Assembling the machine 8
4.3 Preparation for operation 9
5. Cutting operation 13
5.1 Safety measures prior to operation 13
5.2 Ignition and flame adjustment 13
5.3 Cutting and piercing method 14
5.4 Procedures for starting cutting operation and extinguishing flame 14
5.5 Safety measures against backfire and flashback 15
5.6 Cutting operation 15
6. Maintenance and inspection 17
6.1 Disassembly 17
6.2 Daily inspection 17
6.3 6-month Inspection 17
7. Trouble shooting 18
8. Wiring diagram 20
9. Assembly drawing of AUTO PICLE-S 21
10. Parts list 22
10.1 Body unit 22
10.2 Driving unit 24
10.3 Electrical and gas unit 26
10.4 Guide rail 28
11. Cutting Data 30

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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.
The safety messages are classified as follows for machine safety labels:
■WARNING
This word is used in a warning message and a warning label at places that could cause injury or
serious accident.
■CAUTION
This word is used in a caution message and a caution label at places that could cause slight injury or
machine damage. This is also used as a caution for frequent dangerous actions.
■NOTICE SIGNS
This is a sign to show machine operators and maintenance engineers items that relate directly to damage
of machines and surrounding facilities and equipment.
1.1 General machine safety precautions
Read and fully understand the following important safety information:
1.1.1 Machine safety
1.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 drop the machine when carrying it since the alloy is not
designed to withstand such impact.
2.When mounting hoses to the torch and distributor, tighten the nut with the attached wrench. After
mounting, be sure to check there is no gas leak with a detection liquid. If a gas leak is found, retighten the
nut firmly.
3.When fixing a tip to the torch, tighten the nut with the two wrenches attached. In addition, avoid damaging
the taper of the tip since this may cause backfire.
4.Never disassemble the machine other than during maintenance and inspection. Otherwise, malfunction
will result.
5.Never remodel the machine. Remodeling is very dangerous.
6.When changing the direction, make sure that the direction switch is in the neutral (stop) position, and
operate the direction switch after the machine has stopped.
7.Always turn the power off when not in use.
8.Never use the machine outdoors when the weather is wet. This will cause failure of the machine and
could cause a fatal accident byelectric shock.
1.1.2 Safety clothing
1.Be sure to wear protectors gauntlets, goggles, helmet, and safety shoes during operation.
2.Avoid operating themachine with wet clothes or hands in order to prevent electric shock.

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1.1.3 Operation and handling safety precautions
1. Read this instruction manual before operating themachine.
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.
4. Prior to operating the machine, check the safety of the surroundings to avoid accidents.
5. Never move the machine while the preheat flame is on.
6. Take great care of spatters and dross when operating the machine at a high position. They may
injure people below.
7. 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.
8. Week chain tension will make the machine slip. Give an appropriate tension to the chain.
9. Be careful no to get your hand caught between the upper plate and slide bracket.
10. When stretching the chain, be careful not to get your hand caught in the wing bolt.
11. Do not insert your hand into rotary sections (sprocket and wheel).
12. Be careful not to drop the machine when changing the chain.
13. Do not use deformed or rusted chains; otherwise the chain may be disengaged.
14. Do not mistake the top and bottom sides of the chain.
15. The number of chains must match the pipes.
16. Be careful not to damage the wheel.
17. The planer deflection due to a worm wheel causes curved cutting surfaces and discrepancy
between the first and last cutting positions.
18. Do not place the machine on pipes when it is unused.
19. Be sure to hold the handle when carring the machine.
1.1.4 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. The ground pin is attached to the rubber plug of a cabtyre cord. Please use a power receptacle with a
ground pin opening.
4.Stop operation and turn off the power in the following cases,
and ask a qualified electrician to repair the machine.
1)Broken or abraded cables
2)Water leakage from the machine or liquid damage to the machine
3)Abnormal machine operation despite operating the machine according to the instruction manual
4)Machine breakdown
5)Poor machine performance thatrequires repair
5.Periodically inspect the electrical system.
1.1.5 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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1.2 Gas cutting safety precautions
Strictlyobserve the safety rules and precautions to ensure the safetyof 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.
2.Ensure sufficient ventilation for gas cutting to prevent the air from becoming stale.
1.2.2 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 pressureregulators from which gas is leaking, nor malfunctioning pressure regulators.
4.Do not use pressureregulators smeared with oil or grease.
1.2.3 High-pressure gas cylinder safety precautions
1.Never use broken cylinders or cylinders from which gas is leaking.
2.Installcylinders 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.Installcylinders in a place free from heat, sparks, slag, and naked 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.
1.2.4 Safety precautions for hoses
1.Use the oxygen hose for oxygen gas only.
2.Replace cracked hoses or other hoses damaged bysparks, 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 themachine.
6.Periodically check the hoses for damage, leakage, fatigue, loose joints, etc, to ensuresafety.
7.Cut hoses to the minimum possible length. Short hoses reduce hose damage and pressure drop, as well
as reduce the flow resistance.
1.2.5 Safety precautions for fire
Take safetyprecautions to prevent fire prior to gas cutting.
Ignoring hot metal, sparks, and slagcould cause afire.
1.Keep a fire extinguisher, fire extinguishing 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 steel plates that have become hot after cutting, as well as hot cut parts or scrap, before
bringing them close to flammables.
4.Never cutcontainers to which flammable materials arestuck.

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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 awayfrom 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 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.
●When fixing a tip to the torch, tighten the nut with the two wrenches attached.
●If the tip is tightened excessively, it will be heated during cutting and tightened still more, making it
difficult to remove the tip.
●Avoid damaging the taper of the tip since this may cause backfire.
7.Check with soapsuds for any leakage of gas from theconnection 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:
●Place the torch on the torch holder before igniting.
●Always wear the requiredprotectors (gauntlets, goggles, helmet, etc.)
●Check for any obstacles, dangerous materials and flammables near or in the direction of cutting.
Determine the gas pressure.
●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 thesurface after cutting is veryhot so do not touch it even while wearing gauntlets.
10.Never move the machine while the preheat flame is on.
.

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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.

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3 Outline of machine
3.1 Features of the machine
AUTO PICLE-S is a compact pipe cutter developed on the basis of the thoroughgoing examination of the
actual conditions of pipeline installation work sites. Exhibiting its excellent performance in cutting pipes of
various sizes to specified length and in bevel cutting, which are major job of pipe processing, the machine
is habitually used bymany users.The guide rail will permit pipe cutting in vertical position.
3.2 Name and function of each part
Themachine is composed of the following parts:
1.Wheel
Four wheels permit the machine to run stably 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: 5-30mm
6.Gear box
Voltage control by means of a speed controlling resistor
permits stepless speed change.
7.Hose
Installed between the gas distributor and the torch.Three
hoses for preheating oxygen, preheating gas, and cutting
oxygen arecombined as a set.
8.Motor switch
Power switch for the motor
9.Tightening handle
Tighten the handle to secure the machine and pipe.
10.Gas distributor
Division into preheating oxygen, preheating gas,
and cutting oxygen.
11.Clutch lever
Used to let the machine run.
12.Main unit
13.Shaft column
14.Sprocket
15.Slide bracket
16.Motor
23W; 5700rpm
17.Control box
Permits remote control.
18.Speed control knob
For controlling the cutting speed from 100 to 700
mm/min.
19.Directional changeover switch
For switching forward and backward traveling.
20.Directioal changeover switch
For switching forward and backward traveling.

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3.3 Specifications
Weight 15kg
Machine size 270×230×400
Power source ±10%
Speed control control with dial operation
Cutting speed 100～700mm/min
Cutting thickness 5～30mm
Bevel angle 0-45°
Tip 102(for acetylene) 106(for propane) #0,1,2
Gas oxygen, acetylene gas, or LPG gas
Pipe cutting diameter φ400～φ1500 (φ150～φ400)
●Accessories
・Tip102(for acetylene) 106(for propane) #0,1,2 each 1 pc
・Tip cleaner 1set
・Spanner(A,B,C) 1set
・Lighter 1pc
・Fuse(1A) 2pcs
・Chain(80pcs) 1set
・Control box 1set
・Slide bar 1pc
●Option
・Guide rail Pipe cutting diameter
・D-600 φ400～φ600
・D-900 φ600～φ900
・D-1200 φ900～φ1200
・D-1500 φ1200～φ1500

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4 Preparation for operation
4.1 Contents of package
Thestandard pack contains the parts shown below. Check them before assembling.
・Body 1set
・Gas distributor 1set
・Torch 1pc
・Torch holder 1set
・Hose
Distribution hose (3pcs set:900L) 1set
・Slide Bar 1pc
・Control box 1set
・Tip102(for acetylene) or 106(for propane) #0,1,2 each 1 pc
・Tip cleaner 1set
・Spanner(A,B,C) 1set
・Fuse(1A) 2pcs
・Chain(80pcs) 1set
・Lighter 1pc
4.2 Assembling the machine
1.Take out the main unit from the box.
2.Remove the slide spring and stopper attached to the slide bar, and put the slide spring and stopper backe to
their original positions in this order. Then insert the slide bar into the slide cover and cross feed bar in this
order, and tighten the wing bolts (M4×10 and M4×15).

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4.3 Preparation for operation
4.3.1 Connection of power cable
1. Insert the metal plug(7p) of the control box into the metal socket(7p) of the machine.
2. Connect therubber plug on the power supply side. (Never forget grounding.)
3. The metal plugs are screw threaded, therefore, fully tighten them so that they will not come
loose during operation.
4.3.2 Connecting the gas supply hose
1. Connect therespective gas supply hoses to the primaryhose.
2. Securely tighten the joints and check there is no gas leak.
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.
・If the tip is tightened excessively, it will be heated during cutting and tightened still more,
making it difficult to remove the tip.
・In addition, avoid damaging the taper of the tip since this may cause backfire.
4.3.4 Determination of number of chains
Therelationship between the pipe O.D. and the number of chains is as follows:
y = x + 13
where, y = The number of chains
x = Pipe O.D. (Unit:cm; Round off the value inmm to the next value in cm.)
For example, pipe O.D. 114.3 mm→11.43 cm→12
y = x + 13
= 12 + 13
= 25
Therefore, about 25 chains are necessary.
※Calculation formula of the number of the chain is a standard.
After the attaching, please adjust from to check the tension of the chain.

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4.3.5 Securing machine to pipe
1. Calculate the necessary number of chains, place the main unit on the pipe to cut, and turn the
tightening handle counterclockwise to lower the slide bracket.
2. Engage the chain with the sprocket and attach the chain as shown in the figure to set it on the
pipe. (Do not confuse the right side of the chain with its wrong side.)
3. Turn the tightening handle clockwise and fix the main unit to the pipe. When turning the tightening
handle, exercise care so that the spring will not be in close contact, leaving a clearance of 1-2
mm.
4. To avoid a chain engagement error or chain loosening, hold the machine by hand, disengage the
clutch, and turn the handle to the right and left within the range of approx. 120 degrees two or
three times, tensioning the chain gradually. Secure the guide roller of the main unit with the
stopper so that the guide roller will be press-fit to the guide rail.
5. After setting, turn the handle by one turn, and check to see if the hose length is sufficient and the
nozzle returns to the original position.

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4.3.6 Assembling and mounting the guide rail
1. Assembling the rail
Attach supporting bases (set) at intervals of 120 mm to the guide rail that matches the pipe
diameter. Change the number of supporting bases (set), taking into consideration the
overlapping sections of the guide rail.
2. Installation of guide rail
1) Secure the pipe to cut and mark a line 450 mm away from the cutting position. (4 locations
along the periphery)
2) Wind the guide rail along the marked line, set the adjusting shaft (B) in alignment with the
hole (while the hand clamp is being tightened), and secure the guide rail by tightening the
adjusting nut.
Notes: ・Take care that the hand clamp will not be unclamped while tightening the adjusting
nut.
・Tighten the adjusting nut to the extent that the set hole in the adjusting shaft (B) of
the guide rail will not be deformed. (Tension: Approx. 8 kg less)
3) Insert two hand clips alternately into the hole in the overlapping section of the upper and
lower guide rails as shown in the figure in order to prevent lateral misalignment of the
guide rails.
4) Tightening the adjusting nut is necessary only once for cutting pipes of the same diameter.
From the second time onward, operation of the hand clamp alone will permit mounting.

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4.3.7 Trial operation
After setting, turn the machine once to check the secured condition of the machine and the
length of hoses and cabtyre cable.
The machine can be turned automatically or by hand in the manual mode after disengaging
the clutch.
■Automatic turning
Final operation can be checked by means of the main unit of the machine or the operation
box.
・Main unit
Turn on the rotational direction switch in the operation box, and operate the motor switch on
the main unit of the machine for final operation.
・Operation box
Turn on the motor switch on the main unit, and operate the rotational direction switch in the
operation box for final operation.
While the machine is traveling, adjust the cutting speed.
■Manual turning
In the case of the manual mode, disengage the clutch of the drive unit, and gently turn the
machine while holding it by hand.
Be sure to engage the clutch after completely confirming the operation.

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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.
■Method to ground the machine
・The ground pin is attached to the rubber plug of a cabtyre cord. Please use a power receptacle
with a ground pin opening.
5.1.2 Selection of tip
Referring to the Cutting Data, select the suitable tip according to the plate thickness.
For a heavily rusted plate or for a bevel cutting angle of more than 20°, select the tip one grade
higher than the one shown in the Cutting Data.
5.1.3 Operation of running direction changeover switch
・By changing the direction switch, the machine can move forward and backward. The stop position
on the switch is the stop position of the machine.
・When changing the direction, make sure that the direction switch is in the stop position, and
operate the direction switch after the machine has stopped.
・Be sure that the switch is in the stop position before starting the machine.
・Make sure that the switch is in the stop position before turning the power on. If the switch is in the
forward or backward position, the machine will start as soon as the power is turned on, which
could cause serious accidents.
・Never put your hands in the space between the guide roller and rail, as well as between the body
and the rail, while the machine is running, otherwise, your hands may be caught.
5.2 Ignition and flame adjustment
・Adjust the gas pressure according to the Cutting Data. The data shows the pressure when all the
valves are open. Readjust the pressure after ignition.
■Flame adjustment method
1. Open the fuel gas valve 1/4 to 1/2 a turn, and light the torch with an igniter.
2. Then, open the preheating oxygen valve gradually until a white cone of the standard flame has
been obtained. (The incandescent area should be uniform and about 5-6 mm (3/16-1/14’’) in
length.)
3. Open the jet oxygen valve fully. Readjust the flame if its condition has changed. A disorderly flow
of the jet oxygen will adversely affect the quality of the cutting surface. In such a case, clean the
tip with a suitable cleaning needle while the jet oxygen is flowing.
4. Appropriate distance between the tip end and cutting surface:
・Acetylene gas 8-10 mm
・LPG gas 5-8 mm

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Neutral flame ensures a good quality cut surface. (Oxidized flames may be used for bevel cutting.)
The oxidized flame shortens the cutting oxygen flow, causing slug deposition or melting the upper
edge of the cut surface. Excessively high cutting oxygen pressure will cause the same effect.
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.
3) Open the cutting oxygen valve to pierce the steel plate. The tip should be about 15-20 mm
from the plate to prevent slag from splashing onto the tip and adhering there, which will
shorten the working life of the tip.
5.4 Procedures for starting cutting operation and extinguishing the flame
1. Align the tip with the cutting start point, ignite, and then adjust the flame.
2. Sufficiently preheat the cutting start point.
3. After preheating, supply oxygen and simultaneously turn on the motor switch or the turning
direction switch to start cutting.
4. Carefully check the cutting condition, and control the cutting speed with the speed adjuster. For
the cutting speed, refer to the Cutting Data.
5. Extinguish the flame after cutting as follows:
1) Turn off the motor switch (or turning direction switch).
2) Close the cutting oxygen valve.
3) Close the preheating oxygen valve.
4) Close the fuel gas valve.

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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.
The following are causes of backfire:
1) Improper gas pressure adjustment
2) Overheated tip
3) Slag clogged in tip
4) Damage to the tapered section of the tip or torch will cause backfire.
5.5.2 Prevention of flashback
Flashback could cause fire and break the machine. Should there be a hissing sound in the torch,
quickly take the following
action:
1) Close the preheating oxygen valve.
2) Close the fuel gas valve.
3) Close the cutting oxygen valve.
Should flashback occur, find the cause and take appropriate action before using the machine
again.
5.6 Cutting operation
1. Attach the chain to the section to cut, and align the tip with the cutting start-up point.
2. Bring a flame close to the tip for ignition and ensure sufficient preheating.
3. Open the cutting oxygen valve and turn on both motor switch and directional changeover
switch simultaneously to begin cutting.
4. While checking the cutting condition, select the optimal cutting speed with the speed adjuster.
5. After cutting, turn off the switch and close the cutting oxygen valve, preheating oxygen valve and
fuel gas valve in this order.
* Thereafter, repeat operations from step 1.
5.6.1 Bevel cutting
1. Loosen the torch securing thumbscrew and set the
angle for bevel cutting.
2. For internal bevel cutting, remove the torch from
the torch holder, and reversely attach the torch
holder.
3. To reduce the effect of flame on the main unit,
position the torch away from the main unit as
much as possible during cutting operation.
4. Avoid piercing when starting cutting operation.

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5.6.2 Vertical cutting
1. Vertical cutting is possible for max. 500 dia. pipes.
2. Be sure to firmly set the guide rail at that time.