Koike Sanso Kogyo IK-12 NEXT User manual

Portable Automatic Gas Cutter
BCG00B02
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 Gus cutting safety precautions---------------------------------------------------------------3
1.3 Plasma cutting safety precautions ----------------------------------------------------------5
1.4 Welding safety precautions------------------------------------------------------------------11
2. Location of Safety labels---------------------------------------------------------------------------- 16
3. Overview of the Unit --------------------------------------------------------------------------------- 17
3.1 Features of the Unit--------------------------------------------------------------------------- 17
3.2 Specifications----------------------------------------------------------------------------------- 18
3.3 Contents of package-------------------------------------------------------------------------- 18
4. Method of operation---------------------------------------------------------------------------------- 19
4.1 Name of each parts--------------------------------------------------------------------------- 20
4.2 Operation panel ------------------------------------------------------------------------------- 22
5. Gas cutting operation-------------------------------------------------------------------------------- 35
5.1 Standard composition of gas epuipment------------------------------------------------- 35
5.2 Assembling the Unit (for a Single Torch Set) ------------------------------------------- 36
5.3 Preparation for Work ------------------------------------------------------------------------- 36
5.4 Safety Measures before Starting Work--------------------------------------------------- 37
5.5 Ignition and flame adjustment-------------------------------------------------------------- 38
5.6 Cutting and piercing method---------------------------------------------------------------- 38
5.7 Procedures for starting cutting operation and extinguishing the flame ----------- 38
5.8 Safety measures against backfire and flashback-------------------------------------- 39
5.9 Cutting operation------------------------------------------------------------------------------ 39
6. Plasma cutting operation --------------------------------------------------------------------------- 41
6.1 Preparation for Work ------------------------------------------------------------------------- 41
6.2 Cutting operation------------------------------------------------------------------------------ 41
7. Welding Work----------------------------------------------------------------------------------------- 41
7.1 Preparation for Work ------------------------------------------------------------------------- 41
7.2 Welding Work ---------------------------------------------------------------------------------- 42
8. Maintenance Inspections--------------------------------------------------------------------------- 42
8.1 Daily Inspections ------------------------------------------------------------------------------ 42
8.2 Monthly Inspections--------------------------------------------------------------------------- 42
8.3 3-monthly Inspections------------------------------------------------------------------------ 42
8.4 About the Warranty --------------------------------------------------------------------------- 42
9. Trouble shooting-------------------------------------------------------------------------------------- 43
10. Wiring Diagram--------------------------------------------------------------------------------------- 46
11. Assembly drawing of IK-12 NEXT---------------------------------------------------------------- 47
12. Parts list------------------------------------------------------------------------------------------------ 48
12.1 Main body and inside parts --------------------------------------------------------------- 48
12.2 Outside parts --------------------------------------------------------------------------------- 50
12.3 Electrical parts ------------------------------------------------------------------------------- 52
13.Cutting Data------------------------------------------------------------------------------------------- 54

IK-12 NEXT
－1－
01 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:
■DANGER
Improper handling is very likely to cause death or serious injury.
■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 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. 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 by electric shock.