Koike Sanso Kogyo IK-54D User manual

Portable Automatic Gas Cutter
BEA00B22
Pattern Cutter
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 section--------------------------------------------------------------------6
3.3 Specifications------------------------------------------------------------------------------------------------7
4. Preparation for operation ---------------------------------------------------------------------------------------- 8
4.1 Contents of package---------------------------------------------------------------------------------------8
4.2 Machine assembly ---------------------------------------------------------------------------------------- 9
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 Procedure for starting cutting and the method of extinguishing fire (pattern cutting)----- 14
5.5 Cutting operation----------------------------------------------------------------------------------------- 15
5.6 Option ----------------------------------------------------------------------------------------------------- 15
6. Maintenance and inspection---------------------------------------------------------------------------------- 16
6.1 Daily inspection------------------------------------------------------------------------------------------- 16
6.2 Monthly inspection--------------------------------------------------------------------------------------- 16
6.3 3-month inspection--------------------------------------------------------------------------------------- 16
7. Trouble shooting------------------------------------------------------------------------------------------------- 17
8. Wiring diagram--------------------------------------------------------------------------------------------------- 18
9. Assembly drawing of IK-54D---------------------------------------------------------------------------------- 18
10. Parts list---------------------------------------------------------------------------------------------------------- 19
10.1 Gear case, No.1 arm unit----------------------------------------------------------------------------- 19
10.2 Upper arm, Main spindle, unit ----------------------------------------------------------------------- 22
10.3 No.2 arm, weight unit---------------------------------------------------------------------------------- 24
10.4 Circle cutting unit --------------------------------------------------------------------------------------- 26
11. Cutting data------------------------------------------------------------------------------------------------------ 28

IK-54D
－1－
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 indicated on the machine safety labels:
■WARNING
This word is used in a warning message and a warning label is positioned at places that could
cause injury or serious accident.
■CAUTION
This word is used in a caution message and a caution label is positioned 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 part 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.
1.1.2 Safety clothing
1.Be sure to wear protector’s gauntlets, goggles, helmet, and safety shoes during operation.
2.Avoid operating the machine with wet clothes or hands in order to prevent electric shock.

IK-54D
－2－
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).
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. Firmly secure the balance weight.
8. Secure the upper and No.2 arms with a curved handle so that they will not fall off the shaft.
9. Secure the upper, No.1, and No.2 arms when carrying the machine. Exercise special care when
carrying 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) When the machine has been in contact with water, or in case of 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 that requires 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.

IK-54D
－3－
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.
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 pressure regulators from which gas is leaking, nor malfunctioning pressure regulators.
4. Do not use pressure regulators smeared with oil or grease.
1.2.3 High Pressure gas cylinder safety precautions
1. Never use broken cylinders or cylinders from which gas are 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.
1.2.4 Safety precautions for hoses
1.Use the oxygen hose for 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.
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 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.

IK-54D
－4－
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.
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.
●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 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:
●Place the torch on the torch holder before igniting.
●Always wear the required protectors (gauntlets, helmet, goggles, 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 the surface after cutting is very hot so do not touch it even while wearing
gauntlets.
10.Never move the machine while the preheat flame is on.

IK-54D
－5－
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.
󳡬󳡮󳡐󳡘󳡗󳡧
󳡤󳡸󳡷󳡲󳡰󳡤󳡷󳡬󳡦󳡃󳡪󳡤󳡶󳡃󳡦󳡸󳡷󳡷󳡬󳡱󳡪󳡃󳡰󳡤󳡦󳡫󳡬󳡱󳡨
󳡦󳡸󳡷󳡷󳡬󳡱󳡪󳡃󳡦󳡤󳡳󳡤󳡦󳡬󳡷󳡼
󳡦󳡸󳡷󳡷󳡬󳡱󳡪󳡃󳡶󳡳󳡨󳡨󳡧
󳡬󳡱󳡳󳡸󳡷󳡃󳡶󳡬󳡱󳡪󳡯󳡨󳡃󳡳󳡫󳡤󳡶󳡨󳡃󳡤󳡦
󳡶󳡨󳡵󳡬󳡤󳡯󳡃󳡱󳡲󳡑
󳡮󳡲󳡬󳡮󳡨󳡃󳡃󳡶󳡤󳡱󳡶󳡲󳡃󳡃󳡮󳡲󳡪󳡼󳡲󳡃󳡃󳡦󳡲󳡑󳡏󳡃󳡯󳡷󳡧󳡑
󳡰󳡤󳡧󳡨󳡃󳡃󳡬󳡱󳡃󳡃󳡭󳡤󳡳󳡤󳡱
󳢐󳢐
󳢐󳢐󳡒󳢐󳢌󳢑
󴇑
󴇑
󳡹
󳡖󳡔󳡓󳡓
󳡔󳡓󳡓 󳡔󳡓󳡓󳡓

IK-54D
－6－
3 Outline of machine
3.1 Features of machine
The IK-54D is equipped with the following 8 features.
1. The machine is stable.
The fixed type main shaft ensures stability of the machine.
2. The cutting range has been further enlarged.
The arm turns 360 degrees around the main spindle. Put a tracing pattern is on the main shaft,
and cutting operation up to 1,700 dia. is possible.
3. The traveling speed range has been widened to improve the traveling performance.
A DC shunt motor is used for driving, and the PWM control system has been adopted for
wider speed change range and stabler traveling speed.
4. The tip and torch can be changed easily.
A rotary torch holder is adopted, and the high-accuracy stability has been ensured by a
special pin. Therefore torch change and tip cleaning are very easy.
5. Distinguished operability
Operation switches are collected in the No.1 arm section for very easy operation.
6. Several types of magnets can be attached.
In addition to the standard 10 dia. magnet roller, 6, 8, 15 and 20 dia, magnet rollers are
provided.
They can be changed easily. These strong magnets ensure stable tracing.
7. Lightweight stand
A light alloy is used for reduction in weight
8. A pattern is unnecessary for circle cutting.
Use of circle cutting attachment (option) permits cutting 60-400 dia. circles without a pattern.
3.2 Name and function of each section
1. Upper arm
Used for setting the cutting direction.
2. Template holder
Used for attaching a tracing pattern.
3. Magnet roller
Turns along a tracing pattern.
4. Motor
5. Torch
6. No.1 arm
7. No2 arm
8. Stand
9. Weight
10. Main spindle

IK-54D
－7－
3.3 Specifications
Weight: 33kg (without weight )
Machine size: 1,260×695×550mm
Power: ±10%
Motor: DC 23W
Speed control : PWM control system
Cutting thickness: 3 - 100 mm
Cutting speed: 100-1,000 mm/min
Cutting accuracy: with in ± 0.5 at φ500mm
Magnet roller: φ10
Cutting range:
for circle φ30~φ700
for circle (when main spindle rotate)
φ600~φ1,700
for square □30~□600
for square (when main spindle rotate)
□500~□1,200
Tip: 102 (for acetylene) or 106 (for propane)
Gas: Oxygen, acetylene gas, or LPG gas
●Accessories
Tip 102 (for acetylene) or 106 (for propane) # 0,1,2
1 pc each
Power cable 1 set
Tip cleaner: 1 set
Bush 1 set
Spanner 1 pc
Center: 1 set
Ruler 1 pc
Fuse (1A) 2 pcs
Hexagon wrench M6 1 pc
●Option
Magnet roller φ6, φ8, φ15, φ20
Template set plate (used for setting template to main spindle)
Circle cutting unit

IK-54D
－8－
4 Preparation for operation
4.1 Contents of package
The contents of the standard package are shown below. Check then carefully before assembling the
machine.
Stand·································································· 1set
Main spindle························································· 1set
No.2 arm:····························································· 1set
No.1 arm:····························································· 1set
Operation panel:···················································· 1set
Tracing drive unit
(motor, reduction gear, magnet roller):························ 1set
Torch unit (torch, torch holder):································· 1set
Upper arm (slide bar):············································· 1set
Template holder (template set bolt):··························· 1set
Weight (weight bar):··············································· 1set
Power cable (3Px5M): ············································ 1set
Tip 102(for acetylene) or 106 (for propane) #0,1,2:······· 1pc each
Tip cleaner: ·························································· 1set
Brush: ································································· 1pc
Spanner:······························································ 1pc
Center:································································ 1pc
Ruler:·································································· 1pc
Fuse: ·································································· 2pcs
Hexagon wrench M6:·············································· 1pc

IK-54D
－10－
1A
H. Change over switch for snape / Circle cutting
I . Connector
Circle cutting motor

IK-54D
－12－
4. The bolt used to fix the template is M12. Make a hole at the center of gravity of the
template.

IK-54D
－13－
・The ground pin is attached to the rubber plug of a cabtyre cord. Please use a power receptacle
with a ground pin opening.

IK-54D
－14－
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 other adverse effects on the cut surface. Similar defects
will result when the cutting oxygen pressure is too high.
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 Procedure for starting cutting and the method of extinguishing
fire(Pattern cutting)
1. Set the pressure switch in the interlocked position.
2. Set the drive switch in the left or right position.
3. Open the pressure switch valve of the torch.
4. Open the gas valve, slightly open the preheating oxygen valve, and ignite the gas with a lighter.
Then fully open the gas valve immediately. (The gas valve may not be opened fully in some cases
high-quality cutting). Make a neutral flame by controlling the preheating oxygen valve.
5. Control the distance between the tip from the steel sheet. Keep the tip of the white point 2-3mm
away from the steel sheet.
6. After sufficiently preheating the edge of the steel sheet or the small hole made in advance for
starting cutting, open the cutting oxygen valve. When the valve is opened, the pressure switch is
activated simultaneously, and the motor turns to drive the magnet roller.
7. Move the magnet roller by hand to the template (while cutting), bring the roller in close contact
with the template, and begin cutting.
8. After beginning cutting, carefully check the cutting condition to find
the optimum cutting speed.
9. When the cutting tip returns to the starting point, immediately close
the cutting oxygen valve, and the magnet roller stops simultaneously.
Then close the gas valve and preheating oxygen valve in this order,
and return the drive switch to the stop position. (It is not necessary to
return to the stop position when cutting operation is to be continued.)