Koike Sanso Kogyo IK-72T User manual

Portable Automatic Gas Cutter
BJA01B18
IK-72T
Three-Dimensional 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.

IK-72T
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.......................................................................................................7
4.1 Contents of package.....................................................................................................7
4.2 Machine assembly........................................................................................................7
4.3 Preparation for operation..............................................................................................8
5. Cutting operation................................................................................................................. 11
5.1 Safety measures prior to operation............................................................................. 11
5.2 Ignition and flame adjustment..................................................................................... 11
5.3 Cutting and piercing method.......................................................................................12
5.4 Procedures for starting cutting and extinguishing flame..............................................12
5.5 Safety measures against backfire and flashback ........................................................12
5.6 Cutting operation ........................................................................................................13
6 Maintenance and inspection.................................................................................................13
6.1 Daily inspection ..........................................................................................................13
6.2 3-month or 1000-hr inspection....................................................................................13
7. Trouble shooting..................................................................................................................14
8. Wiring diagram..................................................................................................................... 17
9. Assembly drawing................................................................................................................17
10. Parts list...............................................................................................................................18
10.1 Main and driving units............................................................................................... 18
10.2 Distribution and holder units ..................................................................................... 20
10.3 Rail unit ....................................................................................................................22
11. Cutting Data.........................................................................................................................24
CONTENTS

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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.
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 travel 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 used.
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.

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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. When mounting the machine on the rail ,correctly engage the clutch to stop it falling.
8. When operating the clutch in the direction of the space between the machine and the
heat shield, be careful not to get your hand caught between them.
9. Be sure to attach a device to prevent the rail from falling.
10. Correctly fix the rail.
11. To prevent the horizontal bar, and torch holder from falling, fix them with pan head
screws(SP-5×16) on the torch slide holder and support.
12. Be sure to hold the handle 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. Be sure to ground the cabtyre cord of the machine.
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 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.

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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.

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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 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.

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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.
1-1
1-6
1-4
1-2
1-3
1-5
1-1
1-2
1-4
1-3
1-5
1-6

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3 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 reducethecuttingwork.
3.2 Name and function of each section
1. Control panel
The switch and speed adjuster control the
machine operation.
2. Body
3. Fuse
4. Switch
When the switch is inclined in the direction of
the arrow, the machine begins to travel in that
direction.
5. Speed adjuster
Turn the dial clockwise, and the machine
travels faster.
6. Clutch lever
Incline the clutch lever to the right to
disengage the clutch (OFF) and to the left to
engage it (ON).
7. Driving pinion
Engaged with the rail rack, the driving pinion
turns to move the machine.
8. Gear box
The motions of the motor, gears, etc. permit
the machine to travel smoothly.
9. Side roller
When combined with the rail, the side roller
permits the machine to travel smoothly.
10. Torch slide handle
This handle adjusts the lateral position of the
torch.
11. Torch up / down handle
This handle adjusts the vertical position of the
torch.
12. Torch
13. Bevel setting screw
14. Heat shield
The shield protects the machine from the
heating flame.
15. Gas distributor
The gas distributor controls the flow rate of
preheating oxygen, fuel gas and cutting oxygen
to generate the optimal flame.
16. Valve
17. Hose
The hose connects the gas distributor and the
torch. Three hoses for preheating oxygen (blue),
fuel gas (red), and cutting oxygen (blue),
respectively, comprise one set.
18. Rubber rail
There are three kinds of rails –1D (straight AL
rail), 2D (two-dimensional rubber rail), and 3D
(three-dimensional rubber rail). Use them
correctly according to the shape of the steel
parts.
19. Magnet
The magnet fixes the rail to the steel plate. The
lever makes it easy to switch the magnet on
and off.
20. Eye bolt for chain
21. Lever
The lever is used for attaching and detaching
the rail.
22. Primary hose
23. Handle
Hold the handle when carrying the machine.

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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)
・3D (three-dimensional rubber rail with 5 magnets)
Power source : ±10%
Speed control : Dial operation
Cutting speed : 150–700 mm/min
Drive : Rack and pinion method
Cutting thickness : 6–30 mm (by standard accessories cutting tip)
Bevel angle : 0–45 degree
Tip : 102 (for acetylene) or 106 (for propane) #0,1,2 one each
Gas : Oxygen, Acetylene gas or LPG gas
Minimum radius of curve : 2,000 mm (for three-dimensional rail)
2,500 mm (for two-dimensional rail)
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
Distribution hose (3pcs set: 450L biased bend) 1 set
Primary hose (2pcs set: 1450L biased bend) 1 set
•Power cable (3P x 5M) 1 set
•Tip 102 or 106 #0,1,2 one each 1 pc each
•Tip cleaner 1 set
•Screw driver 1 pc
•Spanner (A,B,C) 1 set
•Fuse (1A) 2 pcs
4.2 Machine assembly
1. Carefully take the machine out of its case.
2. Carefully check that the torch holder, gas distributor, torch, etc. are in position.
3. Attach the primary hoses to the gas distributor.
Oxygen hose M12 x P1.5
Gas hose M12 x P1.5 (Left hand thread)

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4.3 Preparation for operation
4.3.1 Connecting the power cable
1. Connect the power cable to the body.
2. Before plugging the metal plug on the cabtyre cord side into the socket on the machine side, check
there is no dust inside.
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 the respective gas supply hoses to the primary hose.
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 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.
■Attaching the safety bracket
・During upward or vertical cutting, there is a
danger that the rail may fall with the
machine depending on workpiece
thickness, condition of the adsorption
surface, heat effects, vibration, etc. Be sure
to fasten the hook bolts securely and safety
fittings on both ends of the rail with ropes
or others. Do not operate under unsecured
situation without fall-prevention measures.
・If the magnet is not completely attached to
the workpiece due to the condition of the
workpiece affected by rust, paint,
deflection, etc., or if the magnetic force get
weak by rise of temperature, the rail may falls with the machine. Remove all obstacles attached
on the magnets before use to avoid dropping the magnetic force and any cutting failure.

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Rail may fall with machine depending on the operating conditions such as workpiece
thickness, condition
of absorption surface, thermal effect and others. Especially, since
the surface of 1D rail is flat, the magnetic force may get weak depending on the
condition of the workpiece such as rust, paint, deflection and others.
・1D rail (straight AL rail)
Used for cutting straight surfaces.
e.g. Straight cutting of ceilings or walls
・2D rail (two-dimensional rubber rail)
Used for cutting two-dimensional curved surfaces.
e.g. Two-dimensional curved surfaces of tanks, etc.
・3D rail (three-dimensional rubber rail)
Used for cutting three-dimensional curved surfaces.
e.g. Three-dimensional curved surfaces of ships, etc.
■Mounting the rail
Never hit the rail rack or the running surface with a hammer when aligning the tip with a marking line.
Dents on the rack or the running surface may result in irregular running such as knocking.
・1D rail (straight AL rail)
This rail is used for cutting flat plate. Four permanent magnets with detaching levers are provided
on this rail. Lift the lever, and while one side is being lifted, align then lower the lever for adhesion.
Confirm alignment with the cutting line with jigs and then attach the rail.
・2D rail (two-dimensional rubber rail)
This rail is used for cutting two-dimensional curved surfaces.
Five permanent magnets with detaching levers are provided
on this rail. Lift the lever, and while one side is being lifted,
align then lower the lever for adhesion. The alignment
procedure is the same as that for the 1D rail.
・3D rail (three-dimensional rubber rail)
This rail is used for cutting three-dimensional curved
surfaces. Five permanent magnets with detaching levers are provided on this rail. Lift the lever, and
while one side is being lifted, align then lower the lever for adhesion. The alignment procedure is
the same as that for the 1D rail.

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■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)
1.Lift the magnet detaching lever on the connection rail to
lift one side.
2.Align the connecting direction as shown in the figure.
3.Insert the fixed rail.
4.After positioning, fix the rail with the magnet.
4.3.5 Mounting the body
Raise the clutch lever, and a side roller on one side will open outward. Insert the body from the rail end
while the side roller is open to mount the body on the rail.
■Moving the rail
・When moving the rail, be sure to remove the body from the rail.
・Set all detaching levers on the rail fixing magnet in the OFF
position.
■Detaching the rail
・Lower the detaching lever to fix the rails to the steel plate.
・To remove the rails from steel plate, lift the detaching lever.

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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.
■How 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 degrees, 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 neutral position
on the switch is the stop position of the machine.
・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.
・Be sure that the switch is in the neutral position before starting the machine.
・Make sure that the switch is in the neutral 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 touch the H-lever while the machine is moving,
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 gas 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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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.
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 followings 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.

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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.
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.
*Rail may fall with the machine depending on the operating conditions such as workpiece thickness,
condition of adsorption surface, thermal effect, etc. Especially, since 1D rail’s surface is flat, the adsorption
force may drop due to the condition of the work piece affected by rust, paint, deflection, and others.
Be sure to take measures such as keeping the torch away from rail, removing rust, paint, and other
obstacles from the workpiece.
In case of operation on wall or at high place, be sure to securely fasten the hook bolts and safety fittings
on both ends of the rail with ropes or others.
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.
2. Remove dust from the rail, rack, and attractive surface of the magnet on the roller running surface.
3. Inspect for excessive play and abrasion in the sliding sections.
4. Inspect for gas leaks from the respective gas hose joints and valves.
6.2 3-month or 1000-hr inspection
1. Disassemble the gear case and motor gear ass’y . Clean them with cleaning oil to remove old grease
inside the gear case as necessary. ( Use the specified grease.)
2. Replace internal parts which are extremely abraded with new ones.

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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
to see if it has blown.
Replace the blown fuse.
3) Disconnection of power
cable
Check the cable with a tester.
Indicates disconnection
Repair the disconnected cable.
4) Poor connection
Check that lead wires are correctly
connected to the terminal block.
Connect the wires again.
5) Defective switch
Remove the switch and check for
continuity between terminals with a
tester.
Replace the switch if it is
defective.
6) Defective speed
controlling resistor
Check with a tester that the resistance
is 50 kΩ.
Replace the resister if it is defective.
7) Disconnection of lead wire
Check for continuity between the
lead wires with a tester.
Replace disconnected lead
wires.
8) Defective motor
If all the above items are normal, the
motor is defective.
Repair or replace the motor with
a new one.
9) Defective controller
If all the above items are normal, the
controller is defective.
Replace the defective controller.
Note:
Protection of the over load.
When the motor was locked by any reason, the motor rotation will be stopped after about four second.
(Recovery: Please turn on the power supply again.)
(2) Speed can not be controlled. (The motor runs.)
Cause
Inspection point
Correction
1) Defective speed control
resistor
Remove the speed control resistor
and apply the probes of a tester to
resistor terminals (2) and (1) or (2)
and (3). If the pointer continuously
moves from 0 to 50 kΩ when the
handle is turned slowly, the resistor
is normal.
Replace the defective resistor.
2) Defective controller
When 1) is normal, the controller is
defective.
Replace the defective controller.

IK-72T
－15－
(3) The machine will not move. (The motor runs)
Cause
Inspection point
Correction
1) Malfunction
Remove the speed reducer box to
check the clutch operation.
Disassemble and clean.
2) Idle rotation of
reduction gear
The reduction gear is rotating idly
when the motor keeps running even if
the direction changeover switch is
turned on or the drive wheel is
stopped by hand.
Replacement of gears (set).
(4) The machine runs incorrectly
Cause
Inspection point
Correction
1) The speed is too fast
The supply voltage is abnormal.
Check the voltage.
2) Low speed is not
possible.
①Speed control resistor is defective.
Replace with a new one.
②Defective wiring.
Correct the wiring.
③Defective motor.
Repair or replace the motor with
a new one.
④Defective controller.
Replace with a new one.
3) High speed is not
possible.
When the supply voltage has
dropped.
Check with a tester.
4) Knocking occurs.
①Abrasion of gears.
Replace .
②Abrasion of clutch key.
Replace or repair.
③Excessive play between shaft and
drive wheel.
Replace or repair.
④Hose or cabtyre cords hinder
smooth running.
Consider during operation.
⑤Flaws on the drive and drive wheel
or adhesion of foreign material.
Replace or repair.