Koike Sanso Kogyo IK-82 M-300 User manual

Portable Automatic Gas Cutter
BEC00B18
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
1.2Gas cutting safety precautions 3
2.Location of safety labels 5
3.Outline of machine 6
3.1 Features of machine 6
3.2Name 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 8
4.3 Preparation for operation 8
5.Cutting operation 11
5.1 Safety measures prior to operation 11
5.2 Ignition and flame adjustment 13
5.3 Cutting and piercing method 14
5.4 Procedures for starting cutting and extinguishing flame 14
5.5 Safety measures against backfire and flashback 15
5.6 Cutting operation 15
5.7 Option 16
6.Maintenance and inspection 17
6.1 Daily Checks 17
7.Troubleshooting 18
8.Wiring diagram 19
9.Assembly drawing of IK-82 M-300 19
10.Parts list 20
10.1 Main unit 20
10.2 Control panel 22
10.3 Tracer head 24
10.4 Torch 26
11.Cutting Data 28

IK-82 M-300
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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 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 the machine will not be used for cutting, turn off the magnet switch
8. Be sure to fix the magnet for securing the machine before starting cutting operation.
9. Be sure to secure the leg with a curved handle.
10. When carrying the machine, pay attention to the movement of the tracer head.
11. Be sure to fix the wing nut for securing the tracer head during cutting operation.
12. When storing or carrying the machine, set the arm in the ring attached to the leg.
13. 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. 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 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 is leaking.
2. Install cylinders upright and take measures to prevent them from falling.
3. Use cylinders only for specified purposes.
4. Do not smear container valves with oil or grease.
5. Install cylinders in a place free from heat, sparks, slag, and 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 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 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 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.
1-1

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3 Outline of machine
3.1 Features of machine
IK-82 is a new and powerful mold cutting series of a concentric tracing type. The simple design
and interchangeable construction have substantially reduced the machine weight and permitted
systematization for easy use.
The model comes in two types The type can be to select according to size of material to be
cut.
Enjoy advanced mold cutting with this IK-82 series.
3.2 Name and function of each section
1. Tracer head
Holds the torch and moves along a mold.
2. Magnet roller
Turns and moves along a mold.
3. Torch up/down handle
Moves the torch up and down.
4. Torch
5. Motor
6. Magnet ON-OFF switch
Turns on and off the magnetism.
7. Arm
8. Handle
9. Leg
10. Magnet
11. Hose

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3.3 Specifications
Total Weight 9.5kg
Power supply ±10%
Cutting speed 100-600mm/min
Effective cutting range 300 dia. circle
600x200 oval
Machine securing 50 kg magnet with detaching lever
Magnet roller 16 dia.
Cutting thickness 5-30mm (reference value when using the tip No.0-2)
Tip Type 400
1/300 speed reducer
Gas Oxygen, acetylene, or LPG
●Accessories
・Tip (Type 400) Nos. 0, 1, 2 1 pc each
・Tip cleaner 1set
・Spanner (A,B,C, and F) 1set
・Screw drive 1 pc
・Fuse (2A) 2pcs
・Brush 1pc
・Cabtyre cord 1pc
・Lighter 1pc
●Option
・Magnet roller 25 dia.

IK-82 M-300
－8－
4 Preparation for operation
4.1 Contents of package
The following are in the packing. Check them before assembling the machine.
・Body 1set
・Torch 1pc
・Distribution hose (2-piece set:700L) 1set
・Cabtyre cord (3Px5M) 1pc
・Tip (type 400) 402 or 406 Nos. 0, 1, 2 1pc each
・Tip cleaner 1set
・Screwdriver 1pc
・Spanner (4pcs) 1set
・Fuse (2A) 2pcs
・Brush 1pc
・Lighter 1pc
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 hose to the gas distributor.
OX hose
Gas hose
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.

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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.
2. Lift the tracer head.
3. Let the torch out with the torch up/down handle.
4. Attach the tip.
5. Secure the tip tightening nut and return the tracer head to the upright position.
4.3.4 Making Template
The torch moves on the locus of the magnetic roller. Cut the rough template shape taking into
consideration the magnetic roller diameter and width of cutting loss for accurate shape cutting
when making template.
1. Caution when making template.
・Template defect may cause faulty cutting.
・In general, adopt an inner tracing template.(IF an outer tracing template is used, it may fall with
the cutting machine when cutting is completed.)
・Make template from plate 6mm thick.
・Remember when making calculations that width of cutting loss is determined by nozzle size.

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Example1
When outer part by cutting is a product.
To cut 100mm dia. hole in 12mm thick plate.
・Kerf width and tip No.#1
1.2x1.6=2mm
φ100+φ16-2=φ114
Product dimension + roller dia. -Kerf
width=Template dimension
Example 2
When inner part by cutting is a product.
To cut 12mm thick 100mm dia. plate.
・kerf width and tip No.#1
1.2x1.6=2mm
φ100+φ16+2=φ118
Product dimension + roller dia. +Kerf
width=Template dimension
2. Template
1) Placed type template
The template should have enough weight or be equipped with a clamp to prevent it from being
drawn up by the magnetic roller or from moving.
The template should be made in such a way that the template bottom surface matches with
the roller bottom surface.
2) Mounted type template
Make mounting holes in the template as shown below when mounting template to cutting
machine.
Use the tapped holes (M8) in the cutting machine to mount the template.
Provide the template supporters to improve the cutting machine steadiness as reqired at the
position where the supporters do not interfere with the magnetic roller movement when the
template size is large.
＊When the magnetic roller diameter is φ16, the template is 16 mm high.
When the magnetic roller diameter is φ25, the template is 66mm high.

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IK-82 M-300 Cutting range

IK-82 M-300
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5 Cutting operation
スパナ
5.1 Safety measures prior to operation
5.1.1 Check for gas leaks at each connection
This machine is a gas cutting machine. Before use, please pay careful attention to the gas connection
part, and make sure to conduct a gas leak inspection and use it safely.
■There are the following nut tightening operations for connecting the torch and tip. Please be careful not
to mistake the procedure.
Correct Incorrect
As shown in the figure, pull out the torch from the tracer head and tighten the tip fixing nut with two
spanners.
The gas joint has the following locations. Use a gas detection liquid or soapy water to check for gas
leaks.Also be sure to use two wrench of appropriate size when tightening the nut of each joint.
■Please refer to the following items and figures for the location to check for gas leaks.
a)Primary hose connection part b)Joint nipple and connection part of each hose
Spanner
Spanner
Spanner
1pc

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c)Torch gas inlet and secondary hose connection d)Check for leaks from each valve mounting
and valve spindle.
e)Check for gas leaks from holes in the side of Overall view
the torch body (*1)
(*1)Please check with the tip attached and the gas ignited.
■Tightning the tip fixing nut and checking for gas leakage.
・When tightning the cip fixing nut, first insert a spanner into the two chamfered portion of the torch body to
secure the torch body. Next,insert another spanner into the two chamfered parts of the tip fixing nut abd
tighten it with a torque of 25N・m.
・Use a gas detection liquid or soapy water to the tip fixing nut, and check for gas leaks.
Note) If there are scratches or rther foreign objects in the tip area or the tip area of the torch body, gas may
leak even if the tip fixing nut is tightened. If the gas is leaking from the tip fixing nut, the IK-82 main
unit be filled with gas, which is very dengerous.
When replacing the tip, be sure to pull out the torch from the IK-82 body, replace the tip, and make
sure that there is no gas leakage from the tip fixing nut.
(With the tip attached and the gas ignaited, run the detection or soapy water through the tip
fixing nut and check.)
a
b
c
d
e

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5.1.2 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.
5.1.3 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.
5.1.4 Operation of running direction changeover switch
・Use the directional changeover switch to change the direction of rotation. The machine is at rest when
the switch is in the OFF position.
・When changing the running direction, be sure to return the changeover switch to the OFF position.
After the machine has stopped once, change the runnning direction.
・Be sure to set the switch in the OFF position unless the machine is tp be moved.
・Set the directional changeover switch in the OFF position when tunring on the power. When the switch
is in the clockwise or couterclockwise tunring position, the machine will begin to move, which is very
dangerous.
・Never put your hand between the magnet roller and the mold when the machine is traveling, otherwise
your hand may be caught between them.
5.2 Ignition and flame abjustment
・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.(See page 28)
■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 5-6mm(3/16-1/14”) in length)
3.Open the jet oxygen valve fully. Readjust the flame if its condition has changed. Adisorderly 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 ……8-10mm
・LPG gas …………5-8mm

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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 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.
Oxidizing Flame
Carburizing Flame
Fiame
Neutral Flame