Koike IK-12 BEETLE User manual

Portable Automatic Gas Cutter
Operation Manual – Version T89001694
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.
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 in
j
ur
y
due to hi
g
h temperature under
certain conditions
Caution: Ignition
！
Possible ignition under certain conditions

- 1 -
CONTENTS
1. Safety Information .................................................................................................................2
1.1 General machine safety precautions ..............................................................................................2
1.2 Gas cutting safety precautions........................................................................................................4
2. Locations of safety labels.......................................................................................................6
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 ...........................................................................................................................8
4.3 Preparation for operation .................................................................................................................9
5. Cutting operation ................................................................................................................. 10
5.1 Safety measures prior to operation...............................................................................................10
5.2 Ignition and flame adjustment .......................................................................................................10
5.3 Cutting and piercing method .........................................................................................................11
5.4 Procedures for starting cutting and extinguishing flame ...............................................................11
5.5 Safety measures against backfire and flashback .........................................................................11
5.6 Cutting operation...........................................................................................................................12
5.7 Set up circle cutting attachment ....................................................................................................12
5.8 Circle rail .......................................................................................................................................12
6 Maintenance and inspection ................................................................................................. 12
6.1 Daily inspection .............................................................................................................................12
6.2 Monthly inspection ........................................................................................................................12
6.3 3-month (2000-hour) inspection....................................................................................................13
7. Trouble shooting.................................................................................................................. 13
8. Wiring diagram ..................................................................................................................... 15
9. Sketch drawing of IK-12BEETLE.......................................................................................... 15
10. Parts list ............................................................................................................................... 16
10.1 Main units....................................................................................................................................16
10.2 Electrical, gas and torch slide holder units..................................................................................19
10.3 Two torch unit..............................................................................................................................22
11. Cutting Data ......................................................................................................................... 24
CONTENTS

2
16

MAIN UNIT IK12 BEETLE - 15CS
ITEM NUMBER
PART DESCRIPTION
QUANTITY
PART NUMBER
REMARKS
1
CASE
1
ZS31802
2
CROSS FEED HOLDER
1
ZS31803
3
CROSS FEED LINER
1
ZS31804
4
HANDLE
1
ZS31805
5
FAN COVER
1
ZS31806
6
BOTTOM PLATE
1
ZS31807
7
HEAT SHIELD
1
ZS31808
8
HEAT SHIELD COLLAR
1
ZS31809
9
SWIVEL G IDE WHEEL
NIT
1
ZS31810
*See notes
on drawing
*
10
N/A
1
Included in #ZS31810
11
N/A
1
Included in #ZS31810
12
N/A
1
Included in #ZS31810
13
N/A
1
Included in #ZS31810
14
N/A
1
Included in #ZS31810
15
LARGE IDLE WHEEL
1
ZS31813
16
COLLAR BEARING (A)
1
ZS31814
17
BEARING RETAINER
2
ZS31815
18
COLLAR BEARING (B)
1
ZS31816
19
DRIVE WHEEL SHAFT
1
ZS31817
WITH KEY
20
COLLAR BEARING (C)
1
ZS31818
21
DRIVE WHEEL
1
ZS31819
22
WORM WHEEL
1
ZS30247
23
CL TCH
1
ZS30246
24
WASHER
2
ZS30242
25
PHILLIPS SCREW
2
9968164400
M5X15
26
PHILLIPS SCREW
12
9968177100
M5X8
27
BEARING BALL
2
1138357000
6300ZZ
28
BEARING BALL
1
1138359400
6302ZZ
29
RETAINING RING
1
9968261100
M15
30
CL TCH LEVER NIT
1
ZS31820
31
SLIDER
1
ZS30265
32
CL TCH SPRING
1
ZS31821
33
WORM SHAFT NIT
1
ZS31822
34
WORM SPRING
1
ZS31823
35
SPEED ADJ STING SHAFT
1
ZS31824
36
SPEED ADJ STING BRACKET
1
ZS31825
37
RACK
1
ZS31826
38
SPEED ADJ STING HANDLE
1
ZS31827
39
SPEED ADJ STING KNOB
1
ZS31828
40
SPEED ADJ STING CONE
1
ZS31860
41
CONE SPRING
1
ZS31829
42
MOTOR DISK
1
ZS31868
43
MOTOR W/FAN DISC
1
ZS31830
100V
-
120V
MOTOR W/FAN DISC
1
ZS31832
200V
44
BEARING BALL
3
1138352500
608ZZ
45
CROSS FEED PINION NIT
1
ZS31835
46
ROLL PIN
1
9968204300
M2.5X16
47
SPEED ADJ STING HANDLE
1
ZS30223
48
PINION, METAL
1
ZS30318
49
PINION
1
ZS30319
50
WING SCREW
1
9968232500
M6X16
51
WING SCREW
1
9968232800
M6X25
52
HEX SCREW
2
9968105700
M6 1X30
53
HEX SCREW
2
9938105400
¼
-
20 X 1 ½
54
PHILLIPS SCREW
3
9968179800
M6X14
55
PHILLIPS SCREW
4
9968177500
M5X15
56
PHILLIPS SCREW
10
9968174900
M4X10
57
PHILLIPS SCREW
4
9968175300
M4X16
58
PHILLIPS SCREW
8
9968174800
M4X8
59
MOTOR FAN W/ SCREWS
1
ZS30289
60
PHILLIPS
SCREW
1
9968175300
M4X16
3
17