Koike PICLE1-II User manual

Ⅱ
Portable Automatic Gas Cutter
Operation Manual – Version T89001732
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.
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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
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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.
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PICLE1- Ⅱ
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CONTENTS
1. Safety Information·································································································
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1.1 General machine safety precautions ............................................................................... 2
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 .................................................................................................................. 6
3.4 Accessories ..................................................................................................................... 6
4. Preparation for operation.......................................................................................................... 7
4.1 Contents of package........................................................................................................7
4.2 Machine assembly...........................................................................................................7
4.3 Preparation for operation................................................................................................. 7
4.4 Securing machine to pipe ................................................................................................ 8
5. Cutting operation...................................................................................................................... 8
5.1 Safety measures prior to operation.................................................................................. 8
5.2 Ignition and flame adjustment.......................................................................................... 9
5.3 Cutting and piercing method............................................................................................ 9
5.4 Procedures for starting cutting operation and extinguishing the flame ........................... 10
5.5 Safety measures against backfire and flashback........................................................... 10
5.6 Cutting operation........................................................................................................... 10
6. Maintenance and inspection................................................................................................... 11
6.1 Daily inspection ............................................................................................................. 11
7. Trouble shooting..................................................................................................................... 11
8. Sketch drawing of PICLE 1-
Ⅱ ................................................................................................ 11
9. Parts list ................................................................................................................................. 12
9.1Main units....................................................................................................................... 12
10. Cutting Data ......................................................................................................................... 15
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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.
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 protectors (gauntlets, goggles, helmet, and safety shoes) during operation.
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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. Prior to operating the machine, check the safety of the surroundings to avoid accidents.
4. Never move the machine while the preheat flame is on.
5. Take great care of spatters and dross when operating the machine at a high position. They may
injure people below.
6. Do not hit any object against the surface of the wheel to be in touch with pipes or drop the
wheel so as not to scratch the surface; otherwise knocking will result.
7. Week chain tension will make the machine slip. Give an appropriate tension to the chain.
8. Be careful not to get your hand caught between the upper plate and slide bracket.
9. When stretching the chain, be careful not to get your hand caught in the wing bolt.
10. Do not insert your hand into rotary sections (sprocket and wheel).
11. Be careful not to drop the machine when changing the chain.
12. Do not use deformed or rusted chains; otherwise the chain may be disengaged.
13. Do not mistake the top and bottom sides of the chain.
14. The number of chains must match the pipes.
15. Do not place the machine on pipes when it is unused.
16. Be careful not to damage the wheel.
17. The planer deflection due to a worm wheel causes curved cutting surfaces and discrepancy
between the first and last cutting positions.
1.1.4 Maintenance and inspection precautions
1. Ask a qualified electrician to perform repair and inspection service.
2. Maintain the machine periodically.
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.
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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.
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.
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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.
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.
PICLE1-Ⅱ -T
CUTTING CAPACITY Φ114～600 mm
SERIAL NO.
KOIKE
NET WEIGHT 8.5
Kg
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PICLE1- Ⅱ
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3 Out line of machine
3.1 Features of machine
PICLE1- Ⅱ (PIPE CUTTER) is a compact pipe cutter developed on the basis of the actual
conditions of installed pipelines and work site where pipe cutting is needed. The machine will
exhibit excellent performance in straight and bevel cutting of all sizes of pipes, which accounts for
most of pipe cutting work, being habitually used by many users.
3.2 Name and function of each section
1. Gas distributor
Controls the flow of preheating oxygen,
fuel gas and cutting oxygen, forming a
cutting flame.
2. Wing nut
Controls the chain tension.
3. Handle
Drives the machine.
4. Torch slide handle
Moves the torch right or left.
5. Lateral bar
6. Torch
7. Up/down handle
Moves the torch up and down.
8. Wheel
9. Sprocket
Engaged with the chain, the sprocket
rotates to move the machine.
3.3 Specifications
Weight: 8.5kg
Length: 410mm
Wheel width: 210mm
Height: 410mm
Effective pipe cutting diameter: 114-600mm
Thickness of pipe to be cut: 50mm
Cutting shape: I-shape cutting and V-bevel cutting (up to 45 degree)
Drive system: Manual
Range of vertical torch movement: 50mm
Range of lateral torch movement: 100mm
3.4 Accessories
Tip 102 (for acetylene) or 106 (for propane): #0.1.2 one each
Tip cleaning needle: 1set
Lighter: 1pc
Chain (80pcs): 1set
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