Portable Automatic Gas Cutter

BCG00B02

OPERATION MANUAL

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.

KOIKE SANSO KOGYO CO.,LTD.

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 Possible injury to fingers if caught in the insertion
fingers caught. 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 Operators must unplug the power plug from the
from the outlet. 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 Gus cutting safety precautions --------------------------------------------------------------- 3
1.3 Plasma cutting safety precautions ---------------------------------------------------------- 5
1.4 Welding safety precautions ------------------------------------------------------------------ 11
2. Location of Safety labels ---------------------------------------------------------------------------- 16
3. Overview of the Unit --------------------------------------------------------------------------------- 17
3.1 Features of the Unit --------------------------------------------------------------------------- 17
3.2 Specifications ----------------------------------------------------------------------------------- 18
3.3 Contents of package -------------------------------------------------------------------------- 18
4. Method of operation ---------------------------------------------------------------------------------- 19
4.1 Name of each parts --------------------------------------------------------------------------- 20
4.2 Operation panel ------------------------------------------------------------------------------- 22
5. Gas cutting operation -------------------------------------------------------------------------------- 35
5.1 Standard composition of gas epuipment ------------------------------------------------- 35
5.2 Assembling the Unit (for a Single Torch Set) ------------------------------------------- 36
5.3 Preparation for Work ------------------------------------------------------------------------- 36
5.4 Safety Measures before Starting Work --------------------------------------------------- 37
5.5 Ignition and flame adjustment -------------------------------------------------------------- 38
5.6 Cutting and piercing method ---------------------------------------------------------------- 38
5.7 Procedures for starting cutting operation and extinguishing the flame ----------- 38
5.8 Safety measures against backfire and flashback -------------------------------------- 39
5.9 Cutting operation ------------------------------------------------------------------------------ 39
6. Plasma cutting operation --------------------------------------------------------------------------- 41
6.1 Preparation for Work ------------------------------------------------------------------------- 41
6.2 Cutting operation ------------------------------------------------------------------------------ 41
7. Welding Work ----------------------------------------------------------------------------------------- 41
7.1 Preparation for Work ------------------------------------------------------------------------- 41
7.2 Welding Work ---------------------------------------------------------------------------------- 42
8. Maintenance Inspections--------------------------------------------------------------------------- 42
8.1 Daily Inspections ------------------------------------------------------------------------------ 42
8.2 Monthly Inspections--------------------------------------------------------------------------- 42
8.3 3-monthly Inspections ------------------------------------------------------------------------ 42
8.4 About the Warranty --------------------------------------------------------------------------- 42
9. Trouble shooting -------------------------------------------------------------------------------------- 43
10. Wiring Diagram --------------------------------------------------------------------------------------- 46
11. Assembly drawing of IK-12 NEXT ---------------------------------------------------------------- 47
12. Parts list ------------------------------------------------------------------------------------------------ 48
12.1 Main body and inside parts --------------------------------------------------------------- 48
12.2 Outside parts --------------------------------------------------------------------------------- 50
12.3 Electrical parts ------------------------------------------------------------------------------- 52
13. Cutting Data ------------------------------------------------------------------------------------------- 54
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01 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:

■DANGER
Improper handling is very likely to cause death or serious injury.

■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 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. 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.

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1.1.2 Safety clothing

1. Be sure to wear protectors gauntlets, goggles, helmet, and safety shoes during operation.
2. Avoid operating the machine with wet clothes or hands in order to prevent electric shock.

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. Make sure that the clutch is engaged before letting the machine travel. Improper clutch
engagement will cause machine failure.
8. Be careful not to get you hand caught between rails when connecting them.
9. When cutting on the rail, correctly fix the caster.
10. Correctly fix the heat prevention plate so that it will not touch the rail.
11. To prevent the torch holder from dropping, fix it with the wing bolt (BS-6x22) on the torch slide.
12. Be sure to hold the handle when carrying the machine.
13. Be sure to remove the machine from the rail when moving the rail.

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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1.1.6 About the transport of the machine

1. Be sure to hold the handle when carrying the machine.
2. Be sure to remove the machine from the rail when moving the rail.
3. Do not lift the carriage by holding its Handle. There is risk of falling off carriage while holding carriage
by handle, if there is shockimpact at carriage or if mounting screw of handle is loose.

1.1.7 Machine noise

1. Volume of at the time of driving the machine is less than 70dB.

1.1.8 About external environment

1. 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.
2. Please avoid high temperature and humidity.
3. Please use in an environment where the internal temperature is 5 ~ 70 ℃.
4. Please use in an environment with internal humidity of 20 to 80% RH.

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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 extinguishing 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 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 .
●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, goggles, helmet, 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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1.3 Plasma cutting safety precautions

In order to carry out plasma cutting safely, it is important to observe precautions and rules for safety,
and to keep in mind safety as a daily practice. In plasma cutting, in particular, or damage the eye by
an arc light, it burns due to high fever member will occur. Please wear protective equipment on your
eyes and body.

1.3.1 Eye safety

Please observe the following in order to prevent eye injury accident caused by strong ultraviolet
rays, sparks, hot metal and burns of face.
1. Wear dark safety glasses, side shielded goggles, welding helmet.
We recommend a light-shielding degree of glasses, such as shown in the following table.
(JIS T8141-1980)

Arc current Shading number

150 ＜ AMP No.11

150～250 AMP No.12
250～400 AMP No.13

400 ＞ AMP No.14

2. Replace damaged shading plate · broken glasses · goggles · helmet.

3. Please warn other people in the workplace to wear eyeglasses, goggles, helmets.
4. We recommend that you can install protective screens and curtains to reduce the reflection and
transmission of ultraviolet rays.

1.3.2 Ear safety

Noise it may harm the hearing. Please wear ear protection.

1.3.3 Skin safety

Protect your skin and limbs from powerful ultraviolet rays, sputtering, slag and dross or from the
parts immediately after cutting.
1. Please wear protective clothing.
2. Please wear long gloves, safety shoes, safety bar.
3. Cover all the exposed portion, please wear clothing to prevent burns
4. In order to prevent the entry of sparks and slag, without a folded pants, please wear working
clothes equipped with a pocket with a flap.

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5. When you press the start button will cause the pilot arc immediately. Be sure to separate the body
from the torch and cut it.
6 .When touching the torch, wait until the surface of the torch cools and perform the work.

1.3.4 Burn prevention

Heat, sputter, sparks may cause fire, burns.

1. Please do not cut near combustibles.
2. Please do not cut containers filled with combustibles.
3. Please do not wear burnable products such as gas lighters and matches.

1.3.5 Hume and gas harmful

1. When working near the cutting torch, please protect especially from the neck to the top from the
fume.
2. Please provide a ventilator to protect workers from fumes and gases discharged during arc cutting.
3. If ventilation is inadequate, please use an effective gas mask.

WARNING

● When cutting a metal containing zinc, lead, cadmium,

beryllium, or metal painted with this metal, work with a
complete ventilation system, dust collection and smoke
evacuation unit.

● If you work near the torch, wear a breathing apparatus or a

helmet to which air is supplied.

1.3.6 Prevention of toxic fume

Fumes generated during cutting is harmful. Please implement measures surely.
1. Ventilate the cutting work area adequately.
2. Before you cut, all of chlorinated solvents from the cutting site carry-out or, please remove.
Certain types of chlorinated solvents are exposed to ultraviolet rays and decompose and
become highly toxic gas phosgene, which is extremely dangerous.
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3. When cutting galvanized metal, wear a mask correctly and use a proper ventilator.
4. Container or the like that contains the substance that contains toxic substances Please do not cut.

1.3.7 Explosion fire accident prevention

If you cut a container that is under pressure, it may explode. Please be careful.
1. Do not cut in an atmosphere containing explosive dust and steam.
2. Do not cut off pressurized cylinders or sealed containers.

WARNING

●The plasma system uses compressed gas.

When using a compression device or a cylinder, please carry
out the correct safety operation.

1.3.8 Fire prevention

In plasma cutting, high temperature metal, sparks and slag are generated, which may cause fire and
burns. Please take the following preventive measure.
1. Please prepare fire extinguishers and things useful for extinguishing on the cutting site.
2. Please move the combustible material to a place at least 10 m away from the cutting place.
3. Always be sure to cool beforehand if you place a newly cut metal or heated metal near the
combustible material.
4. Do not cut containers containing flammable substances with plasma.
5. If you want to cut with plasma system, the flammable gases and vapors, please ventilation. Never
operate the plasma in an atmosphere containing high concentrations of dust, flammable gas,
flammable liquid vapor.

1.3.9 How to use safely

1. For the plasma system, safety interlock design is done. Never perform a bypass circuit,
short circuit, etc. on the safety interlock.
2. Driving with the cover removed involves other people in the accident.It also prevents the
proper cooling effect of the equipment.
3. Please do not use anything other than genuine parts for the torch. It leads to overheating
and other accidents.

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1.3.10 Electric shock prevention

The plasma system uses high voltage when arcing occurs. Please be aware of the following
points when operating.
1. Please dry your body and clothes.
2. Please do not stand or touch the wet floor when cutting the plasma.
3. Please pay sufficient attention to electric shock. Wear insulation gloves and boots as insulation
measures, especially when you must operate in the wet condition or near it.
4. Be sure to install fuses and breakers on the primary power supply side.
If an electric shock accident or a dangerous condition occurs, it is recommended to install an
emergency shutdown device so that the power supply can be cut off instantaneously.
5. Please regularly inspect cracks, cracks etc. of the cover for hoses and cables.
Exposure of wires may result in serious accident, please do not use absolutely damaged power
cord.
If you discover damage to the cables, please replace it immediately.
6. Please inspect the torch lead regularly. If you see damaged parts such as fatigue and wear,
please replace it immediately.

1.3.11 Ground of cutting surface plate

1. Make sure to connect the ground cable directly from the cutting member or securely to the
cutting surface plate.
2. Please secure the ground securely and fix it in a way not loose connection.

1.3.12 Ground
1. Make sure the ground wire of the primary power supply is securely connected to the airframe or
operation panel.
2. Make sure that the ground wire of the plasma power supply is properly connected.
3. Please tighten the earth wire firmly with bolt nut.

1.3.13 Hose
Please attach a display to distinguish the type of gas on the wall piping.
1. Do not use gas other than specified for each fluid hose.
2. Please replace the hose damaged by cracks, sparks, heat, naked fires etc.
3. Please be careful not to twist the hose.
4. To prevent damage to the hose, please laying in a safe condition on the outside of the passage
so that there is no danger of tripping.
5. Please regularly check hose, leakage, fatigue, loose fitting etc.
6. In order to prevent damage to the hose, please keep the minimum length to prevent pressure
drop and minimize the flow resistance.
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1.3.14 Pressure regulator

1. Please use under the condition that all pressure regulators operate properly.
2. Defective regulator can rupture or cause serious accidents. By the skilled repair technician,
repair, please check.
3. Never use pressure regulators that have leaks or malfunctions.
4. Do not use regulators with oil or grease.

1.3.15 Safety of plasma power supply and plasma torch

For handling of each plasma power supply and plasma torch, follow the contents of each
instruction manual.

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1.4 Welding safety precautions

WARNING
Strictly observe the following to prevent accidents resulting in serious injury or death.
■This welding machine is designed and manufactured by taking safety into
consideration. However, never fail to observe the warning and precautions
described in this instruction manual, otherwise accidents leading to serious
injuly or death can result.
■Keep people out of the space around the welding machine and working area.
■The welding machine generates a magnetic field around itself. Such a magnetic
field affects certain types of sensors and clocks. For the same reason, any
person who have a pacemaker in his heart shall not approach the welding
machine in operation or the welding space unless he has obtained doctor's
permission.
■For safety, leave the installation, maintenance, inspection, and repair of the
machine to a person who has thorough knowledge about welding machines or
to a quafified operator.
■For safety, leave the operation of the machine to a person with complete
knowledge of the instruction manual end sufficient skill.
■Do not use this machine for any purpose other than arc welding described in the
instruction manual.
■Do not remodel the machine.
■Check the safety around the machine before operation to prevent accidents.
■Be sure to hold the handle when carrying the machine.
■Wear leather gauntlets when touching the machine during welding or right after
operation.
Do not touch the welded surface antil it has cooled.

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WARNING
Strictly observe the following to prevent electric shock.
■Do not touch the charged section; otherwise fatal electric shock or burns can
result. When the power on the input side is turned on, the Input circuit and the
inside of the welding machine are charged. Even if the input power is turned off,
the capacitor may have been charged. When the welding power is output, the
electrode and base metal, as well as the metal portion in contact with these, are
charged.
■Never touch charged sections.
■ The welding power supply case and base metal, as well as jigs electrically
connected to them, shall be grounded in conformity with the law (Technical
Standard for Electric Equipment) by a qualified electric engineer.
■Turn off all power supplies on the input side by means of switches in the switch
boxes before installation, maintenance, and inspection. The capacitor will not
discharge completely right after the input power is turned off. Check that no
vohage is remaining before maintenance or inspection.
■Periodically conduct maintenance and inspection. Repair damaged parts before
resuming operation.
■Do not use cables with Insufflcient capacity or damaged cables whose conductors
are exposed.
■firmly tighten and insulate cable connections.
■Firmly connect the welding cable on the base metal side at a location as close as
possible to the base metal.
■Do not use the machine with the welding machine case or coser removed.
■Be sure to cover the input and output terminals before use.
■Do not use broken or wet gauntlets.
■Never fail to use a life-line when working in high places.
■Turn oft power switches of all devices and input-side power supply when the
machine is not used.
■Do not wear wet clothes.
■Do not stand on or touch the wet floor.
■Do not use the machine outdoors when it is raining.
■Do not leave the machine outdoors after use.
■Be sure to install a fuse or breaker on the input power supply side.
■Check the supply voltage of the machine before use.
The tolerance for the input supply voltage is plus or minus 10% of the rating. Use
of the machine out of the folerance is prohibited.
■The metal receptacle (plug) on the tough-rubber sheath cable is threaded.
Tighten it firmly.
■Be sure to ground the tough-rubber sheath cable of the machine.
■Turn off the power and stop operation in the following cases, and ask an engineer
with special knowledge of electricity to repair.
*Broken or worn-out cables
*Damage due to water leakage or other liquid
*Malfunction of the machine inspire of operation in conformity with the instruction
manual.
*Breakdown of the machine.
*Abnormal performance of the machine which requires tune-up.
■ Ask an engineer with expertise to maintain, inspect, or repair the machire.
■ Please make sure that any foreign material does not attach to the connector of the
machine nor to the plug of the power cable when the plug of the power cable is
connected to the machine. Foreign materials can cause short-circuits or melt the
connector.
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CAUTION

Use protective gear to protect you and others from arc light, scattered spatters/slugs,
and noise.
■ The arc light includes harmful ultraviolet rays and infrared rays, causing
Inflammation of eyes or burns.
■Scattered spatters and slugs can damage your eyes and cause burns.
■Noise can cause hearing difficulties.
■Wear light-shielding goggles or hand shield, which blocks light sufficiently, for
welding operation or monitoring welding.
■Wear protective goggles to protect your eyes from spatters and slugs.
■Install a protective curtain around the welding site so that arc light will not reach
the eyes of people around the site.
■Wear protective gear such as leather gauntlets. clothes with long-sleeves, leg
cover, leather apron, helmet, and safety shoes.
■When the noise level is high, wear a noise-proofing protector.

CAUTION

Use protective gear to protect you and others from fumes and gas generated by
welding.
■Welding generates fumes and gas. Inhalation of such fumes and gas can
damage your health.
■Welding operation in a smell space causes deficiency of oxygen, which is very
likely to cause suffocation.
■To prevent gas poisoning and suffocation, use the local waste disposal facilities
stipulated by the law (lndustriat Safety and Health Law snd Regulations to
Prevent Damage due to Dust) or use an effective inhaler.
■When the welding space is small, ventilate the space sufficiently or wear an
inhaler. Have a trained watchman monitor welding.
■Welding operafion near places where degreasing, washing, or opraying is
conducted may lead to generation of harmful gas. Do not conduct welding near
such places.
■Welding zinc plated steel sheets or other coated steel sheets will generate
harmful fumes. Remove the coating before welding, or wear an inhaler before
operation.

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CAUTION

Strictly observe the following to prevent gas cylinders from falling or bursting.
■Gas cylinders, when they fall, can cause accidents leading to death or injury.
■High-pressure gas is contained in gas cylinders. Improper handling of gas
cylinders can cause a burst or emission of high-pressure gas, causing
accidents that lead to death or injury.
■Handle gas cylinders in conformity with the law (High Pressure Gas Control
Law).
■Do not expose gas cylinders to high temperatures.
■Set gas cylinders in a special cylinder stands to prevent the gas cylinders from
falling.
■Never generate arcs on gas cylinders. Do not hook the welding torch on gas
cylinders, or do not allow electrode to touch gas cylinders.
■Do not bring your head close to the discharge port when opening the valve on
the gas cylinder.
■Attach a protective cap to gas cylinders when they are kept unused.
■Use a gas flow rate controller made or recommended by a welding machine
manufacture.
■Read the instruction manual for the gas flow rate controller before use, and
strictry observe the precautions.
■Never use a gas cylinder from which gas is leaking or a broken gas cylinder.
■Use gas cylinders only for specified purposes.
■DO not apply oil or grease to the valve on gas cylinders.
■When the valve on gas cylinders is hard to open, contact the dealer.

CAUTION

Strictly observe the following to prevent injury due to rotary section.

■Do not bring your hands, hair, or clothes close to the cooling fan of the welding
power supply or the feeder roller of the wire feeder; otherwise you can be
caught in them.
■Do not bring your head near the end of the welding torch during wire inching;
otherwise the wire may stick in your eyes.
■When the spool of wire is released, you can get hurt.
■Do not use the welding machine with its case or cover removed.
■Ask a trained person who has thorough knowledge of welding machines or a
qualified person to remove the case for maintenance, inspection, or repair.
Install a protective fence around the welding machine to prevent people from
getting near carelessly.
■DO not bring your hand, fingers, hair, or clothes close to the rotating cooling fan
or the roller of the feeder.
■Do not bring your head near the end of the welding torch during wire inching.
■Secure the end of the wire with the wire stopper on the spool when storing or
moving the spool of wire or when setting it in the wire feeder.
■When inserting the spool of wire into the wire guide on the wire feeder, firmly
hold the wire so that it will not be released.

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CAUTION

Strictly observe the following to prevent fire, explosion, or burst.

■Spatters and hot base metal right after welding can cause tire.
■Imperfect connection of cables or imperfect contact on the route of the electric
current on the steel bar and other base metal can cause fire because of
heating due to resistance.
■Arcs generated on the container of gasoline or other inflammables can cause
explosion.
■welding of sealed tanks or pipes can cause bursts.
■Do not do welding in a place where scattered spatters will be in contact with
inflammables.
■Do not do welding in a place near inflammable gas.
■Do not bring hot base metal right after welding close to inflammables.
■Welding on ceilings, floors, an walls may cause fire on the hidden side. Remove
inflammables from the hidden side.
■Firmly tighten cable connections, and firmly connect the welding cable on the
base metal side at a location as close as possible to the base metal.
■Do not weld gas pipes filled with gas.
■Do not weld sealed tanks or pipes.
■Provide a fire extinguisher near the welding place to prepare for the worst.
■Do not weld a container that has inflammables inside.
■Do not have a lighter, matches, or other inflammables with you during welding.

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2 Location of Safety labels

Safety labels and labels for correct operations are stuck to the machine.
■Carefully read labels before operation and follow the instructions decried on them.
■Never peel off the labels. Keep them clean and legible at all times.

1-4 1-1
1-3

1-5 1-2

1-6

1-1
1-2

1-3 1-4 1-5 1-6

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3 Overview of the Unit

3.1 Features of the Unit
1）It offers excellent operability.
2）It can travel over a wide speed range, from 40～2400 mm/min/1.575～94.488 inch/min.
3）It incorporates a motor equipped with an encoder and the actual speed is displayed on a digital
meter.
4）three speed settings can be saved by using the speed presetting function.
5) Pressing a button instantly switches to slow travel to help to prevent uncut material being left at the
start and finish ends when cutting thick material.
6) The incorporated arc coupling function enables both plasma cutting and arc welding by changing
the torch set.
7) A weaving control function is incorporated, making it possible to perform weaving welding by
installing the kit to mount the WU-3R weaving unit, with no need to add a control box.
8) Torch sets, rails and other accessories of the existing IK-12max3 model can be used without
modification.

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3.2 Specifications
Weight (body): 8.5Kg/18.74lb
Machine size: 432mm/17inch
Machine width 220mm/8.66inch
Wheel width 160mm/6.3inch
Power source: AC100～240V±10％ 1.1～0.7A 50-60Hz
Motor: DC24V motor with an encoder 23W 5600rpm
Transmission Dial acceleration formula、Variable speed
Traveling speed 40～2400mm/min/1.57～94.49inch
Creep speed 40～300 mm/min/1.57～11.81inch
Speedometer digital display
Max loaded weight 50kg/110.23lb
●option
1) Rail（1.8M）
2) Circle rail
3) Circle cutting attachment
4) S-100 torch set
5) S-200 torch set
6) SP-100 torch set
7) SP-200 torch set
8) SR-100 torch set
9) SR-200 torch set
10) SPR-100 torch set
11) SPR-200 torch set
12) SP-300 torch set
13) SP-400 torch set
14) L-100 torch set
15) 6023 thick cutting set
16) EPOCH300 thick cutting set
17) EPOCH600 thick cutting set
18) A type holder set for welding
19) TYPE-F WELDING HOLDER SET
20) TYPE-F WU-3R WEAVING HOLDER SET
21) TYPE-F PLASMA HOLDER SET
22) Cooling fan

3.3 Contents of package

・Body ......................................................................................... 1set
・Chip support ............................................................................. 1set
・Hexagon bolt M10×20(WF) ................................................ 2pieces
・Power cable（5P×5M） ........................................................... One
・Instruction manual、Written guarantee ............................ 1pc each

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4 Method of operation

Kindly take care about following things to avoid getting an electric

shock.
WARNING

 Kindly remove input plug from outlet while checking, dis-assembling or

repairing and turn OFF the control source while leaving. If it is
necessary to carry out checking in the energized state, professional
engineer having enough knowledge and skill about electric handling
should go since there is risk of short circuit, getting electric shock.
 Do not use welding equipment without case or cover.
 Kindly use power outlet with earth pin outlet since input plug has earth pin. It is connected
to main body of carriage in operation panel.
 Kindly use input voltage within ±10%for power supply input to input plug (Kindly use input
voltage in the range of AC100V~AC240V)
There is risk of short circuit due to failure of printed board on operation panel.
 In case of crack in insulation cover of power cable and torch cable, do not expose it to
high temperature. There is risk of short circuit due to tearing of insulation covering.
 Kindly weld below the rated current and usage rate of torch to prevent dielectric
breakdown due to overheating.
 Kindly place power cable and torch cable in proper manner so that they are not stretched
or pulled. There is possibility of breakage of insulation by damaging holding part and
connector part due to pulling.
 Do not throw or drop main body of carriage. There is risk of damaging insulationby
breaking.
 While connecting to power cable plug to main body, kindly connect after verifying that
foreign object is not touching to connector of main body, power cable plug .There is risk of
connector erosion due to short circuit by foreign object.

WARNING

Strictly observe the following to prevent burns.

■Never directly touch the torch nozzle, tip, orifice, insulation cylinder, and the
surface of the carriage which are very hot right after welding.

Kindly take care about following things to avoid falling off of carriage
WARNING

 Do not lift the carriage by holding its Handle. There is risk of falling off
carriage while holding carriage by handle, if there is shockimpact at
carriage or if mounting screw of handle is loose.

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CAUTION

Set the welding power switch in the "No Self-Holding (or No Crater Treatment)" position.

■When the switch ot the welding power supply, which is to be connected to the
welding machine, is set in the “Self.Holding (or Crater Treatment)” position, the
welding arc will not stop even if the welding operation is stopped.

4.1 Name of each parts

Fig.1 Name of each part

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(1) Receptacle
Kindly connect power cable to this receptacle.

WARNING

Never fail to ground the clip.

■ The grounded clip prevents short circuits or electtic shock which results from a
short circuit in the carriage, etc.

Ground wire position (No.3)

(2) Operation plate cover

If you want to connect the weaving unit WU-3R (sold separately) option, remove the plate,
Masu mounting a receptacle for WU-3R. Refer the volume that how to use method of
WU-3R (Weaving unit WU-3R instruction manual).

In case if you connected WU-3R make sure Turn Off the Power
CAUNTION

■When the power is on if it gets connected there is a possibility of failure

(3) Operation panel

The detail is shown below.

(4) Heat insulating plate

It prevents heat from gas · plasma cutting · welding.

(5) Clutch lever

Switch the clutch on / off by operating the steering wheel.
When the position of the arrow is START, the clutch is ON, and when it is STOP it is OFF.

(6) Direction selector switch

It is used when starting the running of carriage or stopping the running of the carriage.
(7) CREEP button
Switch to creep speed, single action of weaving or when determining parameters.
(8) Stand
Use it for mounting each torch set. There is a long length as an option.
Standard：84L
Option： 114L、180L、300L、400L、500L

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4.2 Operation panel V4.02

Kindly take care about following things to avoid getting an electric

WARNING
shock.

■ Kindly remove input plug from outlet while checking, dis-assembling

or repairing and turn OFF the control source while leaving. If it is
necessary to carry out checking in the energized state, professional
engineer having enough knowledge and skill about electric handling
should go since there is risk of short circuit, getting electric shock.
 Do not use welding equipment without case or cover.
 Kindly use power outlet with earth pin outlet since input plug has earth pin. It is connected
to main body of carriage in operation panel.
 Kindly use input voltage within ±10%for power supply input to input plug (Kindly use input
voltage in the range of AC100V~AC240V)
There is risk of short circuit due to failure of printed board on operation panel.
 In case of crack in insulation cover of power cable and torch cable, do not expose it to
high temperature. There is risk of short circuit due to tearing of insulation covering.
 Kindly place power cable and torch cable in proper manner so that they are not stretched
or pulled. There is possibility of breakage of insulation by damaging holding part and
connector part due to pulling.
 Never fail to turn OFF the power switch (1) before attaching or detaching the metal plug.
 When you remove the plug, put rubber cap on the receptacle to prevent dust and dirt.
 When you found dust and dirt in the receptacle, remove these before connecting electric
power cable plug.

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4.2.1 Explanation of the Operation Panel

Indication Name Function
This switch is used to start, or stop, travel of the carriage. On
flipping the switch while the multi-function selector switch is set
Direction
to any of the SPEED (1) to (3) positions, the carriage will travel
selection switch
in the direction of the arrow flipped to. Setting the switch at the
neutral position stops the carriage.
This three-point selection switch allows selection of the
following three modes.
MANUAL: Use this position for wire inching and arc tests。
* An arc is generated while the tip of the torch is in contact
with the material to be welded. Be careful.
ARC ON: Use this position for normal operation.
When the carriage starts traveling, the arc signal is output.
OFF: While at this position, the arc signal is not output and only
carriage travel is possible.

Arc selection
Note Do not operate the direction selection switch
while this switch is flipped to the MANUAL
switch
side.
● If the direction selection switch is operated while this
switch is flipped to the MANUAL side, the arc signal will
continue to be output after it is returned to ARC ON, and
the carriage will travel if it is set to OFF.
Setting the direction selection switch to neutral stops
output of the arc signal and travel of the carriage. If the
direction selection switch has been operated while this
switch is flipped to the MANUAL side, turn the power OFF
and back ON.

This switch is used to select each parameter and to select the

Multi-function travel mode.
selector switch For details on each parameter, check 4.2.2 About the
multi-function selector switch.

This switch is used to set the carriage travel speed and each
parameter.
Volume switch Turning it clockwise increases the value and turning it
counterclockwise reduces the value.
Turning the switch quickly magnifies the increase/decrease.
This button is used to start creeping.
It may also be used when confirming parameters.
* When an error has occurred, pressing the START/STOP
CREEP button switch resets the error display.
However, if the cause of the error occurrence remains, the
error will occur again. Check what action to take against each
error and eliminate the cause.
The digital meter displays the speed of the carriage or the value of each
LED parameter.
The LED display on the digital meter indicates the operation status of the
carriage.
RDY: Lit while the carriage power is on.
WEL: Lit while the arc signal is being output while the carriage is traveling.
Digital meter BSY: Lit while the carriage is traveling, irrespective of whether there is an arc
signal or not.
ARC: Lit while the arc selection switch is at the MANUAL or ARC ON
position.
ERR: Lit when an operation error has occurred. At this time, the digital meter
displays the error number corresponding to the error details.

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<About error numbers> Error indications are three-digit numbers that start with “E.”. Example indication
Error
Error details Cause Corrective action
number
There may be a contact failure
Check for cable disconnections, and for
in the wiring between electrical
contact failures of connectors and crimp-type
boards (connector numbers
Link unit configuration failure terminals.
001 CN2, 3 for all boards in
error (The LEDs on each board will flash when the
common, connector numbers
power is turned on: if the LEDs do not flash or
CN4, 5 for the L-DSP display
light, the circuit board may be faulty.)
board).
002 Power failure detection error
003 Inverter error In the event that it is displayed, contact the
This is an error that occurs on
004 Emergency stop error distributor where you purchased this product
other equipment.
005 3-phase power supply error or our sales office.

006 Breaker OFF error

The encoder line may be
007 Encoder line connection error connected to MD-CN10 on the Connect the encoder line to MD-CN5.
L-MD-A board.
Check for disconnections in all wires, and for
There may be a contact failure contact failures of connectors and crimp-type
008 Motor deviation error on the motor line or the encoder terminals. Connect the motor line to MD-CN4,
line. and the encoder line to MD-CN5, on the
L-MD-A board.
Welding current detection
010 signal ON timeout (5 seconds)
error
Signal logic inversion error
011 while detecting welding In the event that it is displayed, contact the
current This is an error that occurs on
distributor where you purchased this product
other equipment.
012 Encoder selection error or our sales office.
Unit configuration unsuitable
013
error
Weld movement distance
014
during tack operation error
016 Servo driver error
017 Copying signal error
018 Thermal guard error
019 Thermal guard error In the event that it is displayed, contact the
This is an error that occurs on
Link unit configuration failure other equipment. distributor where you purchased this product
020 or our sales office.
error
021 X-axis-direction derailing error
022 Y-axis-direction derailing error
023 Z-axis-direction derailing error
An abnormal load may be being
Motor overload error Remove any abnormal load from the drive
024 applied to the drive section or
(encoder equipped) section or motor.
motor.
It is possible that the power was
Carriage backup error
025 turned off during carriage Turn the power off and back on again.
(Parameter)
operation or fine adjustment If the error display indication is not cleared
movement by limit switch, and after repeating the above several times,
Carriage backup error
026 the backup was not replace all the circuit boards being used.
(System Parameters)
implemented correctly.
WU-3R backup error
125 In the event that it is displayed, contact the
(parameter) This is an error that occurs on
distributor where you purchased this product
WU-3R backup error other equipment.
126 or our sales office.
(System Parameters)
※ To recover from an error, unplug the power cable from the operation panel, turn off the power supply, check the corrective
action described above, plug the power cable back into the operation panel and turn the power back on.
※ When an error occurs, the error indication is reset by pressing the CREEP button, but eliminate the cause by referring to the
corrective action described above before pressing the button.

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4.2.2 About the multi-function selector switch

With IK-12 NEXT, various operations can be set by selecting individual modes and parameters
with the multi-function selector switch.
The individual modes and parameters are as follows.
Operation
Panel Digital Display Setting Range Default Value
Indication
40～300 mm/min 100mm/min
1.574～11.811 inch/min 3.937 inch/min
Function

CREEP travel speed setting

Select this mode to change the speed during CREEP travel
The carriage travels at the speed set in the CREEP travel mode only
when the CREEP button is pressed while the carriage is traveling or
when this mode has been selected with the multi-function selector
switch
The value for the CREEP travel speed is displayed while the carriage
is stopped and while it is traveling.
The travel speed of the carriage can be changed by turning the
volume switch while the carriage is stopped and while it is traveling.
To increase the speed, turn it clockwise, and to decrease the speed
turn it counterclockwise.

Operation
Panel Digital Display Setting Range Default Value
Indication
40～2400 mm/min 40mm/min
1.574～94.488 inch/min 1.575 inch/min
Function

Travel mode (1)

Select this mode to make the carriage travel.
When the direction selection switch is flipped while this mode is
selected, the carriage will start traveling in the direction of the arrow.
Selecting this mode while the carriage is traveling causes the travel
speed of the carriage to change to the set speed.
The value for the carriage travel speed is displayed while the carriage
is stopped and while it is traveling.
The travel speed of the carriage can be changed by turning the
volume switch while the carriage is stopped and while it is traveling.
To increase the speed, turn it clockwise, and to decrease the speed
turn it counterclockwise.

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Operation
Panel Digital Display Setting Range Default Value
Indication
40～2400 mm/min 500mm/min
1.574～94.488 inch/min 19.685 inch/min
Function

Travel mode (2)

Select this mode to make the carriage Travel.
When the direction selection switch is flipped while this mode is
selected, the carriage will start traveling in the direction of the arrow.
Selecting this mode while the carriage is traveling causes the travel
speed of the carriage to change to the set speed.
The value for the carriage travel speed is displayed while the carriage
is stopped and while it is traveling.
The travel speed of the carriage can be changed by turning the
volume switch while the carriage is stopped and while it is traveling.
To increase the speed, turn it clockwise, and to decrease the speed
turn it counterclockwise.

Operation
Panel Digital Display Setting Range Default Value
Indication
40～2400 mm/min 2400mm/min
1.574～94.488 inch/min 94.488 inch/min
Function

Travel mode (3)

Select this mode to make the carriage Travel.
When the direction selection switch is flipped while this mode is
selected, the carriage will start traveling in the direction of the arrow.
Selecting this mode while the carriage is traveling causes the travel
speed of the carriage to change to the set speed.
The value for the carriage travel speed is displayed while the carriage
is stopped and while it is traveling.
The travel speed of the carriage can be changed by turning the
volume switch while the carriage is stopped and while it is traveling.
To increase the speed, turn it clockwise, and to decrease the speed
turn it counterclockwise.

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Operation
Panel Digital Display Setting Range Default Value
Indication
400～1500 mm/min 400mm/min
15.748～59.055 inch/min 15.748 inch/min
Function
When WU-3R
not connected
Weaving Oscillation Speed Setting
ウ Select this mode to set the oscillation speed during weaving operation.
The digital meter displays the oscillation speed value while the carriage
is stopped and while it is traveling.
The digital meter displays the oscillation speed value while the carriage
is stopped and while it is traveling.
The oscillation speed can be changed by turning the volume switch
while the carriage is stopped and while it is traveling.
The oscillation speed can be changed by setting the multi-function
selector switch to SWING SPEED while the carriage is stopped and
while it is traveling.
When WU-3R
Pressing the CREEP button while the carriage is stopped and the
connected
multi-function selector switch is set to SWING SPEED starts weaving
as an independent operation. (No arc is generated in independent
operation.)
This is not used when no weaving unit is connected.

Operation
Panel Digital Display Setting Range Default Value
Indication
0～100.0 mm 10.0mm
0～3.937 inch/min 0.394 inch
Function

When WU-3R
not connected

Weaving Oscillation Width Setting

S Select this mode to set the oscillation width during weaving operation.
Th The digital meter displays the oscillation width value while the carriage
is stopped and while it is traveling.
The oscillation width can be changed by turning the volume switch
while the carriage is stopped and while it is traveling.
The oscillation width can be changed by setting the multi-function
selector switch to SWING WIDTH while the carriage is stopped and
while it is traveling.
When WU-3R Pressing the CREEP button while the carriage is stopped and the
connected multi-function selector switch is set to SWING WIDTH starts weaving
as an independent operation. (No arc is generated in independent
operation.)
This is not used when no weaving unit is connected.

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Operation
Panel Digital Display Setting Range Default Value
Indication
0～10.0 s 0s
Function
When WU-3R
not connected

Right Torch Stop Time Setting

Select this mode to set the right torch stop time during weaving
operation.
The digital meter displays the right torch stop time value while the
carriage is stopped and while it is traveling.
The right torch stop time can be changed by turning the volume
switch while the carriage is stopped and while it is traveling.
The right torch stop time can be changed by setting the multi-function
selector switch to TIMER RIGHT while the carriage is stopped and
while it is traveling.
When WU-3R Pressing the CREEP button while the carriage is stopped and the
connected multi-function selector switch is set to TIMER RIGHT starts weaving
as an independent operation. (No arc is generated in independent
operation.)
This is not used when no weaving unit is connected.

Operation
Panel Digital Display Setting Range Default Value
Indication
0～10.0 s 0s
Function
When WU-3R
not connected

Center Torch Stop Time Setting

Select this mode to set the central torch stop time during weaving
operation.
The digital meter displays the center torch stop time value while the
carriage is stopped and while it is traveling.
The center torch stop time can be changed by turning the volume
switch while the carriage is stopped and while it is traveling.
The center torch stop time can be changed by setting the
When WU-3R multi-function selector switch to TIMER CENTER while the carriage is
connected traveling.
Pressing the CREEP button with the multi-function selector switch set
to TIMER CENTER starts weaving as an independent operation. (No
arc is generated in independent operation.)

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Operation
Panel Digital Display Setting Range Default Value
Indication
0～10.0 s 0s

Function

When WU-3R
not connected
Left Torch Stop Time Setting
Select this mode to set the left torch stop time during weaving
operation. * The left torch stop time in the tack travel mode is also set
here.
The digital meter displays the left torch stop time value while the
carriage is stopped and while it is traveling.
The left torch stop time can be changed by turning the volume switch
while the carriage is stopped and while it is traveling.
The left torch stop time can be changed by setting the multi-function
selector switch to TIMER LEFT while the carriage is traveling.
When WU-3R Pressing the CREEP button while the carriage is stopped and the
connected multi-function selector switch is set to TIMER LEFT starts weaving as
an independent operation. (No arc is generated in independent
operation.)
This is not used when no weaving unit is connected.

Operation
Panel Digital Display Setting Range Default Value
Indication
― ―

When WU-3R Function

not connected

Origin Position Adjustment Setting

The origin position of the torch can be changed by turning the volume
switch while the carriage is stopped and while it is traveling.
Turning the volume switch clockwise moves the torch to the left.
Turning it counterclockwise moves the torch to the right.
When WU-3R Pressing the CREEP button while the carriage is stopped and the
connected multi-function selector switch is set to ORG starts weaving as an
independent operation. (No arc is generated in independent
operation.)
This is not used when no weaving unit is connected.

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Operation
Panel Digital Display Setting Range Default Value
Indication
0～10.0 s 0s
Function
Arc Stabilization Time Setting
Select this mode to set the arc stabilization time during traveling
mode.
This is the time between flipping the direction selection switch and the
carriage starting to travel. During arc stabilization time, the arc signal
is output while the carriage is stopped, and the time counts down on
the digital meter.
The value of the arc stabilization time is displayed on the digital meter
while the carriage is stopped.
The arc stabilization time can be changed by turning the volume
switch only while the carriage is stopped.
* The arc stabilization time does not work when the arc selection
switch is set to OFF.
* Do not change to a mode other than the traveling mode with the
multi-function selector switch while the direction selection switch is
flipped and the countdown for the arc stabilization time is in progress.
This may cause the carriage to operate unexpectedly.
In order to weld for the arc stabilization time with
the initial arc current, an initial arc setting has to be
made at the welding power source.
The arc stabilization time at the carriage side is
Note essentially the time between flipping the direction
selection switch (arc signal ON) and the carriage
starting to travel.
Check the instruction manual for the welding
power source for details on initial arc setting.

Operation
Panel Digital Display Setting Range Default Value
Indication
0000～0011 ―
Function
Parameter Setting Mode
The parameters can be set in this mode.
* Operation is only possible while the carriage is stopped.
Check Parameter Number Details for details on the parameter
numbers.
Setting Procedure
1) Turn the multi-function selector switch to
2) Select the parameter number to change by turning the volume
switch.
3) Press the CREEP button to confirm.
4) Turn the volume switch to edit. Note that the WEL LED is lit during
editing.

Lights
5) After editing is completed, press the CREEP button to confirm.
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Parameter Number Details

Parameter number Explanation
Unintended input prevention setting
Parameter editing is enabled when the value of this parameter is
If it is any other value, input is possible only for this parameter.
Use this to prevent unintended input.
Setting range: 0000～9999
At shipment from factory : 0114

Not used

Arc Stabilization Time Setting

Setting range: 0～10.0 s
At shipment from factory: 0 s
* This setting can also be made at the WAIT TIME position of the
multi-function selector switch.
Torch Switch ON Output Time Setting (Crater Filling)
Setting range: -0.1～1.0 s
At shipment from factory: 0
Sets the output ON time for the arc signal.
• If the power supply setting is not self-latching (crater filling not supported),
set this parameter to 0.
• Set this value to between 0.4 and 1.0 if the power supply setting is
self-latching (crater filling supported)
・If the value above is set and the arc is frequently interrupted, set the value to -0.1.
In this case, the signal will remain in the ON state up until the arc stop timing.
However, since the specifications of some welding power sources do not support
the setting of -0.1, set the value to 1.0 and adjust.
crater (self-latching)''ON'' crater (self-latching)''OFF''

Welding with crater current Welding with main current

※Precautions on Use
Be sure to make the crater filling (self-latching) setting at the welding power source
and that at the carriage agree
Set the crater filling (self-latching) switch of the welding power source according to
the following table.
Please set in “parameter setup mode No.0003” the setting method of the truck
side.
Welding power source side carriage side

crater (self-latching) ''ON'' -0.1 or 0.4～1.0

match

crater (self-latching) ''OFF''

If the settings do not agree, the welding operation

CAUTION may not proceed as set. Be sure to make the crater

filling (self-latching) settings agree.

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Not used

Not used

Not used

Not used

Torch switch signal minimum time setting

Setting range: 0.4～1.5 s
At shipment from factory: 0.7 s
Sets the time to guarantee the ON/OFF state of the torch switch. Reducing
this value may mean that the welding power source is unable to receive a
signal, so care is required.
Speed, Position Display Unit, Inch Setting
0 : mm display
1 : Inch display
After setting this parameter, switch the power off and back on.

Speed Correction
Setting range: 50～200%
At shipment from factory : 100%
Sets the value for correcting the actual speed with respect to the speed
indicated at the digital display.
Actual speed = speed displayed × [This parameter value]%

Not used

Model Selection Setting

0: WH-MULTI NEXT
1: IK-12NEXT
After setting this parameter, switch the power off and back on.
When using the IK-12NEXT, be sure to set this parameter to 1.
Creeping mode
* This is the same as the CREEP setting made with the multi-function
selector switch.
Use the CREEP setting on the multi-function selector switch.
Travel mode (1)
* This is the same as the SPEED (1) setting made with the multi-function
selector switch.
Use the SPEED (1) setting on the multi-function selector switch.
Travel mode (2)
* This is the same as the SPEED (2) setting made with the multi-function
selector switch.
Use the SPEED (2) setting on the multi-function selector switch.

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Travel mode (3)

* This is the same as the SPEED (3) setting made with the multi-function
selector switch.
Use the SPEED (3) setting on the multi-function selector switch.

4.2.3 Weaving movement time chart

The weaving movement at the time of the weaving welding becomes like the following time chart.
Example1) Parameter settings
Central torch stop time 0sec
Left torch stop time 0sec
Right torch stop time 0sec
Weaving swing width 10mm / 0.39inch

Weaving swing width

Origin position

Example2) Parameter settings

Central torch stop time 1.0sec
Left torch stop time 1.0sec
Right torch stop time 1.0sec
Weaving swing width 10mm / 0.39inch

Left torch stop time

Weaving swing width

Right torch stop time

Central torch stop time

Origin position

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※Weaving swing width, swing speed is the numerical value of at a distance 100mm from the
center of rotation.

回転中心
Rotation center

振り速度
Swing speed

振り幅
Swing width

Origin
原点位置 position

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15 Gas cutting operation

5.1 Standard composition of gas epuipment
1) Composition of gas equipment for linear and parallel cutting
Composition F-type single torch set F-type two torch set E-type single torch set E-type two torch set
Pipe arm Pipe arm 350L Pipe arm 500L Pipe arm 350L Pipe arm 500L
Arm holder ○ ○ ○ ○
Single distribution with Double distribution Single distribution with Double distribution
Distributor
valve with valves valve with valves
Torch holder 1set 2set 1set 2set
Torch 1pc(No rack) 2pcs(No rack) 1pc(No rack) 2pcs(No rack)
No rackNo rack
600L 900L 600L 900L
Hose (OX)2pcs (OX)4pcs (OX)2pcs (OX)4pcs
(GAS)1pc (GAS)2pcs (GAS)1pc (GAS)2pcs
102(acetylene) 102(acetylene) 102(acetylene) 102(acetylene)
Tip or 106(propane) or 106(propane) or 106(propane) or 106(propane)
＃0,1,2each 1pc ＃0,1,2each 2pcs ＃0,1,2each 1pc ＃0,1,2each 2pcs
Guide roller × × ○ ○
Weight × ○ × ○

2) Bevel cutting torch set configuration

Composition SP-300 torch set SP-400 torch set
Pipe arm Pipe arm 500L Pipe arm 500L
Arm holder ○ ○
Distributor Double distribution with valves Triple distribution with valves
Torch holder Profiling system Profiling system
Bevel attachment For cutting V For cutting X
Torch 2pcs(With rack) 3pcs(With rack)
102(acetylene) 102(acetylene)
Tip or 106(propane) or 106(propane)
＃0,1,2each 2pcs ＃0,1,2each 3pcs
900L 1200L
Hose (OX)4pcs (OX)6pcs
(GAS)2pcs (GAS)3pcs
Guide roller ○ ○
Weight ○ ○

3) Thick cutting torch set configuration

Composition L-100 torch set 6023 thick cutting set EPOCH-300 torch set EPOCH-600 torch set
Pipe arm Pipe arm 500L Pipe arm500L Pipe arm500L Pipe arm 500L
Arm holder ○ ○ ○ ○
Distribution for Distribution for Distribution for Distribution for
Distributor
thick materials 6023 EPOCH-300 EPOCH-600
Torch holder φ35 for rack φ35 for rack φ35 for rack φ35 for rack
Torch A3B2 6023 EPOCH-300 EPOCH-600
102(acetylene)
Tip or 106(propane) For 6023 #250,#350 For EPOCH-300 For EPOCH-600
＃6,7,8 each 2pcs
Flexible hose
Flexible hose Flexible hose Flexible hose
Hose 1/2 1500L×1
3/8 1000L×3 3/8 1000L×3 3/8 1000L×3 3/8 1500L×2
Weight ○ ○ ○ ○
Heat insulating
plate ○ For thick cutting For thick cutting For thick cutting
Stand × × 114L 120L
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5.2 Assembling the Unit (for a Single Torch Set)

1. Take the unit body out of the packing box.
2. Fit the primary hose to the gas distributor.
• Blue hose (oxygen)
• Red or orange hose (acetylene or LPG)
3. Fit the arm support (set) to the stand and insert the pipe arm into the arm support (set).
4. Insert the torch holder (set) into the pipe arm.
5. Connect the hoses to the distributor and insert them into the stand.
※ When fitting the hoses, check their individual engraved marks and colors: the cutting
oxygen (JO) is blue, the preheating oxygen (PO) is blue, and acetylene gas and LPG (AC,
LPG) are red or orange.
6. Connect the torch, three single valves (set) and hoses, and insert them into the torch
holder.
Hose
Wing bolt Distributor
Hose

Pipe arm

Arm support（set）

Stand
Single valve

Torch
Torch holder (set)
Torch holder

5.3 Preparation for Work

5.3.1 Connecting the cabtire cable
1. Connect the cabtire cable to the unit body.
2. Connect the metal plug on the cabtire cable to the metal receptacle on the unit side. Make sure
that there is no foreign object or debris before plugging it in.
3. The metal receptacle is fitted with screws. Be sure to tighten the screws in order to prevent
the plug coming out while the unit is traveling.
* When turning on the power supply after turning off the unit body, leave an interval of around
three seconds.

5.3.2 Connecting a nozzle

Select the appropriate nozzle from the nozzle capacity standard table according to the
thickness of the steel plate to be cut.
Use the top nozzle number in the standard table when the steel plate is very rusty or the
groove angle is greater than 20 degrees.
(Nozzle No. “00” or “0” is indicated.)

5.3.3 Connecting the nozzle

1. Select a nozzle according to the thickness of the material to be cut and fit it to the torch.
Refer to the nozzle capacity standard table for selection of the nozzle.
• Be sure to securely tighten the nozzle using two spanners when fitting the nozzle on the
torch.
• If the nozzle is tightened too firmly, it is heated up during cutting, which can further tighten it
and make it difficult to remove.
• Do not scratch the mounting taper of the nozzle. This will cause backfiring.

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5.3.4 Installing the rails

1. Place the rails parallel to a scribed line, and check that they are parallel either by making the
carriage travel along them by hand, or by using a jig. In addition, when considering the
thermal effects on the rails, ideally the distance between the rails and the scribed line should
be at least 100 mm.
5.4 Safety Measures before Starting Work

5.4.1 Grounding the ground wire

As a safety measure for the operator, first check that the appropriate supply voltage is input and
that the cabtire cable is securely connected.

■ How to connect the ground wire

The rubber plug of the cab tire cable has a grounding pin. Use a power outlet with an opening to
receive the ground pin.

5.4.2 Operating the direction selection switch

• The direction selection switch is used to switch between forward and reverse travel. The neutral
position is to stop the unit.
• When switching the direction, always return the direction switch to “stop” (neutral position) and
ensure the unit has stopped before switching the direction of the travel.
• Always leave the switch at “stop” (neutral position) except when you want the unit to travel.
• Set the direction switch to “stop” (neutral position) before turning the power on. If the power is
turned on with the switch set to forward or reverse the unit will start traveling, which is
dangerous.
• Never put your hands between the guide rollers or between the unit body and rails while the unit
is traveling. Your hand may get trapped.

Forward

Neutral

Reverse

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5.5 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 1/4～1/2 a tum, 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 5-6 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 ················8-10mm
・LPG gas ·······················5-8mm

5.6 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.

5.7 Procedures for starting cutting operation and

extinguishing the flame
1．Set Multi-function selector switch to SPEED①～③ and adjust to the cutting start position. Ignite it
and adjust the flame.
2．Set the clutch in the START position to sufficiently heat the cutting start position.
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.

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5.8 Safety measures against backfire and flashback

5.8.1 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 following 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.

5.8.2 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.

5.9 Cutting operation

1. Place the tip along the marked cutting line.
2. Set Multi-function selector switch to SPEED①～③
3. Open the gas valve and slightly open the preheating oxygen valve, and then ignite the oxygen
with an ignition lighter. Then fully open the gas valve and make the flame neutral by controlling
the preheating oxygen.
4. Adjust the height of the tip as against the steel sheet. (2-3 mm from the tip of the white point)
5. Engage the clutch, and after sufficient preheating, open the oxygen valve and turn on the
forward or backward switch simultaneously. Then cutting operation will begin.
6. When cutting begins, carefully observe the cutting condition to set the optimum cutting speed.
7. After cutting, close the cutting oxygen valve and turn off the switch. Then close the gas valve
and preheating oxygen valve in this order, and return the clutch to the stop position.

[Note]
● Check that the flow of cutting oxygen is at the right angles to the steel sheet.
● For correct cutting, set the gas pressure according to the Cutting Data. Correct the gas pressure
according to the actual cutting conditions.

5.9.1 Straight cutting

The use of a high-accuracy plate rail ensures correct straight cutting. Plate rails are of a
connection type, and connection of several rails will permit straight cutting of objects of any length

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5.9.2 In bevel cutting

In case of bevel cutting, tilt torch to the desired angle. Depending on the combination of tip, it is
possible to cut as shown in the figure.

V bevel cutting Welding

Y bevel cutting Welding

X bevel cutting Welding

5.9.3 In circle cutting

The machine is set up differently in two configurations as shown in the photograph to Weight
the left. Set up for circle cutting is as follows.
■ For circle cutting attachment
1. Remove the shield plate, and free the idle wheel Bar
by removing the fixing washer.
2. Attach pivot pin and weight to radius bar. Please attach
weight as close to the center as possible.
3. Free the guide wheel and pull the machine so that
it describes a natural arc, and tighten the guide
wheel in its natural position.
4. Cutting capacity φ600～φ2200

Circle cutting
arm assembly
■ For circle rail
1. Align the idle wheel to the inside groove of the
track, and the guide wheel to the outside groove.
2. Free the guide wheel and tighten it in its natural
position.
3. Cutting performance may be improved by forward
travelling.
4. Cutting capacity
φ100～φ360 φ770～φ1150

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5.9.4 Gas cutting condition

1. The drag must be correct.
2. The cut surface must be sufficiently smooth and the drag groove must be shallow without notches
3. The upper edge of the cut surface must be sharp
4. Slag must be separated easily

16 Plasma cutting operation

6.1 Preparation for Work

1. Attach the plasma torch holder to IK - 12 NEXT.
2. Connect the plasma power cable to the main unit.
3. Connect the cord side receptacle (plug) to the main unit side receptacle (receptacle).
Before connecting, check that foreign matter, dust, etc. are not contained.
4. The plug is screwed type. Be sure to tighten the screws to prevent disengagement of the
plug while running.
5. Please connect to each joint according to the instruction manual of plasma power supply.
6.2 Cutting operation
1. Please align the tip of the torch with the marking line you want to cut.
2. Set Multi-function selector switch to SPEED①～③.
3. When putting the clutch into START and tilting the direction change switch to forward or
reverse, an arc occurs only when the arc changeover switch is ON. If the arc stabilization time
is set, an arc will be generated while the carriage stops for the set time. After the set time
elapses, the carriage starts to move.
4. Please observe the cut state carefully after starting cutting and adjust it to the optimum speed.
5. After cutting, please return the direction change switch to neutral. The arc and carriage will
stop.

17 Welding Work
7.1 Preparation for Work
1. Attach welding holder to IK-12 NEXT.
2. Connect the welding power cable to the main unit.
3. Connect the cord side receptacle (plug) to the main unit side receptacle (receptacle).
Before connecting, check that foreign matter, dust, etc. are not contained.
4. The plug is screwed type. Be sure to tighten the screws to prevent disengagement of the
plug while running.
5. Please connect to each joint according to instruction manual of welding power supply.

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7.2 Welding Work

1. Align the wire tip with the welding position.
2. Set the multi-function selector switch to any of the SPEED (1) to (3) positions.
3. The arc will be generated only while the arc selection switch is set to ON with the clutch at
START and the direction selection switch is flipped to forward or reverse. If an arc stabilization
time is set, the arc will be generated with the carriage stopped for the set time. After the set
time has elapsed, the carriage will start moving.
4. When welding starts, observe the conditions carefully and adjust to the optimum cutting speed.
5. After the welding is finished, turn the direction selection switch back to neutral. Arc generation
and the carriage will stop.

8 Maintenance Inspections
Disassemble the unit by following the procedure below.
1. Remove the heat insulating plate.
2. Remove the six screws in the operation panel.
3. Take the connecting bar off the pins.
4. Remove the four screws that secure the upper case and the lower case of the unit body.
It will now be possible to separate the upper and lower cases of the unit body.
Carry out the following maintenance and inspection work in order to be able to use this unit in the
best condition at all times.

8.1 Daily Inspections

1. Wipe off the dirt on the unit with a clean cloth (especially the pipe arm key slots and rack parts).
2. Lubricate the axles of the casters.
3. Wipe the outer peripheries of the wheels and idlers with an oily cloth.
8.2 Monthly Inspections
1. Lubricate the clutch lever.
2. Measure the insulation resistance. (Measure the resistance between one terminal of the power
outlet and the metal part of the case and check that it is at least 5 mW.)
3. Remove dust from the electrical components inside the unit.
4. Remove and clean the glass retainer of the speed display.

8.3 3-monthly Inspections (Every 2,000 Hours)

1. Separate the lower case and the gearbox, and, depending on the situation, thoroughly flush out
the old grease in the gearbox with washing oil and apply new grease. (Obtain grease from our
sales office.)
2. Replace internal parts with significant wear.

8.4 About the Warranty

We will make “repairs free of charge for one year” from the date of delivery only in the case of
failures that are “attributable to the manufacturer”, where the product has been subject to “normal
conditions of use” in accordance with this operation manual. Note, however, that consumables are
not covered by the warranty. (The specifications of this equipment and contents of this manual are
subject to change without notice.)

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9 Trouble shooting
Defects Cause/check position
1) No power supply voltage to outlet
2) Cable is disconnected

WARNING Kindly take care about following things

to avoid getting an electric shock.
● Since above mentioned 1) and
(1)No electric power 2) checkingare to be carried out
supply while control power supply is
ON, professional engineer
having enough knowledge and
skill about electric handling
should go to prevent risk of
short circuit, getting an electric
shock.

WARNING Kindly take care about following things

to avoid getting an electric shock.
● Kindly carry out continuty
check by tester while electric
supply is turned OFF.
● Since above mentioned 2) and
(2) Traveling speed of 3) checking are to be carried out
carriage is not while control power supply is
changing ON, professional engineer
having enough knowledge and
skill about electric handling
should go to prevent risk of
short circuit, getting an electric
shock.
1) Defective motor
2) Defective printed board
3) Disconnection of motor encoder line
(3) Flipping direction
selection switch
1) Defective direction selector switch
while stopped will
2) Defective printed board
not output an arc
3)Disconnection of short circuit connector
signal and will not
run.
(4) Flipping direction
selection switch
1) Defective printed board
while it is stopped
2) Disconnection of motor (disconnection of DC line or
will output an arc
disconnection of both DC line and encoder line)
signal, but will not
run.

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 IK-12 NEXT

1)ARC OFF option is selected in Arc mode changing over

switch.
(5) Flipping direction 2) No welding current.
selection switch 3) Metal outlet for torch switch is not connected.
while stopped will 4) Kindly verify whether there is short circuit between ①-②
not output an arc metal outlet pin
signal and will run. ・In case of short circuit, welding current is defective
・In case of no short circuit, there must be disconnection of
cable , defective printed board
(6) Even if direction
selection switch is
returned to neutral
while running, the 1) Defective direction selector switch
running of the 2) Defective printed board
carriage and the
output of the arc
signal do not stop.
(7) Carriage travel stops,
but arc signal output
1) The crater filling (self-latching) ON/OFF setting does not agree
fails to stop, when
with that at the welding (plasma) power source and the carriage.
the direction selection
2) Printed circuit board failure
switch is returned to
neutral during travel.
(8) Output of the arc
signal stops, but
carriage travel fails to
stop, when the 1) Printed circuit board failure
direction selection
switch is returned to
neutral during travel.
(9) The travel speed of
the carriage does not 1) Printed circuit board failure
change when the 2) Creep button failure
CREEP button is 3) Wire disconnection
pressed.
(9) The digital meter
display does not
change when the 1) Printed circuit board failure
multi-function 2) Wire disconnection
selector switch
setting is changed.
(12) The parameter value
does not change 1) Printed circuit board failure
when the volume 2) Wire disconnection
switch is turned.
1) When the crater filling (self-latching) ON/OFF setting is ON
there is no function for synchronization with the welding power
13) The arc is interrupted
source, so when the arc is interrupted during welding operation
and the operation of the
there may be a mismatch between the operation of the carriage
carriage and welding
and the welding operation.
become abnormal while
* When the arc is interrupted and carriage travel is stopped,
the carriage is traveling
discrepancies between the welding current and carriage
with self-latching ON.
operation can be prevented by turning the welding power source
off and back on again.

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1) Connecting bar and lever pins not connected

2) Failure of the spring / ball plunger (loose)
(14) Clutch malfunction
3) Failure of the clutch wheel / worm wheel
4) Clutch wheel and the axle lubrication shortage
1) Foreign object trapped in the gears
(15) High level of vibration 2) Wear of gears
or noise 3) Motor failure
4) Speed reducer failure
1) Gear wear
2) Play between the axle and wheels
3) Foreign objects or damage on rail grooves
(16) Knocking occurs
4) Hoses and cables interfering with travel
5) Failure of the casters
6) Damage to, or adhesion of foreign matter to, a wheel or idler

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10 Wiring diagram

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11 Assembly drawing of IK-12 NEXT

215mm=8.465inch
220mm=8.661inch
432mm=17.008inch

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012 Parts list

12.1 Main body and inside parts

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 IK-12 NEXT

Main body and inside parts

ITEM STOCK ITEM STOCK
PART NAME QTY REMARKS PART NAME QTY REMARKS
No. No No. No

1 Cover 1 20506249 30 DU bush 1 6D710607 MB0607-12FDU

Hexagon socket head Hexagon socket head
2 2 6C450510 BC-5×10(WS,WF) 31 4 6C450625 BC-6×25(WS,WF)
cap screw cap screw
Hexagon socket head
3 4 6C450512 BC-5×15(WS,WF) 32 Gear box assembly 1 20506421
cap screw
Hexagon socket head
4 Connecting bar 1 20506222 32-1 4 6C450625 BC-6×20(WS,WF)
cap screw
5 Speed dial 1 20506236 32-2 Gear box cover 1 20506229
Hexagon socket 1 20504669-
6 6C560408 SSS-4×8 32-3 Screw 2 M4×8
setscrew Y
7 Screw 3 6C500408 SF-4×8 32-4 Gear box bearing plate 1 20503579

8 Clutch support 1 20506244 32-5 Bearing 2 6A030698

9 Clutch lever assembly 1 20507111 32-6 Gear box 1 20503565

10 Screw 4 6C570408 M4×8(WS,WF) 32-7 Key 1 20503768

11 Speed plate 1 20506227 32-8 Worm gear 1 61007941

Gear box bearing
13 Clutch lever shim (0.2) (1) 20506670 32-9 1 20503575
spacer
14 Clutch lever shim (0.5) (1) 20506245 32-10 Gear head 1 61007942 IG-43-KS5 1/49

15 Screw 4 6C500510 SF-5×12 32-11 Motor 1 61007939 With the pinion

16 Clutch lever base 1 20506242 32-12 Spring washer 4 6D510040 WS-4

Hexagon socket head
17 Lever pin 2 60032325 32-13 4 6C030450 BC-4×50
cap screw
18 Bearing 2 6A036200 6200ZZ 33 Clutch shaft 1 20506220

19 Bearing plate 2 20503582 34 Nut 1 6D030080 NH-8

20 Screw 6 6C500410 SF-4×10 35 Ball plunger 1 20506237 BST8AL

Hexagon socket head
21 Wheels spacer 2 20506246 36 1 6C030630 BC-6×30
cap screw
22 Idler wheel 1 60030244 37 Nut 2 6D030060 NH-6
Hexagon socket head
23 Drive wheel 1 60030243 38 1 6C030620 BC-6×20
cap screw
24 Fixed washer 2 60030242 39 Spring 1 20506261

25 Round washer 2 60030241 40 Connecting bar B 1 20506224

26 Screw 2 6C510515 SM-5×15 41 Wave shape washer 1 20509327-Y W-16

27 Drive shaft assembly 1 20506422 42 Metal washer 1 20509328

27-1 Drive shaft 1 20506221

27-2 Key for drive shaft 1 20506262

27-3 Clutch wheel 1 20506225

27-4 Worm wheel 1 20506232

27-5 Worm wheel spacer 1 20506228

27-6 Wave shape washer 2 20509332 PACK-WVWS-V12-D15

28 Key 1 20506247 4×4×10L

29 DU bush 2 60038164 MB0806-15FDU

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 IK-12 NEXT

12.2 Outside parts

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 IK-12 NEXT

Outside parts
ITEM STOCK ITEM STOCK
PART NAME QTY REMARKS PART NAME QTY REMARKS
No. No No. No

50 Heat insulating plate 1 20506234

Heat insulating plate
51 2 20506334
spacer
Hexagon socket head
52 4 6C411020 BH-10×20(WF)
cap screw
53 Stand 1 60030204
Hexagon socket head
54 4 6C450515 BC-5×15(WS,WF)
cap screw
55 Chip support assembly 1 60035003 Accessories
Universal wheel
56 1 20506418
assembly
56-1 Spacer 1 20506235

56-2 Washer 1 60030211

56-3 U nut 1 6D400003 M4

56-4 Roller 1 60030213

56-5 Universal wheel spacer 1 60039352

Hexagon socket head
56-6 1 6C030422 BC-4×22
cap screw
Universal wheel
56-7 1 60039350
assembly
57 Undercover 1 20506226
SP-4×10
58 Screw 4 6C570410 (WS,WF)

59 Wing nut 1 6C120815 8×15

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12.3 Electrical parts

103

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 IK-12 NEXT

Electrical parts
ITEM STPCK ITEM STOCK
PART NAME QTY REMARKS PART NAME QTY REMARKS
No. No No. No
Operation board Push button switch ～ switch harness
80 1 20506436 88 1 20506474
assembly assembly plaiting

80-1 Operation name plate 1 20507065 Push button switch 1 60036249 SB-221

80-2 Screw 10 SP-3×8(WS,WF) 89 Screw 5 6C570308 SP-3×8(WS,WF)

6C570308
80-3 Screw 2 6C570305 SP-3×5(WS,WF) 90 Ground wire plaiting B 1 20506532

80-4 Panel spacer 1 20506239 91 Spacer 4 20506525 ASB-306E

80-5 Acrylic plate 1 20503617 92 Power supply 1 64000511 ZWS50B-24/CO2

80-6 Glass 1 20503619 93 Ground wire plaiting A 1 20506531

CN1～
80-7 Glass support 1 20503588 94 Harness plaiting A 1 20506483
Receptacle assembly

80-8 Operation plate cover 1 20506313 95 Screw 5 6C570306 SP-3×6(WS,WF)

80-9 Dustproof nut 1 60032480 96 L-MD-A substrate 1 20508809 ★

CN51～
80-10 Waterproof cap 1 60032431 97 Harness plaiting B 1 20506482
MD-CN1
MD-CN6～
80-11 Spacer 2 60036469 SP-5 98 Harness plaiting C 1 20506481
Receptacle assembly
～Harness plaiting A Harness plaiting D(4P MD-CN3～
80-12 Receptacle assembly 1 20506464 99 1 20506478
～Harness plaiting C ～4P) SW-CN2
Terminating resistance
Receptacle 1 64000510 NCS-255-R(square) 100 1 61006519 MD-CN2
assembly 4P
80-13 L-DSP-A substrate 1 20508806 ★ 101 Screw 7 6C570410 SP-4×10(WS,WF)
DSP-CN2～
80-14 Harness plaiting(4P～4P) 1 20506476 102 Polycarbonate plate 1 20507153 0.25t×90W×120L
SW-CN3

80-15 Short circuit connector 1 20506479 DSP-CN7 103 Power cable 1 20506329 ★

Short circuit connector 1 20506479 DSP-CN8

Terminating resistance
80-16 1 61006520 DSP-CN5
assembly 5P
DSP-CN9
80-17 Switch harness plaiting 1 20506470 With arc selector switch

80-18 Arc selector switch (1) 6N110009

80-19 L-SW-A(MAIN) substrate 1 20508811 ★

80-20 Nut (54D) 1 6D400001

80-21 Knob 1 61005744 K-90-S

80-22 Screw 2 6C570306 SP-3×6(WS,WF)

81 e-box 1 20506231

82 Nut(54D) 1 6D400001
L-SW-A(MULTISWITCH)
83 1 61006244
substrate
Harness plaiting E SW-CN4～
84 1 20506477
(3P～3P) ENC-CN4

85 Dustproof nut 1 60032480

86 Water proof cap 1 60032431

Direction selector switch ～ switch harness
87 1 20506475
assembly plaiting

Direction selector switch 1 20506230 S-3A

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13 Cutting Data
Cutting hole diameter（ｍｍ）
TIP SIZE
TYPE 00 0 1 2 3 4 5 6 7 8

STANDARD 0.8 1.0 1.2 1.4 1.6 1.9 2.3 2.7 3.0 3.4

D5 type 0.8 1.0 1.2 1.4 1.6 1.8 2.1

D7 type 0.6 0.9 1.1 1.3 1.5 1.8 2.1 2.6 3.2

102(STANDARD SPEED) For Acetylene

PRESSURE
PLATE CUTTING FLOW RATEＬ/H
TIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN ACETYLENE ACETYLEN
OXYGEN OXYGEN
3～5 00 700～660 1.5 / 0.15 0.2 / 0.02 690 410 370
5～10 0 660～550 2.0 / 0.2 0.2 / 0.02 1,200 410 370
10～15 1 550～490 2.5 / 0.2 0.2 / 0.02 2,100 480 430
15～30 2 490～400 3.0 / 0.25 0.2 / 0.02 3,400 480 430
30～40 3 400～350 3.0 / 0.3 0.2 / 0.02 4,300 480 430
40～50 4 350～320 3.5 / 0.35 0.25 / 0.025 6,500 550 500

102-D5 type（Acetylene）
PRESSURE
PLATE CUTTING FLOW RATEＬ/H
TIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN ACETYLENE ACETYLEN
OXYGEN OXYGEN
5～10 0 700～625 1,600 520 470
10～15 1 625～550 2,400 600 550
15～30 2 550～475 5.0 / 0.5 0.2 / 0.02 3,600 600 550
30～40 3 475～425 4,800 600 550
40～50 4 425～350 5,600 750 680

102-D7(HIGH SPEED) For Acetylene

PRESSURE
PLATE CUTTING FLOW RATEＬ/H
TIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN ACETYLENE ACETYLEN
OXYGEN OXYGEN
5～10 0 750～680 1,100 520 470
10～15 1 680～600 2,500 600 550
15～30 2 600～500 7.0 / 0.7 0.2 / 0.02 3,800 600 550
30～40 3 500～450 5,400 600 550
40～50 4 450～400 7,300 750 680

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 IK-12 NEXT

106(STANDARD SPEED) For Propane

PRESSURE
PLATE CUTTING FLOW RATEＬ/H
CHIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN PROPANE PROPANE
OXYGEN OXYGEN
3～5 00 700～660 1.5 / 0.15 0.2 / 0.02 690 1,180 310
5～10 0 660～550 2.0 / 0.2 0.2 / 0.02 1,200 1,180 310
10～15 1 550～490 2.5 / 0.2 0.2 / 0.02 2,100 1,180 310
15～30 2 490～400 3.0 / 0.25 0.25 / 0.025 3,400 1,370 360
30～40 3 400～350 3.0 / 0.3 0.25 / 0.025 4,300 1,370 360
40～50 4 350～320 3.5 / 0.35 0.3 / 0.03 6,500 1,860 490

106-D5 type （Propane）

PRESSURE
PLATE CUTTING FLOW RATEＬ/H
CHIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN PROPANE PROPANE
OXYGEN OXYGEN
5～10 0 700～625 0.2 / 0.02 1,600 1,180 310
10～15 1 625～550 0.2 / 0.02 2,400 1,180 310
15～30 2 550～475 5.0 / 0.5 0.25 / 0.025 3,600 1,370 360
30～40 3 475～425 0.25 / 0.025 4,800 1,370 360
40～50 4 425～350 0.3 / 0.03 5,600 1,860 490

106-D7(HIGH SPEED) For Propane

PRESSURE
PLATE CUTTING FLOW RATEＬ/H
CHIP (kg/c ㎡) / (Mpa)
THICKNESS SPEED
SIZE CUTTING PREHEATING
(mm) (mm/min) OXYGEN PROPANE PROPANE
OXYGEN OXYGEN
5～10 0 750～680 0.2 / 0.02 1,100 1,180 310
10～15 1 680～600 0.2 / 0.02 2,500 1,180 310
15～30 2 600～500 7.0 / 0.7 0.25 / 0.025 3,800 1,370 360
30～40 3 500～450 0.25 / 0.025 5,400 1,370 360
40～50 4 450～400 0.3 / 0.03 7,300 1,860 490

NOTE
1) All pressures are torch inlet pressures.
2) Oxygen purity is minimum of 99.7%, propane is minimum of JIS Grade 3.
3) Depending on the surface condition of the steel plate (scale, paint) either increase the fuel gas
pressure or decrease the cutting speed. Also, when precision cutting is required, adjust all data.

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IK-12 NEXT OPERATION MANUAL

Date of issue : Sep.2018

2nd: Nov.2018
3rd: Dec.2018

KOIKE SANSO KOGYO CO.,LTD

Printed in Japan