Plate Pro Mi0549a

ARONSON TECHNICAL MANUAL
KOIKE ARONSON, INC.

635 W. Main St., Arcade NY, 14009-0307 (585) 492 2400, Fax (585) 457 3517
Visit us at WWW.KOIKE.com
PLATE-PRO
INSTRUCTION MANUAL
MI0549A
May, 2010
Revision E
CONTENTS
PLATE-PRO®
SECTION 1 SAFETY PRECAUTIONS .......................................................... 1
Section 1.1 General Safety ........................................................................... 4

Section 1.2 General Safety, Plasma Cutting ................................................. 5
Section 1.3 General Safety, Miscellaneous................................................... 8
SECTION 2 General Introduction .............................................................. 11
Section 2.1 Scope....................................................................................... 11

Section 2.2 Description ............................................................................... 11
Section 2.3 Axis Definition .......................................................................... 11
Section 2.4 Rail Assembly .......................................................................... 11
Section 2.5 Saddle Assembly ..................................................................... 11
Section 2.6 Transverse Beam Assembly (Drive)......................................... 11
Section 2.7 X-Drive Assembly..................................................................... 12
Section 2.8 Y-Drive Assembly..................................................................... 12
Section 2.9 Gas System Assembly ............................................................. 12
Section 2.10 Gas Control Panel.................................................................... 12
Section 2.11 Operator Control Console ........................................................ 12
Section 2.12 Limit Switches .......................................................................... 12
Section 2.13 Torch Station (Main)................................................................. 12
Section 2.14 Torch Station (Slave) ............................................................... 12
Section 2.15 Steel Band Assembly ............................................................... 13
SECTION 3 Pre-installation Requirements .............................................. 14
Section 3.1 Pre-installation Safety .............................................................. 14

Section 3.2 Site Location ............................................................................ 14
Section 3.3 Site Preparation ....................................................................... 14
Section 3.4 Electrical Requirements ........................................................... 15
Section 3.5 Compressed Air ....................................................................... 15
Section 3.6 Oxy-Fuel Requirements ........................................................... 15
Section 3.7 Burning Table........................................................................... 16
SECTION 4 Installation .............................................................................. 18
Section 4.1 Installation Safety Precaution................................................... 18

Section 4.2 Handling and Storage .............................................................. 18
Section 4.3 Unpacking and Cleaning .......................................................... 18
Section 4.4 Rail Installation......................................................................... 19
Section 4.5 Machine Mounting.................................................................... 20
Section 4.6 Motor/Gear Unit Installation ..................................................... 20
Section 4.7 Torch Carriages ....................................................................... 21
Section 4.8 Torch Stations .......................................................................... 21
Section 4.9 CNC Interface .......................................................................... 21
Section 4.10 Utilities ..................................................................................... 21
Section 4.11 General Plasma Connections .................................................. 21
i
SECTION 5 Operation ................................................................................ 23
SECTION 6 Maintenance ........................................................................... 24
Section 6.1 Safety Precautions ................................................................... 24

Section 6.2 General Information ................................................................. 24
Section 6.3 Preventative Maintenance Schedule........................................ 25
Section 6.3.1 Each Eight (8) .......................................................................... 25
Section 6.3.2 Each Fifty (50) Operation Hours............................................... 25
Section 6.3.3 Each Two Hundred Fifty Hours ................................................ 26
Section 6.3.4 Each One Thousand (1000) Hours .......................................... 26
Section 6.4 Guide Roller Adjustment .......................................................... 26
Section 6.5 Rail Cleaning............................................................................ 26
Section 6.6 Roller Cleaning......................................................................... 26
Section 6.7 Wheel Cleaning........................................................................ 26
Section 6.8 Gears and Pinions.................................................................... 26
Section 6.9 Gas Control System ................................................................. 26
Section 6.10 Cut Quality Troubleshooting..................................................... 26
Section 6.11 Check Valve Test ..................................................................... 27
Section 6.12 Drive Tuning............................................................................. 28
SECTION 7 Replacement Parts................................................................. 28
LIST OF ILLUSTRATIONS /TABLES
Figure 1.1 Machine Safety Frame ............................................................. 10

Figure 3.1 Generic Ground Layout............................................................ 17
Figure 4.1 Rails ......................................................................................... 19
Table 4.2 Plasma Systems/KAR Manuals................................................ 22
Figure 6.1 Check Valve ............................................................................. 27
Figure 7.1 Machine Overview Front .......................................................... 28
Figure 7.2 Machine Overview Side ........................................................... 29
Figure 7.3 Y-Axis Carriage ........................................................................ 30
Figure 7.4 X-Axis Carriage ........................................................................ 31
Figure 7.5 Band Assembly ........................................................................ 32
Appendix A List of Terms and Abbreviations...............................................A1

Appendix B Model G Torch Lifter ................................................................B1
Appendix C Pulse Ignition........................................................................... C1
Appendix D Hi/Lo Gas Control.................................................................... D1
Appendix F Air Scribe Marker .....................................................................F1
ii
Safety
SECTION 1
SAFETY PRECAUTIONS
USER RESPONSIBILITY - This equipment will perform in conformity with the description thereof
in this manual and accompanying labels and/or inserts when installed, operated, maintained and
repaired in accordance with the instructions provided. THIS EQUIPMENT MUST BE CHECKED
PERIODICALLY. Defective equipment should not be used. Parts that are broken, missing, plainly worn,
distorted or contaminated should be replaced immediately. Should repair or replacement become
necessary, KOIKE ARONSON recommends that a request for service be made to the KOIKE ARONSON
Authorized Distributor from whom purchased or directly to the KOIKE ARONSON Service Department.
This equipment or any of its parts should not be altered without prior written approval of KOIKE
ARONSON. The user of this equipment shall have sole responsibility for any malfunction, which
results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other
than KOIKE ARONSON or a facility, designated by KOIKE ARONSON, INC.
NOTES, CAUTIONS & WARNINGS

Throughout this manual, notes, cautions, and warnings are used to describe
situations that require additional information. The following formats are used for
each:
Notes: A note offers additional information, such as an operating tip, that aids the user in
operating the equipment.
Caution: A caution describes a situation that may cause damage to the machine and offers
advice to avoid or rectify the situation.
WARNING
A warning describes a situation that presents a physical danger to the operator, and
offers advice to avoid or rectify the situation. Each type of warning displays an
applicable danger symbol, such as fire, explosion, electrical shock, and so on.
1
Safety
KOIKE ARONSON
SYMBOL LIBRARY
SYMBOL MEANING
GENERAL INFORMATION
ELECTRICAL SHOCK CAN KILL
POISON/TOXIC
FLAMMABLE/COMBUSTIBLE
EXPLOSION HAZARD
DO NOT WATCH THE ARC
OPEN GEARING
GROUND THIS EQUIPMENT
COMPRESSED GAS
2
Safety
SYMBOL MEANING
EYE PROTECTION REQUIRED
USE AN APPROVED RESPIRATOR
WEAR APPROVED EAR PROTECTION
INSULATED GLOVES REQUIRED
INSULATED FOOTWARE REQUIRED
NO OPEN FLAME
HOT SURFACE DO NOT TOUCH
DO NOT REMOVE GUARDS
WEAR PROPER EYE PROTECTION WHEN PLASMA CUTTING
WEAR PROTECTIVE CLOTHING
3
Safety
Before using this equipment and its options each person operating, maintaining or
supervising the use of this equipment must read the following safety instructions.
1.1 GENERAL SAFETY, OXY/FUEL 4. Keep combustibles away from the work
CUTTING area or protect them from sparks and
Operation of oxy/fuel torches involves flames.
oxygen and flammable gases under
pressure, open flames, flying slag and hot 5. Check for proper function of check
metal, fumes and combustion products. valves regularly. Do not remove or
Follow the precautions in this General bypass check valves.
Safety Section as well as those throughout
this manual for your personal safety and the 6. Always open gas valves slowly.
safety of people in the area that may be
affected. 7. Never use oxygen to ventilate the area
or clean off clothing.
1.2 GENERAL SAFETY
8. Keep oil, grease, and combustible dust
Operation of this machine involves various away from all oxygen equipment.
moving and rotating parts that could prove
to be dangerous. Follow the precautions in
this General Safety Section, as well as
those throughout this manual, for your
personal safety and the safety of people in
the area that may be affected. Failure to
observe these safety practices may cause
9. Purge oxygen and fuel lines individually
serious injury or death.
whenever combustible mixtures in the
lines are suspected.
1. Install and operate this machine only in a
well-ventilated area.
10. Never use the oxygen hose for any
other gas than oxygen.
11. Replace hoses that are damaged by

physical abuse or by sparks, heat or
open flame.
2. Connect and maintain electrical grounds
12. Examine hoses at regular intervals for
to the equipment according to local
leaks, wear, loose connections or other
codes and the National Electrical Code.
hazards.
13. Coil excess hose and place it out of the

way to prevent damage and to eliminate
tripping danger.
3. Check gas and electrical connections for 14. Maintain all pressure regulators in
tightness after installation and on a proper working condition.
regular basis thereafter.
4
Safety
15. Never use a regulator for any gas other
than that for which it is intended.
16. Never use a regulator that leaks,

creeps excessively or is physically
damaged in any way.
27. Wear filter-lens safety eye protection.
17. Never attempt to lubricate a regulator Wear gauntlet gloves, safety shoes,
with oil or grease. flame-retardant clothing, and no-cuff
trousers. Do not wear loose clothing
around this machinery because it can
catch on the machine.
28. Shut off power and gas supplies

whenever leaving the machine
18. Handle and use compressed gas unattended or before servicing.
cylinders in accordance with safety
standards published by the 29. Keep equipment clean and in good
Compressed Gas Association (CGA), operating condition.
and Canadian Standards Association
(CSA). 30. Read accessory instruction manuals
supplied for these items for additional
19. Never use a cylinder that leaks or is safety and operating guidelines before
physically damaged. operating this equipment.
20. Never use a cylinder that is not upright 31. No repair should ever be undertaken or
and secured in place. attempted by anyone other than a
KOIKE ARONSON designated
21. Never move or transport a cylinder technician.
without the protective valve cover in
place. 32. Read and understand further detailed
safety precautions throughout this
22. Never use a gas cylinder or its contents manual.
for any purpose other than that for
which it is intended. 1.2 GENERAL SAFETY, PLASMA
CUTTING
23. Never lubricate cylinder valves with oil
or grease.
24. Never expose cylinders to excessive

heat, sparks, slag or open flame.
25. Never use hammers, wrenches or other Plasma Arc cutting is a high intensity source
tools to open stuck cylinder valves. of visible light emission as well as ultraviolet
and infrared radiation. It can cause severe
26. Never cover the gas panel without eye damage and inflict burns on exposed
venting the bottom of the cover. Fuel skin when those portions of the body are not
gases are heavier than air. suitably protected.
5
Safety
Follow the precautions in this General 6. Warn other people in the area not to look
Safety Section and read the supplied directly at the arc unless they wear
plasma equipment instruction manual for glasses/goggles or a helmet.
additional and more detailed safety
precautions. 7. Never, start the plasma arc without
making certain that nearby personnel are
1. Facilities should be available for the wearing adequate protective equipment.
medical treatment of arc flashes or
burns to the eyes.
2. Provide radiation protection for the

operator and for personnel in the
adjacent area.
8. All areas of the body must be covered by
dark substantial clothing (preferably
flame retardant) to protect against arc
burn, sparks and flying hot metal.
9. The plasma operation should be located

3. Do not, under any circumstances, look in an area where protection for other
at a plasma arc without full eye personal may be readily provided.
protection. When near the plasma Portable non-combustible reflecting
cutting equipment always wear flash screens or enclosures with non-reflecting
goggles with side shields and walls may be used. Screens and
containing No. 4 filter lenses. enclosures should permit free circulation
of air at floor level.
4. The operator must use in addition to

flash goggles, a suitable helmet for eye 10. Do not cut in the presence of
and face protection when cutting. The atmospheres containing even minute
helmet must be equipped with a amounts of chlorinated solvents. The
number filter plate as indicated: heat and ultraviolet radiation can
decompose these vapors to form
Arc Current US Shade No. ISO 4850 Phosgene, a highly toxic gas, and other
Up to 100 Amps 8 11 irritating decomposition products.
100 to 200 Amps 10 11-12
200 to 400 Amps 12 13 11. Do not cut in atmospheres containing
Over 400 Amps 14 14
explosive dust or vapors.
5. Only use helmet or hand shields that 12. Keep the cutting area well ventilated.
are in good condition. Repair or replace
damaged equipment promptly. Protect
colored filter plates with a clear glass
cover plate.
6
Safety
the operator to turn the power supply off
quickly in an emergency.
22. Conform to all local codes for primary

wiring sizes and types.
13. Wear proper breathing mask when 23. Inspect the primary power cord
cutting galvanized metal and use frequently for damage or cracking of
proper ventilation. the cover. Bare wiring can kill. Do not
use the system with a damaged power
cord. If a power cord is damaged,
replace it immediately.
24. Inspect the torch leads. Replace if

frayed or damaged.
14. Do not cut pressurized cylinders or any
closed container. 25. Never operate the plasma system
unless the power supply unit covers
15. Make fire extinguishers available in the are in place. Exposed power supply
cutting area. connections present a severe electrical
hazard.
26. Do not pick up the work piece,

including the waste cutoff, while you
cut. Leave the work piece in place or
on the worktable with the work cable
16. Remove combustible material from the attached at all times.
immediate cutting area.
27. Before changing the torch parts,
17. Quench freshly cut metal or allow metal disconnect the main power supply.
to cool before handling it or bringing it After changing the torch parts and
in contact with combustible materials. returning the retaining cap to its
operating position, plug the power
18. To prevent electric shock keep your supply in again.
body and clothing dry.
28. Never, bypass or shortcut the safety
19. Do not stand in, sit on or lie on any wet interlocks.
surface when using the plasma system.
20. Maintain proper insulation against

electrical shock. If you must work in or
near a damp area, use extreme
caution. Wear insulated gloves and 29. Before removing a power, supply cover
boots. for maintenance USE APPROVED
LOCKOUT PROCEDURES, disconnect
21. Provide a wall mounted disconnect the main power at the wall, shut off
switch with proper size fuses close to switch or unplug the power supply. To
the power supply. This switch allows avoid exposure to severe electrical
hazard, wait five (5) minutes after
7
Safety
disconnecting the main power to allow
capacitor discharge to occur. Test for
zero volts.
30. Be sure the power cord is plugged into

a properly grounded outlet or that the
power cord ground wire is properly 36. When using a water table to confine
connected to the ground in the slag etc. while plasma arc cutting plate,
disconnect box. especially aluminum or magnesium,
cutting may cause an accumulation of
31. If installation of the plasma system explosive gas below the plate. Do not
involves connecting the power cord to allow aluminum or magnesium dross to
the power supply, ensure that the accumulate in a water table. Prior to
power cord ground wire is properly cutting, raise and lower the water level
connected. Conform to CSA standards several times to dissipate trapped
by placing the power cord ground wire gases. Do not leave plate on the table
on the stud first; then place the other for extended periods, for example
ground wires on top of the power cord overnight or weekends. When the table
ground. Fasten the retaining nut tightly. is not in use, keep the water level down.
Do not cut these materials under water.
32. Make sure that all electrical Read additional cautions in the related
connections are tight to avoid manuals.
excessive heating.
37. No repair should ever be under taken or
33. Clamp the work cable to the worktable. attempted by anyone other than a
This is the “star” ground connection. KOIKE ARONSON designated
technician.
34. Connect the worktable to a good earth
ground. Consult the National Electrical 1.3 GENERAL SAFETY, MISCELLANEOUS
Code, Grounding Electrode System, or
other appropriate national or local 1. Keep the working area dry to avoid an
codes. electrical shock.
2. Check that the machine voltage and

supply voltages are the same before
turning on the power switch.
3. Never operate this machine unless all

35. Plasma cutting operation noise levels electrical box covers are attached.
may be high enough to require ear Exposed electrical connections present
protection for the operator and other a severe electrical hazard.
personnel in the adjacent area. 4. When igniting or adjusting torch flame at
the start of cutting take care not be
burned.
5. Never touch torch tip when lit, or you

may be burned.
8
Safety
6. When replacing or cleaning a torch tip 9. During the cutting operation never touch
during cutting be sure to give the tip the torch flame or plasma arc.
sufficient time to cool. The tip will be
very hot. 10. Do not climb on the cutting table, as it is
possible to slip and cause injury.
11. Take care not to climb on or over the rail

as it has rack attached to it and can
cause injury.
12. There is no pressure relief valve in the

7. After cutting never touch the work-piece
gas system therefore supply pressures
or scrap until they cool. You can be
should be adjusted at the supply source
burned.
regulators.
8. During the piercing operation on heavier Maximum supply pressures are:

plate (25mm or larger) there can be a
good deal of spatter. Be sure to stay Oxygen 1034 kPA (150psi) (10.3 bar)
away from the torch and stay in the
operation zone to prevent exposure to Fuel 103 kPA (15psi) (1.3 bar)
burn from the spatter.
WARNING
Protect yourself and others. Read and understand these instructions. FUMES AND
GASES can be dangerous to your health. HEAT RAYS (INFRARED &
ULTRAVIOLET) from flame, arc or hot metal can injure eyes. Read and understand
the manufacturers’ instructions and your employer's safety practices. Use enough
ventilation/exhaust at the flame/arc, or both, to keep fumes and gases from your
breathing zone, and the general area. Keep your head out of the fumes.
9
Safety
Walkway
Rails
Cutting
Table
Cutting Machine Fence
Flame
Adjustment
Figure 1.1
1. The working area shown, Figure 1.1 is 3. Only qualified personnel should operate or
required to ensure safe operation. This service this equipment. The work area
area should have a fireproof floor, must must be checked for personal and
provide adequate clearance around the obstructions prior to starting machine or
machine for proper operation and initiating machine motion.
personnel safety per local code and
should be clearly marked with appropriate 4. Machine operation and monitoring of the
warnings cutting process should be performed from
the operation station, at the control
2. This machine moves in multiple directions console.
and at various speeds. All personnel,
materials and equipment not involved in 5 Consumables should be changed in the
the production process must be kept clear Operation Area in front of the machine
of the work area. noted above.
10
General Introduction
SECTION 2
GENERAL INTRODUCTION
2.1 SCOPE 2. The Y-axis is parallel to the longitudinal
rail system.
This manual provides general installation,
operation and service information for the KOIKE 2.4 RAIL ASSEMBLY
ARONSON PLATE-PRO® series of cutting
machines. This manual includes an illustrated The PLATE-PRO® rail system consists of a
part listing to aid in ordering parts. main rail weldment and rail with an outboard
support tube and rail construction. The main
2.2 DESCRIPTION rail weldment is fabricated 1/2 inch thick steel
plate for rigidity and ease of installation. The
Your PLATE-PRO series is designed with time mounting surface for anchoring to the floor
proven construction techniques. This machine are pre-welded with the level bolts already
uses the latest in electronic and mechanical attached. All rail lengths are pre-fabricated.
technologies. Speed, accuracy, versatility and See table 2.1 for length. All hardware for
durability have been engineered into the installation is included with the rail package.
PLATE-PRO® for demanding production jobs.
The Dual HI/LO gas system along with the CNC 2.5 SADDLE ASSEMBLY
programmable control and selectable features
combine for ease of operation and cutting of Two saddle assemblies travel on the Y-axis
plate steel. In addition, accessories for specific rail system, driven by a Y-axis main drive
purposes are available to further enhance the motor and planetary gearbox assembly
versatility of the PLATE-PRO®. mounted on the outboard side of the main
carriage. Two (2) wheel assemblies support
The Koike Aronson Inc. PLATE-PRO® is the main saddle, one on the forward end and
designed to meet your cutting and marking one on the aft end of the saddle to provide
requirements of steel plate. Optional equipment stability. The main saddle (inboard), on the
available will increase production and reduce operators control side of the machine utilizes
production cycle time. two sets of rollers to provide guidance down
the rail system. The inboard roller, facing the
The PLATE-PRO® features a single control unit front of the machine, is eccentric to adjust to
the guide rail and maintain positive machine
that contains the AC servo drive, Dual micro
alignment.
processor CNC, and a mechanical switch
interface for ease of operation.
2.6 TRANSVERSE BEAM ASSEMBLY
(X-drive)
2.3 AXIS DEFINITION
This is a structural steel tube extending in a
To avoid confusion in determining direction and
left to right direction facing the machine and is
aid in identifying part locations:
supported by the inboard and outboard
saddles. The beam is factory squared to both
1. The X-axis is parallel to the transverse
saddles, pinned in position and bolted. A
(main) beam.
precision, replaceable linear round way has
been mounted to keep the master and slave
carriages in precise position.
11
2.7 X-AXIS DRIVE ASSEMBLY optional ease on valve assembly allows for
gradual activation of cutting oxygen to prevent
The X-axis drive carriage supports one torch blow back during thick plate piercing.
station and or one or more options. The drive is
located on the transverse beam master 2.11 OPERATOR CONTROL CONSOLE
carriage. A motor and planetary gear assembly
drives the carriage along the X-axis. The X axis The operator/CNC control is mounted to the
pinion engages to a rack assembly mounted to machine on the main rail saddle assembly.
the transverse beam to provide precise motion.
The pinion is engaged to the rack using a spring 2.12 LIMIT SWITCHES
washer assembly to ensure positive
engagement of the pinion to the rack. Two (2) limit switches are mounted on the
transverse beam assembly. The limit switches
2.8 Y-AXIS DRIVE ASSEMBLY prevent an over-travel condition of the X-axis
drive unit.
The inboard Y-axis drive assembly is mounted
at the rear of the main saddle assembly facing A limit switch mounted to the main (inboard)
out. A pivot mount assembly supports the motor saddle, limits Y-axis travel.
and planetary gear unit. The pinion is engaged
Should a limit switch be tripped, the drive
to the rack using a spring washer assembly to
signal is interrupted, and all cutting operations
ensure positive engagement of the pinion to the
are stopped. To recover from a limit trip see
rack.
the operation section of this manual.
2.9 GAS SYSTEM ASSEMBLY
2.13 TORCH STATION (Main)
One torch station is mounted on the
The manifold assembly is located on the transverse drive carriage. This station could
machine near the center of the shelf assembly. be an oxy/fuel or plasma torch station. The
Connections are made from the manifold to the oxy/fuel station consists of the torch, fuel and
torch stations. The cut manifold is located at the oxygen hoses, check valves, cut oxygen
bottom section of the mounting bracket. The solenoid, motorized lifter, electrical cable, and
preheat oxygen manifold is located just above
a flexible cable carrier assembly. The plasma
the cut manifold. The fuel manifold is located
station consists of the plasma torch and
above the preheat oxygen manifold. The
leads. Optional height controls are also
optional ignition manifold is supplied from a tee
mounted here.
connection from the preheat fuel manifold and
is located above the fuel manifold. Five (5) 2.14 TORCH STATION (Slave)
outlet bushings on each manifold pipe allow for
connection of torch hoses. Individual preheat
Oxy/fuel or tool slave stations include a
solenoids are provided for each oxy-fuel station.
carriage for mounting to the transverse beam.
Caps for unused manifold outlets are provided.
These stations are manually locked to the
steel band assembly for securing the carriage
2.10 HI-LO GAS CONTROL PANEL
to the beam once the correct cutting distance
is set.
The gas control panel contains gauges for
observing the gas pressures and solenoids for
the transition of HI to LO pressure to the
manifold assemblies. Regulators are provided
for oxygen and fuel pressure adjustment. The
12
2.15 STEEL BAND ASSEMBLY
The steel band assembly consists of a single

pulley assembly. The assembly is mounted on
the extreme left and right of the transverse
beam assembly. A 25mm steel band is
threaded around the assembly and is firmly
connected to the transverse drive carriage. This
allows motion for the slave torch stations. The
steel band assembly allows the slave station to
have like image cutting of the master carriage.
13
Pre-installation Requirements
SECTION 3
PRE-INSTALLATION REQUIREMENTS
3.1 PRE-INSTALLATION SAFETY
The machine requires a space where floor
All equipment must be installed in vibration is at a minimum. Precision
accordance with local requirements and the operation is necessary for accurate part
National Electrical Code. Connect and processing. Avoid areas where vibrations
maintain good electrical grounds, as per caused by drop hammers, heavy
article 250 of the NEC, to the supply ground machinery and punch presses are used.
wire, cutting machine and cutting table. Do Position the unit close to the production
not ground to electrical conduit, or pipes line, with adequate lighting and ventilation.
carrying gases or flammable liquids. Use
only correct sizes of electrical cable. Special consideration must be used in the
selection of a site for machine operation.
Plan to provide ventilation. Proper Gas supply, electrical power, clean dry
ventilation is vital for safety, good visibility shop air and water in the immediate vicinity
and personal comfort. are essential for economical operation of
the machine. Material handling is important
Equipment necessary for lifting the machine for safe loading and unloading of the parts.
weight must be available at the time of
installation for example, an overhead crane, 3.3 SITE PREPARATION
forklift, etc.
All normal safety precautions used in Solid, secure and accurate rail and
working with flammable gases, electrical pedestal installation is critical to insure
equipment and heavy machinery, as well as maximum accuracy for the cutting, oxy-fuel
procedures listed in your company safety and plasma machine. The floor for the
manual must be followed to prevent possible machine installation should be level within
injury. 9.5mm (3/8”) over the entire length and
width. The floor area supporting the rails
should be specified by a contractor and be
Caution: free from cracks or other imperfections.
When welding, DO NOT ground to the
machine, the rail system or to burning table, If any possibility of floor settlement exists,
to avoid damage to electronic components. separate footing should be provided over a
Evidence of welding to the cutting machine firmly packed base. If a possibility of
equipment will void all warranties. equipment vibration exists, the machine
should be provided with an adequate
NOTE: The following preparations should isolation pad.
be complete before the arrival of the
installing technician.
3.2 SITE LOCATION
14
3.4 ELECTRICAL REQUIREMENTS copper, 4.5M (14’) in length. If you cannot

drive a 4.5M ground rod you may use two
The position of cables is very important for (2) 2.5M (8’) ground rods connected to
proper operation of the system. Use care each other with 4/0 cable and then to the
when routing electrical wires and cables to Star ground. The wire to the Star ground
avoid pinching or chafing against metallic or connection will be a minimum of 4/0 cable
other abrasive objects. and should not exceed 1.2M (4’) in length.
Local codes as well as the National Note: Ground rods must be installed
CAUTION
Electrical Standard must be followed for all according to the National Electrical
The AC power
power and groundingto installations.
the cutting machine Code Standards.
must come from a dedicated source. No
other machinery or equipment should be All ground connections must make intimate
connected to this line. contact with the components they are
grounding. All rusted or painted surfaces
must be cleaned and the connections
Cutting machine electrical requirements are made should be tight. Any grounding strap
115 Volts AC (±10%), 50-60 Hz, single should be sized to current load per article
phase, 10 Amps. Koike Aronson provides 250 of the NEC.
the machine main power cable. Koike
Aronson recommends all power cables be 3.5 COMPRESSED AIR
kept as far as possible from auxiliary
components such as machine control boxes, Compressed air for general blow down and
solenoids, etc. Avoid random placement of clean up should be dry, clean and oil free
wiring. Keep all wiring as short as possible, with a 5-micron maximum particle size.
Do Not coil any cables. Make sure all
supply hoses and cable are long enough for 3.6 OXY-FUEL REQUIREMENTS
the type of carrier system used.
Oxygen and fuel gas supply systems
should be recommended and installed by
CAUTION your local gas supply distributor. For most
Proper grounding of the cutting machine multi-torch production cutting machines, a
and peripheral equipment is critical to cylinder bank or pipeline system is usually
the reliable operation of the system. required.
During an installation of this type, care

This requires careful and proper installation should be taken to ensure that oxygen
of ground rods and associated wire valves, lines and fittings are cleaned for
connections. Ground wires will connect to oxygen service. Station drops, fuel and
the headstock and through a "STAR" ground oxygen should be spaced at least 300 mm
connection. Ground rod size for plasma apart center-to-center, and identified by
systems of 100 amperes or less should be color. All fuel and oxygen lines should be
12mm (1/2”) diameter solid copper, 2.5M (8’) installed according to applicable
in length. The wire connection to the Star regulations and safety rules.
ground should be a proper sized stranded
wire, and should not exceed 1.2M (4’) in
length. The ground rod for machines with a
plasma system of 100 amperes or more
should be 19mm (3/4”) diameter solid
15
Station drops should be installed on a wall or A locally supplied pressure booster is

column for rigid support. Installation should normally required for low-pressure natural
be at the rear of the rail system for use with gas.
the type of carrier system used for machine
supply. 3.7 BURNING TABLE
The burning table, fabricated enclosed or

open frame, is a customer responsibility.
Refer to the layout drawing in Section 2
figure 2.1, for your cutting machine to
determine clearance available for the
burning table before fabrication. The
burning table may be as long as the cutting
WARNING length provided by the rail system less the
Do not allow oil, grease, or combustibles cutting machine parking space. Table
to be exposed to oxygen equipment. width and the outside dimensions, may be
Use only thread-sealing compound as wide as the designated cutting width of
approved for oxygen service when the machine plus 305 mm (12.0in). A table
making up threaded joints. surface (bottom of plate) height of 609.6
mm (24.0in.) to 711.2 mm (28.0in) is
recommended. Do not anchor the table in
place before rail installation.
Oxygen supply requirements must be
calculated on the maximum number of
torches to be used and the maximum
material thickness expected. Your local gas
supplier is best suited to assist you in
determining your supply requirements.
16
Figure 3.1
17
Installation
SECTION 4
INSTALLATION
4.1 INSTALLATION SAFETY PRECAUTION Inspect each piece for signs of mishandling or
apparent damage. If discrepancies exist or any
evidence of damage exists, note it BOLDLY
across the face of the waybill BEFORE YOU
WARNING SIGN IT. Sign the waybill only after this
inspection. If you note discrepancies on the
delivery ticket, DO NOT open the cartons.
Voltages used with this machine can Call the freight carrier’s local office and ask
be injurious to personnel if improperly that a claims investigator be sent as soon as
used. All equipment must be installed possible to verify the status of the shipment.
and maintained in accordance with Also, call your Koike Aronson representative.
local requirements and the National Try to arrange the meeting so that the claims
Electric Code. investigator and the representative will be
present when the damage/shortage is verified.
The freight carrier will supply you with the
Connect and maintain suitable electrical necessary claims forms if required. Freight
grounds to the supply ground wire. Do not claims are the receivers’ responsibility. Please
connect ground to electrical conduit or to pipes follow these instructions carefully; Koike
carrying gases or flammable liquids. Use only Aronson and your distributor will support you
the recommended size of electrical cable, in fully in the unlikely event that a freight claim is
accordance with article 250 of the NEC. necessary.
If it was necessary to install forced ventilation, Handle the packing cartons carefully, right side
operate the cutting machine only when such up as marked. Store cartons in a dry location
ventilation is running to prevent harmful and until ready to install.
dangerous accumulations of fumes.
4.3 UNPACKING AND CLEANING
Avoid enclosing areas where fuel gas leaks
may occur, or insure that such leaks cannot The equipment has been packaged to prevent
occur in lines passing through or ending in damage in transit. Unpack carefully to prevent
confined spaces. accidental damage by uncrating tools. After
uncrating, examine the equipment for signs of
Use normal precautions when loading or damage, particularly to control knobs, switches
operating heavy equipment. Follow the and electrical components. Report any damage
procedures in your company safety manual. to the freight carrier and Koike Aronson
immediately.
4.2 HANDLING AND STORAGE
Remove preservation coating from all
When the shipment arrives at your location, unpainted surfaces, as components are
accompany the driver in counting all the needed for installation, with WD-40®, LPS-1®
cartons indicated on the driver's waybill. or mineral spirits.
18
Installation
4.4 RAIL INSTALLATION e. Check the main rail level across the top
through the entire length.
Proper installation of rails and their mechanical
alignment is CRITICAL to insure cutting f. Using the anchor boltholes, drill the holes
accuracy with coordinate drive cutting for mounting to the floor. Use a ½” roto
machines. hammer type drill.
The main rail of the PLATE-PRO® consists of a g. Install the anchors in the holes and
Koike Aronson, Inc. rigid fabricated weldment tighten.
assembly with the main rail assembly pre-
mounted to it for ease of installation. The drive h. Re-install the Y-axis nylatrac support
rack is also installed on the main rail assembly. channel.
The outboard rail assembly consists of rigid i. Re-check the level of the entire rail, front
tubular steel construction with the rail mounted to back and side-to-side. Small
to it for ease of installation. adjustments can be made using the
hardware on the rail assembly.
Both rail assemblies have hardware attached
to the rail for fine level adjustment during the j. Check that all rail and rack hardware is
installation. tight.
4.4.1 STEPS FOR RAIL INSTALLATION k. Check the rail gauge at each adjustment
position and anchor the outboard rail.
a. Remove the Y-axis nylatrac support Figure 4.1
channel from the main rail support
weldment.
Main Rail Weldment
Note: The support channel is mounted with w/main Drive Rail
angle clips and once removed the and Rack
channel will fall rapidly. Take care in
removing the channel.
b. Keep in mind the pre-installation

requisites; place the main rail into
location. Using the rail gauge for the Main Rail Support
Channel
machine as a reference, place the
outboard rail into location.
Note: DO NOT ANCHOR TO THE FLOOR AT Outboard Rail

THIS TIME.
c. Using a manometer (water level), locate

the highest point of the main rail Rail
FINAL INSTALLATION Gauge
NOTE: WHEN THE RAILS ARE
assembly. INSTALLED AND CHECKED FOR LOCATION AND ALL
FASTENERS ARE CHECKED FOR TIGHTNESS, THE
ENTIRE RAIL SYSTEM MUST BE GROUTED. THE
d. Level the main rail assembly to within GROUT MUST MEET THE ASTM C-109 6000PSI/24
+/- 1/32” over the entire length. If shims HOURS CORPS OF ENGINEERS SPEC CRD-C 621. 0%
are required, use solid steel shim. SHRINKAGE, 0% EXPANSION
19
Installation
The rail gauge is measured from the Vertical Mounting: Align all four (4) wheels of
outside edge of the main rail to the both carriages with the rails and gently lower
outside edge of the outboard rail the full weight of the carriages onto the rails.
assembly. The outboard rail Reposition the machine, if necessary, to a
assembly sets one-half of an inch lower than position where the fixed rollers (front and rear)
the main rail assembly. are against the rail.
The guide rail must be straight within 0.1 mm Adjust the rollers equally against the rail so that
over the entire length. It must be level within ± when the guide roller is held between the
1mm over the entire length. The outboard rail thumb and forefinger, the roller will just slip
must be straight within 0.1 mm over the entire against the rail. Carriages should be level and
length. It must be level within 1mm over the roll freely. Install the mechanical end stops to
entire length. The rail gauge between the guide the rail.
rail and the outboard rail must be parallel within
1 mm the entire length. The level between the Horizontal Mounting: With carriages aligned
guide rail and outboard rail must be maintained straight and level with the rails, make contact
within 1 mm the entire length. Also remove with the rear guide rollers of the main carriage.
Kosmoline from entire rail surface both inboard Roll the carriage slowly inward until the rear
and outboard rail. wheels of the carriage make contact with the
rails followed by the front carriage wheels.
4.5 MACHINE MOUNTING
Adjust the guide rollers as indicated in the
The cutting machine can be mounted on the vertical mounting section. Install the
rail system from above (vertically) using an mechanical end stops to the rails.
overhead crane or from the front (horizontally)
when overhead clearance is too low. 4.6 MOTOR/GEAR-UNIT INSTALLATION
Suspend the cutting machine assembly by

means of the two (2) lifting strap assemblies
under the two beams located near the inside of
the inboard saddle assembly and one located WARNING
near the inside of the outboard saddle
assembly. Balance the machine by test
lifting.
This machine has open gearing. Keep
When the machine is suspended, and the load hands clear when the machine is being
is secured, clean the fixed guide and main operated.
rollers. This is necessary for the machine to
clear the rack when it is placed on the rails.
Clean the adjustable guide rollers before The motor and planetary gear units have been
placing the machine on the rails. factory installed on the machine. To engage
the units, remove all the packing and support
NOTE: Maintain straight and level alignment of banding from the unit. Engage the gear pinion
carriages with the rails when making contact, to the rack. Install the spring washer assembly
to prevent damage to wheels, guide rollers, by tension. The tension on the assembly
rails or rack. should be tight enough that the spring can just
move by grabbing them and turning your
thumb and forefinger.
20
Installation
Note: For proper engagement and tension to Koike Aronson, Inc. as to where they connect
the rack, pull out on the mount assembly. This to the CNC.
should be difficult. Note that it will not fully
disengage the pinion but should spring back to
fully engage to the rack. Improper tension of 4.10 UTILITIES
the spring assembly will cause premature wear
of the pinion and rack. The machine is supplied with a cable carrier
system. Route all supply hoses and cables
4.7 TORCH CARRIAGES through the carrier system in a neat and
orderly fashion. Tie all cables and hoses to the
All slave carriages for individual torches/tools tie plates located at teach end of the cable
are installed and adjusted at Koike Aronson, carrier using provided tie-wraps.
Inc. There is no installation required. Remove
all packing and support bands from the
carriage assembly. Check bottom eccentric
bearing and tighten if loose.
4.8 TORCH STATIONS

Connect the power cable from a properly fused
Torch lifters mount directly to the torch dedicated source (review Section 3 Pre-
carriages using the spacer provided and four Installation) to the power disconnect on the
(4) hex head capscrews. The torch station machine. Check to see that the power source
closest to the operator control console is is off and/or tagged Out of Service to avoid a
designated as station number one (1). potential electrical shock.
With the torch “free” hanging, connect the Connect the fuel and oxygen supply hoses
correct hose(s) to the cutting torch. Loosen the from the station drop to the correct connecting
clamp screw on the motorized lifter. Route the point on the manifold or HI/LO gas control. One
cable and hoses through the support ring on green 3/8 inch “B” R/H fitting, oxygen supply
the torch riser assembly. Insert the torch holder hose connects from the oxygen tank to the to
to the torch support bracket and tighten in the cutting oxygen on the manifold. The other
place. To achieve accurate cutting, the torch green 3/8 inch “B” R/H fitting, oxygen supply
must be perpendicular to the surface of the hose connects from the oxygen tank to the to
plate. A swivel adjustment on the motorized the preheat oxygen on the HI/LO panel. A red
lifter and the torch support bracket will allow for 3/8 inch “B” L/H fitting, fuel supply hose
the necessary adjustment. Connect the torch connects to the fuel on the HI/LO panel from
lifter cable to the lifter assembly. Check the the fuel supply tank.
tightness of all hardware and hose
connections. Check for leaks using soap water 4.11 GENERAL PLASMA MACHINE
in a spray bottle. CONNECTIONS
4.9 CNC INTERFACE Plasma system installations differ from
installation to installation due to the type of
The CNC control has been removed from the system and height control ordered at the time
machine for shipment. Unpack it CAREFULLY of purchase.
and install the CNC at the operator’s control
console. Connect the proper cable assembly to
the CNC. All cable assemblies are labeled at Some of the hoses and cables are left on the
machine neatly coiled and packed for shipping.
These are labeled as to where their connection
21
Installation
is to the plasma system. The remaining hoses Check all grounding for the plasma system.
and cables are packed separately. After the Make sure all ground connections are properly
flexible cable carrier is installed, locate the tightened. For a more detailed view of the
remaining hoses, cables, and route through the installation, refer to Koike Aronson Inc. drawing
carrier, paying close attention as to connectors and the vendor manual. Table 4.2 includes a
and fittings. Routing of the hoses and cables listing of the manuals used by Koike Aronson
has to be accomplished in a neat and orderly Inc. for plasma systems.
fashion. The hoses and cables are labeled to
where they connect.
Table 4.2 KOIKE ARONSON/VENDOR PLASMA MANUAL

Vendor Vendor Manual Manual Part Number
Thermal Dynamics Ultracut 100
Thermal Dynamics Autocut 100

INNERLOGIC PL2150 MI2008v718082

INNERLOGIC FL100 MI2008v718050
HYPERTHERM Powermax 1250 MI0043v395

HYPERTHERM Max 200 hand torch MI0043v87
HYPERTHERM Max 200 machine torch MI0043v98
HYPERTHERM HT2000LHF MI0043v302
HYPERTHERM HPR130 manual gas MI0043v457
HYPERTHERM HPR130 auto gas MI0043v496
HYPERTHERM HPR260 manual gas MI0043v494
HYPERTHERM HPR260 auto gas MI0043v500
22
Installation
SECTION 5
OPERATION
5.1 OPERATIONAL SAFETY
7. Open cylinder or supply valves slowly.
Follow the precautions in the SAFETY Never use oxygen to ventilate area or clean
section and throughout this manual for your off clothing.
personal safety and the safety of people near
the equipment. 8. Keep oil, grease and combustibles away
from oxygen equipment.
This system is designed to operate with a
dedicated 3 wire grounded 115vac single 9. Purge oxygen and fuel lines before
phase power source Failure to meet this igniting each torch, by briefly opening and
specification can be hazardous to the closing each valve in turn.
machine and or operator.
10. Wear appropriate eye protection safety
1. Operate cutting equipment only in a well- goggles with filter lens.
ventilated area.
11. Keep equipment clean and in good
2. Check gas connections for tightness operating condition.
regularly.
12. WELDING: DO NOT ground to the
3. Keep combustibles away from the work machine, the rail system or to the cutting
area or protected from sparks and flames. table at any time to avoid damage to
electronic components. Failure to follow
4. Verify the functionality of all check valves this warning may void all manufacturers’
regularly. warranty.
5. Before connecting a pressure-reducing 5.2 GENERAL OPERATIONS

regulator to an oxygen cylinder or
manifold, always wipe the outlet 1. For machine control operations, refer
connection with a clean, oil free cloth and to the CNC Operation Manual.
slightly open the cylinder valve to remove
any dirt or contaminate particles.
6. Always drain gas from the oxygen

regulator before opening cylinder or
manifold valve. Proceed by engaging the
adjusting screw and opening down-
stream valves to allow gas to escape. The
adjusting screw may then be released
before opening the cylinder valve.
23
Maintenance
SECTION 6
MAINTENANCE
6.1 SAFETY PRECAUTIONS 9. Keep power cables dry, free of oil and
grease, and protected at all times from
damage by hot metal and sparks. Do Not
use any power cable with worn or
damaged insulation, repair or replace
immediately.
1. Shut OFF main power switch; pull fuses, or
lock and red tag switch before attempting 10. Equipment that is not functioning properly
work on electrical circuits. Do not touch should Not be used until all repairs have
electrically HOT parts or those with residual been completed and the equipment has
voltage, such as capacitors until they have been tested to ascertain that it is in proper
been grounded and their electric charge operating condition.
dissipated.
11. When welding Do Not ground to the
2. Check gas cylinder valves, regulators, machine, the rail system, or to the cutting
hose, and torch connections regularly for table at any time to avoid damage to
leaks. electronic components. Failure to follow
this warning may void manufacturer's
3. Always open gas valves slowly. warranty.
4. Always purge oxygen and fuel lines 12. Except for inspection and maintenance
individually to discharge combustible listed in this manual, it is recommended
mixtures before lighting each torch. Close that all other servicing be done by an
each torch valve before opening the next authorized Koike Aronson, Inc. service
one. technician.
5. Do Not purge in the presence of flame, lit 13. Goggles with correct filter lenses must be
cigarettes and other sources of ignition, nor worn whenever torches are lit. Suitable
towards persons or clothing. protective clothing must be worn where
necessary.
6. Before attempting to disassemble any part
of the Gas System, depressurize the Comply with these and other safety procedures
System. Do Not disconnect any part of the listed in this manual. Refer to appropriate
Gas System that is under pressure. manuals, furnished by the manufacturer, for
safety procedures for plasma, drive, N/C or
7. All parts, repaired, replaced or otherwise other optional equipment.
handled, must be cleaned for oxygen
service. 6.2 GENERAL INFORMATION
8. Regularly, inspect check valves and keep This manual provides standard preventative
them in operating order. They prevent maintenance procedures required for accurate
reverse flow (from torches to hoses) of and proper operation of the PLATE-PRO®
hazardous mixtures of flammable gas and cutting machine. Follow these procedures to
air (or oxygen). Refer to 6.11 on how to test maintain machine operation at peak efficiency
a check valve. and to extend the useful life of the machine.
24
Maintenance
The machine has been assembled, properly 1. Blow off rails, rollers and wheels with low-
adjusted and factory tested before shipment. pressure shop air (Not Oxygen).
Factory settings, other than those listed in the
installation section of this manual, should not 2. Spray a clean cloth lightly with WD-40®or
be changed. If machine performance is LPS-1®, and wipe the wheels, rollers,
unsatisfactory, contact a Koike Aronson, Inc. gears, rails and rack.
authorized service representative for advice.
3. Ensure that the main saddle side guide
Keep the machine clean, in good condition and rollers are tight to the side of the rail. The
free of oil, grease and other combustibles. If outside rollers are non-adjusting; the inside
replacement parts are required, it is rollers are adjustable.
recommended that they be purchased from
Koike Aronson, Inc. through an authorized 4. Clean torches and tips.
distributor.
5. If the machine is equipped with an air scribe
The manufacturer for optional items such as or punch marker, check that the air supply
plasma systems, microprocessor controls and is clean and dry. Moisture free air is
certain other components has furnished important to the operation of these options.
separate manuals, listing maintenance
procedures. 6.3.2 EACH FIFTY (50) OPERATION HOURS
6.3 PREVENTATIVE MAINTENANCE 1. Check gas system for leaks with soap and
SCHEDULE water solution.
Although this machine does not require a great 2. Check for damage to the gear rack. Repair
deal of maintenance, the following procedures with a file or replace if damage is
should be preformed routinely based on excessive.
operation hours. The following maintenance
guidelines are solely the responsibility of the 3. Remove wheel guards located on the
operator (customer). Failure to comply with outside of the saddles and clean main
these guidelines for your machine can result in wheels.
poor cut quality, a rough running machine or
service calls at the expense of the customer 4. Clean, readjust and grease torch holders.
and are not covered under machine warranty
neither by the Distributor nor by Koike 5. Check roller bearings on X-axis carriage for
Aronson, Inc. smooth operation. Clean and lube if
necessary.
6.3.3 EACH TWO HUNDRED FIFTY (250)

HOURS
CAUTION
DO NOT allow any grease that has not been
approved for oxygen use come in contact
with oxygen equipment. 1. Check for backlash in X and Y drive pinions
to the rack. Make sure the pinion is not
worn. If backlash exists, check the rack for
6.3.1 EACH EIGHT (8) OPERATION HOURS wear.
25
Maintenance
b. Move the carriage in a direction away
2. Check that the steel band that runs the from the bar, holding the bar against the
idler carriages is tight. roller for at least one complete revolution
to scrape off dirt build up.
3. Check gas system for leaks with soap and
water solution. 6.7 WHEEL CLEANING
6.3.4 EACH ONE THOUSAND (1000) At least once each shift, remove dirt buildup
HOURS from wheels on the Y- axis saddle.
Scrape off buildup from wheels with the edge

of a steel flat bar (1.6 x 25 mm, or pocket
rule) while rolling carriage through one
revolution of each wheel.
1. Clean and dust off all electrical
equipment. 6.8 GEARS AND PINIONS
2. Test cutting oxygen check valves for At least once each shift remove debris from
reverse flow. Refer to Section 6.11 on gears and pinions using a stiff wire brush.
how to test a check valve. Spray on a light film of LPS-1®.
6.4 GUIDE ROLLER ADJUSTMENT 6.9 GAS CONTROL SYSTEM
After prolonged usage, the main saddle Refer to the appropriate appendix on the Gas
eccentric guide rollers may require Control System Manual for Set-up and
adjustment. operation.
Adjust eccentric bolts until rollers can just be 6.10 CUT QUALITY TROUBLE-SHOOTING
turned, using thumb and forefinger, against
the side of the rail. Check that all guide 1. Cut edges distorted or melted - Preheat
rollers turn easily as the machine is moved. flame too high.
6.5 RAIL CLEANING 2. Flame backfiring - Preheat flame too low,

to close to work piece.
Spray a clean cloth lightly with WD-40®or
LPS-1®, and wipe the top, sides and rack 3. Distorted flames - Dirty cutting tip, replace
clean. When cutting splatter settles on the or clean.
rails, clean or chip off with a steel flat tool. Be
sure not to damage the rail or rack. 4. Dispersed or slanting oxygen jet - Cutting
tip is dirty or distorted.
File off larger burrs that may appear on the
rails as they could affect cutting performance. 5. Cut edge is cambered toward bottom -
Preheat flame too low, cutting oxygen too
6.6 ROLLER CLEANING high.
At least once each shift, remove dirt buildup
from small rollers, main carriage side guide 6. Too much drag on the cut surface - cutting
rollers and torch carriage rollers as follows: speed is too fast.
a. Hold a steel flat bar (1.6 x 25 mm cross If incoming supply pressures are correct and
section or a steel pocket rule) flat on rail gas panel pressure setups are correct for the
edge against roller surface. fuel gas, but torch and tip combination
problems persist, contact your Koike
26
Maintenance
Aronson, Inc. service representative for Turn off gas supplies and depressurize the
assistance. gas and oxygen system.
6.11 CHECK VALVE TEST a. Remove suspected bad check valve.

b. Using nitrogen, at .07psig, the check
valve will allow flow through following
the direction of the arrow stamped on
the valve.
c. Reversing the flow of nitrogen, the

WARNING check valve will not allow flow through
Always test and purge in a well-ventilated area the valve.
free from open flame or other sources of ignition
If nitrogen flows though, replace the valve.
Check valves are mechanical devices that
can leak when dirty or misused. Reference: Figure 6.1
Normal Reverse
GAS GAS
FLOW FLOW
IN STOPS
GAS REVERSE
FLOW GAS
OUT FLOW
Figure 6.1Check Valve
6.12 DRIVE TUNING
Please consult Koike Aronson Ransome for more detail. Address and phone
number on cover page.
27
SECTION 7
REPLACEMENT PARTS
To assure minimum down time, it is recommended that spare parts noted by an
asterisk * in the Part Number column of the parts list be kept on hand. To assure
proper operation, it is recommended that only genuine KOIKE ARONSON parts
and products be used with this equipment.
To order replacement parts:
a. Contact Koike Aronson Inc. service at 1-800-252-5232.

b. Provide Sales Order (SO#), serial number and model of equipment from the
Serial Tag located on the main beam.
c. Provide part number, description and quantity of part.
d. Be sure to indicate any special shipping instructions.
X-Cable Carrier
Assembly
Heat Shield
Y-Cable Carrier Assembly
Rail Gauge is the Measurement of the Outside of the
Assembly Main Rail to the Outside of the Outboard rail
Guide Roller
Assembly
2500
Rail Gauge 123.5”
2000
Rail Gauge 99.5”
1500
Rail Gauge 87.5”
Main Rail Outboard Rail

Assembly Assembly
FIGURE 7.1
28
X-Motor and Planetary
Gear Unit CNC
Y-Motor and Planetary

Gear Unit
Y-Cable Carrier
Y-Gear Rack Assembly
4.3 Meter
4.9 Meter
7.3 Meter
FIGURE 7.2
29
1
1a
2a
AC Drive Unit
5
3
FIGURE 7.3 Y-Axis Carriage
Item Number Part Number Part Description Quantity

1 0868-5763-06 Motor(DC) 1
1a 0868-9228-00 Motor(AC) 1
2 0868-8769-25 Planetary Gearbox(DC drive) 1
2a 0868-9228-00 Planetary Gearbox(AC drive) 1
3 0868-8814-00 Drive Pinion 1
4 0868-8812-00 Bearing, Ball 2
5 1138-3513-00 Bearing, Ball 4
30
1a
1
2a 2
AC Drive Unit
FIGURE 7.4 X-Axis Carriage

1 0868-5763-06 Motor(DC) 1
1a 0868-9228-00 Motor(AC) 1
2 0868-8769-25 Planetary Gearbox(DC drive) 1
2a 0868-9228-00 Planetary Gearbox(AC drive) 1
3 0868-8814-00 Drive Pinion 1
4 1138-3133-01 Washer, Belleville Spring, M8 24
5 0868-8807-00 Roller 4
31
MI0548A
1 2
Figure 7.5 Band Assembly
Note: Only Major Components are listed.

1 0866-6511-00 Bearing 4
Pulley, Steel Band,
2 0868-3201-00 2
4.25DIA x1.5W
Steel Band, .01x1x25 ft.
3 0868-9025-00 1
Plate-Pro® 2500
0868-9025-01 1
Plate-Pro® 2000
0868-9025-02 1
Plate-Pro® 1500
32
APPENDIX A
PLATE-PRO®
List of Terms and Abbreviations
Abbreviation Term
AC Alternating Current
Amph Aphenol
amp(s) Ampere(s)
BTU British Thermal Units
ccw Counter-Clockwise
CGA Compressed Gas Association
CSA Canadian Standards Association
cw Clockwise
dia. Diameter
DVM Digital Volt Meter
E-Stop Emergency Stop
etc And so forth
HHCS Hex Head Cap Screw
Hz Hertz
ie That is for example
in Inches
INC. Incorporated
ipm Inches per Minute
kPa Kilopascals
L/H Left Hand
M Meter
MFD Microfarad
mm Millimeter
NC Normally Closed
NEC National Electric Code
NG Northrup Grumman
No. Number
NO Normally Open
NPT National Pipe Thread
oxy Oxygen
oz Ounces
psi Pounds Per Square Inch
PWM Pulse Width Modulator
Recpt Receptacle
R/H Right Hand
SO# Sales Order Number
TP Test Point
vdc Volts direct current
“ Inches
--F Female
--M Male
A-1
MODEL G SERIES
TORCH LIFTERS
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS ...................................................... B-3
Section 1.1 General Safety, Oxy/Fuel Cutting........................................... B-3

Section 1.2 General Safety, Plasma Cutting ............................................. B-3
SECTION 2 INTRODUCTION.................................................................... B-6
Section 2.1 Scope..................................................................................... B-6

Section 2.2 Description ............................................................................. B-6
Section 2.3 Specifications ......................................................................... B-6
SECTION 3 INSTALLATION..................................................................... B-7
Section 3.1 Installation G6 - G12 .............................................................. B-7

Section 3.2 Installation GP6 - GP12 ......................................................... B-7
SECTION 4 MAINTENANCE................................................................... B-10
Section 4.1 Safety Precautions ............................................................... B-10

Section 4.2 General Information ............................................................. B-10
Section 4.3 Daily Routine Maintenance .................................................. B-10
Section 4.4 Monthly Routine Maintenance.............................................. B-10
Section 4.5 Electrical Maintenance ......................................................... B-14
Section 4.6 Mechanical Maintenance ..................................................... B-14
SECTION 5 REPLACEMENT PARTS..................................................... B-18
SECTION 6 OPTIONAL ACCESSORIES................................................ B-21
B-1
ILLUSTRATIONS & TABLES
Figure 3.1 Model G Lifter Installation ...................................................... B-8

Figure 3.2 Model GP Lifter Installation .................................................... B-9
Figure 4.1 Lifter Shaft Extended............................................................ B-11
Table 4.1 Troubleshooting Guide......................................................... B-12
Figure 4.2 Adjustment Assembly........................................................... B-15
Figure 4.3 Motor & Coupling Assembly ................................................. B-16
Figure 4.4 Wiring Diagram .................................................................... B-16
Figure 4.5 Lifter Cable Configuration .................................................... B-17
Figure 4.6 Ball screw Replacement....................................................... B-17
Figure 5.1 Model G Parts Breakdown ................................................... B-19
Figure 5.2 Model GP Parts Breakdown ................................................. B-20
Figure 6.1 Short Torch Support............................................................. B-22
Figure 6.2 Long Torch Support ............................................................. B-22
Figure 6.3 Manual Torch Holder, Small Handle .................................... B-23
Figure 6.4 Manual Torch Holder, Large Handle .................................... B-23
Figure 6.5 Manual Torch Holder, 1-3/8" Oxy/Fuel or Plasma Torch...... B-24
Figure 6.6 Torch Fore-Aft Adjuster........................................................ B-24
B-2
SECTION 1
SAFETY PRECAUTIONS
USER RESPONSIBILITY - This equipment will perform in conformity with the description
thereof in this manual and accompanying labels and/or inserts when installed, operated,
maintained and repaired in accordance with the instructions provided. This equipment
must be checked periodically. Defective equipment should not be used. Parts that are
broken, missing, plainly worn, distorted or contaminated should be replaced immediately.
Should repair or replacement become necessary, Koike Aronson recommends that a
request for service be made to a Koike Aronson Inc. Authorized Distributor from purchased
or directly to the Koike Aronson Inc. Service Department.
This equipment or any of its parts should not be altered without prior written approval of
Koike Aronson. The user of this equipment shall have sole responsibility for any
malfunction which results from improper use, faulty maintenance, damage, improper repair
or alteration by anyone other than Koike Aronson or a facility designated by Koike
Aronson.

situations that require additional information. The following formats are used for each:
Notes: A note offers additional information, such as an operating tip, that aids
the user in operating the cutting system.
Caution: A caution describes a situation that may cause damage to the

lifter and offers advice to avoid or rectify the situation.
WARNING
A warning describes a situation that presents a physical danger to the

operator, and offers advice to avoid or rectify the situation.
1.1 GENERAL SAFETY, OXY/FUEL

CUTTING
1. Check gas and electrical connections for
Operation of oxy/fuel torches involves oxygen tightness after installation and on a regular
and flammable gases under pressure, open basis thereafter.
flames, flying slag and hot metal, fumes and
combustion products. 2. Keep combustibles away from the work area
or protect them from sparks and flames.
Follow the precautions in this General Safety
Section as well as those throughout this 3. Check for proper function of check valves
manual for your personal safety and the safety regularly. Do not remove or bypass check
of personnel in the area that may be affected. valves.
B-4
4. Always open gas valves slowly. 18. Shut off power and gas supplies whenever
leaving machine unattended or before
5. Never, use oxygen to ventilate the area or to servicing.
clean off clothing.
6. Keep oil, grease, and combustible dust away

from all oxygen equipment. 19. Keep equipment clean and in good
operating condition.
whenever combustible mixtures in the lines are 20. Read and understand further detailed
suspected. safety precautions throughout this manual.
8. Never, use the oxygen hose for any other 21. Also, refer to the latest revisions of the
gas than oxygen. following sources of safe practices in welding
and cutting.
9. Replace hose that is damaged by physical
abuse or by sparks, heat or open flame. A. National Fire Protection Association
Standard 51B CUTTING AND WELDING
10. Examine hoses at regular intervals for PROCESS, obtainable from NFPA,
leaks, wear, loose connections or other Batterymarch Park, Quincy, MA 06269.
hazards.
B. NFPA Standard 51, OXYGEN/FUEL GAS
11. Examine hoses at daily intervals for leaks, SYSTEMS FOR WELDING AND CUTTING,
wear, loose connections or other hazards. obtainable same as item A.
12. Coil excess hose and place it out of the C. American Welding Society publication
way to prevent damage and to eliminate C4.2-90, OPERATOR'S MANUAL FOR
tripping danger. OXY/FUEL GAS CUTTING, obtainable from
AWS, Box 351040, Miami, FL 33135.
13. Maintain all pressure regulators in proper
working condition. 1.2 GENERAL SAFETY, PLASMA CUTTING
14. Never, use a regulator for any gas other Plasma Arc cutting is a high intensity source of
than that for which it is intended. visible light emission as well as ultraviolet and
infrared radiation. It can cause severe eye
15. Never, use a regulator that leaks, creeps damage and inflict burns on exposed skin
excessively or is physically damaged in any when suitably protected.
way.
Follow the precautions in this General Safety
16. Never, attempt to lubricate a regulator with Section and read the supplied plasma
oil or grease. equipment instruction manual for additional
and more detailed safety precautions.
17. Wear filter-lens safety eye protection. Wear
gauntlet gloves, safety shoes, flame retardant 1. Facilities should be available for the medical
clothing, and no-cuff trousers. Do not wear treatment of arc flashes or burns to the eyes.
loose clothing around this machinery as they
can catch on the machine. 2. Provide radiation protection for the operator
and for personnel in the adjacent area.
B-3
3. Do not, under any circumstances, look at a
plasma arc without full eye protection. When
near plasma cutting equipment always wear
flash goggles with side shields and containing
suitable filter lenses.
B-4
4. The operator must use in addition to flash 12. To prevent electric shock keep your body
goggles, a suitable helmet for eye and face and clothing dry.
protection when cutting. The helmet must be
equipped with a filter plate as indicated: 13. Do not stand in, sit on or lie on any wet
surface when using the plasma system.
Arc Current Up to 100 Amps Shade No. 8
Arc Current 100 to 200 Amps Shade No. 10 14. Maintain proper insulation against electrical
Arc Current 200 to 400 Amps Shade No. 12 shock. If you must work in or near a damp
Arc Current Over 400 Amps Shade No. 14 area, use extreme caution. wear insulated
gloves and boots.
5. Do not use a helmet or hand shield that is
not in good condition. Repair or replace 15. Inspect the torch leads. Replace if frayed or
promptly. Protect colored filter plates with a damaged.
clear glass cover plate.
16. Before changing the torch parts, disconnect
6. Warn other people in the area not to look the main power supply. After changing the
directly at the arc unless they wear torch parts and returning the retaining cap to its
glasses/goggles or a helmet. operating position, plug the power supply in
again.
7. Never, start the plasma arc without
determining that nearby personnel are wearing 17. Never, bypass or shortcut the safety
adequate protective equipment. interlocks.
8. All areas of the body must be covered by 18. Plasma cutting operation noise levels may
dark substantial clothing (preferably flame be high enough to require ear protection for the
retardant) to protect against arc burn, sparks operator and other personnel in the adjacent
and flying hot metal. area.
9. The plasma operation should be located in 19. When using a water table while plasma arc
an area where protection for other personnel cutting plate, especially aluminum or
may be readily provided. Portable non- magnesium may cause an accumulation of
combustible reflecting screens or enclosures explosive gas below the plate. Do not allow
with non-reflecting walls may be used. Screens aluminum or magnesium dross to accumulate
and enclosures should permit free circulation of in a water table. Before cutting, raise and lower
air at floor level. the water level several times to dissipate
trapped gases. Do not leave plate on the table
10. Remove combustible material from the for extended periods, i.e. overnight or
immediate cutting area. weekends. When the table is not in use, keep
the water level down. Do not cut these
11. Quench freshly cut metal or allow metal to materials under water. Read additional
cool before handling it or bringing it in contact cautions in the related manuals.
with combustible materials.
B-5
SECTION 2
INTRODUCTION
2.1 SCOPE
The G6 and GP6 have 6 in. (152.4mm) of
This manual provides general installation, vertical travel at 37.5ipm (952.5mm/min).
operation and service information for the Their lifting capacity is 50 lbs. (22.68Kg).
Koike Aronson Models G6, GP6, G12 and The maximum rotational movement at a
GP12 Motorized Torch Lifters. This point 3 in. (76.2mm) from center when
manual includes an illustrated part listing subjected to a 10 lb. (4.54Kg) force acting
to aid in ordering parts. first in one direction and then the other is
0.005 in. (.127mm). The lifter weights 17
2.2 DESCRIPTION lbs. (7.71Kg).
The Koike Aronson Model G Motorized The G12 and GP12 have 12 in.
Torch Lifter is a compact, rugged (304.8mm) of vertical travel at 37.5ipm
accessory for most heavy-duty cutting (952.5mm/min). Their lifting capacity is 50
machines. The lifter may be mounted by lbs. (22.68Kg). The maximum rotational
one of two methods, bolt on or pin clamp, movement at a point 3 in. (76.2mm) from
on most two axis cutting machines. The center when subjected to a 10 lb.
heavy-duty aluminum casting, stepper (4.54Kg) force acting first in one direction
motor and ball screw drive provides and then the other is 0.005 in. (.127mm).
accurate vertical placement of the torch in The lifter weights 20 lbs. (9.07Kg).
relationship with the work piece.
Lifter style: G6 Lifter style: GP6
Lifter style: G12 Lifter style:
2. 3 SPECIFICATIONS
B-6
SECTION 3
INSTALLATION
3.1 INSTALLATION G6-G12 3.2 INSTALLATION GP6-GP12
Installation of the G6 - G12 Motorized Installation of the GP6 - GP12 Motorized

Torch Lifters is accomplished using four Torch Lifter is a simple matter of
(4) M8 Hex Head Cap screws that fasten loosening the cap screw on the torch
the lifter to a torch carriage. A 60mm x carriage support collar and inserting the
64mm M8-1.25 pattern needs to be torch lifter mounting 1-1/4 inch diameter
drilled and tapped in the torch carriage for pin into the support collar. Plumb the lifter
installation. Typically, the pattern would and tighten the cap screw on the support
be centered on the carriage, being level collar. Keep in mind the stroke length of
and plumb, but it can be placed in the lifter and the height of the cutting
different positions if there is adequate table. Connect the lifter cable from the
material for the tapped holes and the control to the cable connection on the top
balance of the carriage is not of the lifter (See Figure 3.2).
compromised. Keep in mind the stroke
length of the lifter and the height of the
cutting table. Connect the lifter cable from
the control to the cable connection on the
top of the lifter (See Figure 3.1).
B-7
Cable Connection
64mm
(2.51”)
60mm
(2.36”)
Figure 3.1 Model G Lifter
B-8
Cable Connection
31.75mm
(1.250")
Figure 3.2 Model GP Lifter
B-9
SECTION 4
MAINTENANCE
4.1 SAFETY PRECAUTIONS
The motorized torch lifter has been
1. Shut OFF main power switch; pull fuses, or assembled, properly adjusted and factory
lock and red tag switch before attempting work tested before shipment. Factory settings
on electrical circuits. Do not touch electrically should not be changed. If lifter performance is
HOT parts or those with residual voltage, such unsatisfactory, contact a Koike Aronson
as capacitors until they have been grounded authorized service representative for advice.
and their electric charge dissipated.
PREVENTIVE MAINTENANCE means the
2. Keep lifter cables dry, free of oil and grease,
maintaining of equipment in sound condition
and protected at all times from damage by hot
and is a way of avoiding breakdowns and
metal and sparks. Do Not use any power cable
accidents and the consequent expense of
with worn or damaged insulation. Repair or
repairs and interruption in production flow.
replace immediately.
4.3 DAILY ROUTINE MAINTENANCE
3. A lifter that is not functioning properly should
Not be used until all repairs have been
1. Fully extend the motorized torch lifter shaft
completed and the lifter has been tested to (See Figure 4.1). Shut OFF the main power
ascertain that it is in proper operating
switch. Ensure that the circuit breaker for the
condition.
cutting machine is in the OFF position.
Uniformly spray a light coat of WD-40® or
4. Inspection and maintenance of the lifter as
equivalent on the lifter shaft.
indicated in this manual may ordinarily be
undertaken by a competent person having at
2. VerifyCheck that lifter cable connections
least general experience in the maintenance of
are secure.
equipment of this nature.
4.4 MONTHLY ROUTINE MAINTENANCE
CAUTION: No such maintenance or repair
should ever be undertaken by anyone not 1. Fully extend the motorized torch lifter shaft
having such qualifications. (See Figure 4.1). Shut OFF the main power
switch. Ensure that the circuit breaker for the
4.2 GENERAL INFORMATION cutting machine is in the Off position. Using a
clean shop cloth wipe the shaft clean of
This manual provides standard preventive lubricant and iron oxide dust. Uniformly apply
maintenance procedures required for accurate a light coat of Never Seez® lubricant or
and proper operation of the Model G Series equivalent. Fully retract and extend the lifter
Motorized Torch Lifters. Follow these shaft several times. With the shaft in the
procedures to maintain lifter operation at peak retracted position wipe off any excess
efficiency and to extend the useful life of the lubrication.
lifter.
B-10
Lifter Shaft
Fully
Figure 4.1 Extended Lifter Shaft.
B-11
TROUBLESHOOTING GUIDE
PROBLEM PROBABLE CAUSE SOLUTION

Torch Lifter does not Motor not operating Check for power on lifter cable.
move.
Ball Screw Clutch not holding Replace Ball Screw assembly.
Broken motor coupling Replace motor coupling.
(See Sections 4.5 and 4.6)

Excess rotational Improper detent (bronze Adjust detent so the shaft can be turned
movement. bushing) adjustment approximately 1/5 of a turn using
moderate force.
Raise and lower the torch lifter. If the

torch will not raise loosen the tension
adjustment set screw until the lifter
moves smoothly (See Section 4.6).
Lifter motor becomes Defective motor capacitor Replace capacitor
hot and the motor will
only run intermittently.
Torch Lifter runs in Faulty Motor Replace Motor
one direction only.
Open circuit in the electrical Troubleshoot the wiring inside the drive
assy wiring control.
Short in the electrical assy Check for 110VAC ±10V at pins C & D
wiring using pin B for neutral.
Torch Lifter will not Defective Motor Replace defective component.
run.
Defective Capacitor Troubleshoot the wiring.
Defective Resistor Return Lifter to Koike Aronson Service

Center for repair.
Open Circuit
Loose Connection
B-12
TROUBLESHOOTING GUIDE (CONT’D)
PROBLEM PROBABLE CAUSE SOLUTION

Torch Lifter blows Defective Motor Unplug lifter cable and operate the
fuses. drive control. If the fuse blows the
Defective Capacitor problem is in the drive control and the
control must be diagnosed per
Defective Resistor Circuit manufacturer’s recommendations. If the
problem is in the cable, check
Short in Motor Controller continuity.
Short in Drive Control or Cable If the fuse does not blow,

troubleshooting must be performed on
the torch lifter (See Section 4.5).
Lifter operates the Shorted, grounded or broken Check continuity, connections and
same direction (up or connection in the black or red shielding on the black and red wires.
down) regardless of motor wiring.
the control switch
direction.
B-13
4.5 ELECTRICAL MAINTENANCE the bushing is not damaged, reinstall it (See
Figure 4.2).
If the torch lifter does not move it can be either
an electrical or mechanical problem. If it is
electrical, the following should be checked: Caution: The bushing should slide in and out
smoothly and turn freely within its housing. If
The first check is on the lifter cable. With the it does not the shaft or lifter may be
control switch in the up/down position, remove damaged.
the cable from the torch lifter. On the lifter
cable plug check for 110VAC ±10V at pins C Lower the lifter shaft three (3) inches. Slide a
(up) & D (down) using pin B for neutral (See steel bar or screwdriver through the two (2)
Figure 4.5). If there is no power, the problem is holes in the bottom of the lifter shaft. Reinstall
in the drive controller and you need to use its the tension spring and adjustment plug by
documentation for corrective actions. If there is turning the plug clockwise until the lifter shaft
power to the lifter, remove the motor cover by will only rotate 1/5 of a turn. Without
removing the four (4) M4 retaining cap screws reattaching the lifter to the torch carriage,
securing the cover using a 3 mm allen wrench. operate the lifter up and down to check that
Remove the four (4) M5 retaining cap screws there is no binding. If binding occurs, loosen
from the motor assembly using a 4 mm allen the adjustment plug accordingly.
wrench. Remove the motor assembly (See
Figure 4.3). Using the drive controller attempt Note: The lifter shaft should be adjusted so
to raise and lower the lifter. If the motor turns, that it can be turned NO more than 1/4 turn.
the problem is mechanical (See Section 4.6). If
the motor does not turn check for power at Move the shaft off center in either direction; it
either black wire on the capacitor while using should always return to center.
the drive controller switch to move the lifter in
the up and down directions. If there is power If the lifter will not move and it has been
present, the motor must be replaced. If power determined that it is a mechanical problem:
is not present, replace the capacitor (See
Figure 4.4). Remove the four (4) retaining cap screws
securing the cover using a 3mm allen wrench.
4.6 MECHANICAL MAINTENANCE Remove the four (4) retaining cap screws from
the motor assembly using a 4 mm allen
Although this lifter does not require a great wrench. Remove the motor assembly. If the
deal of maintenance (if the routine problem is the motor coupling, it can be
maintenance is preformed), there are a couple replaced by inserting the new coupling into the
of items that may need to be maintained or slotted shafts in the ball screw and motor and
adjusted. reassemble. If the coupling is not the problem,
the problem is probably the ball screw clutch.
If there is excessive rotational movement, the
rotational braking, tension must be adjusted. To change the ball screw, remove the four (4)
Before trying to adjust the tension, the bronze M4 retaining capscrews securing the cover
detent, bushing should be inspected for using a 3 mm allen wrench. Remove the four
damage or uneven wear. If either is found, it (4) M5 retaining cap screws from the motor
should be replaced. To check the detent- assembly using a 4 mm allen wrench. Remove
bushing, remove the lifter from the machine. the motor assembly (See Figure 4.3). Remove
Remove the adjustment plug (one inch socket the motor coupling. Using an appropriate size
head set screw) from the lifter. Remove the snap ring pliers, remove the snap ring from the
tension spring and bronze detent bushing. If bearing and ball screw assembly. Remove the
B-14
bronze detent bushing, tension spring and
adjusting plug from the lifter tube.
Slide the shaft and balls crew assembly out of

the torch lifter tube. Heat the upper section of
the shaft to loosen the Loctite® and using a
strap wrench turn the ball clutch nut counter
clockwise removing it from the torch lifter shaft.
Reverse the process to install a new ball

screw. There are a couple of added steps.
Before inserting the new ball screw, clean the
lifter tube, especially the bronze bushings at
the lower end of the tube. Lubricate the lifter
shaft with a uniformly applied light coat of
Never Seez® lubricant or equivalent. Loctite®
Stud Lock Red #7331 must be used where the
ball screw attaches to the lifter shaft (See
Figure 4.2 and 4.6)
Detent Bushing
Tension Spring
Lower Bushings
Adjustment Plug
Figure 4.2 Adjustment Assembly
B-15
Figure 4.3 Motor and Coupling Assembly
MOTOR LEADS
CABLE RECP.
WHITE
B COMMON
C UP
RED
D DOWN
E GROUND
50 25W
BLACK
GREEN GROUND
SCREW
CAPACITOR
5 MFD 300 VAC
Figure 4.4 Wiring Diagram
B-16
Not used
Neutral Ground
A
B E
C D
Up Down
Figure 4.5 Lifter Cable
Use Loctite here
Figure 4.6 Ball screw Replacement
SECTION 5
REPLACEMENT PARTS
To assure minimum down time, it is recommended that spare parts noted by an asterisk * in the
Part No. column of the parts list be kept on hand.
B-17
To assure proper operation, it is recommended that only genuine Koike Aronson (KAR) parts and
products be used with this equipment.
To order replacement parts:
a. Provide part number, description and quantity of part.

b. Indicate any special shipping instructions.
B-18
4 4 6 7 5
MOTOR LEADS
CABLE RECP.
1 WHITE B
C
COMMON
UP
D DOWN
E GROUND
50 25W
3 GREEN GROUND
2 SCREW 9
8
CAPACITOR 11
10 5 MFD 300 VAC
Figure 5.1 Model G Torch Lifter
Item Part No. Description
1 0866801000 Spring
2 9938138400 Set Screw, 1-14 x 3/4, Flat Point
3 9938228300 Bushing, 7/8 x ½ x 1
4 9938228400 Bushing, 1-3/4 x 1-3/8 x 1
5 9938431100* Coupling, 85197-2
6 9938431400 Ball Screw, 6" Stroke
9938431401 Ball Screw, 12" Stroke
7 9968253100 Snap Ring, Internal, 42mm
8 9938938000 Motor, Step
9 0868612300 Receptacle
10 0868642800* Capacitor, 5 MFD
11 0868630900* Resistor, 50 OHMS, 25 Watt
B-19
12 4 6 7 5
3
1
MOTOR LEADS
CABLE RECP.
WHITE B COMMON
13 2 C
D
UP
DOWN 8 9
E GROUND
50 25W
GREEN GROUND
SCREW
10 CAPACITOR
5 MFD 300 VAC
11
Figure 5.2 Model GP Torch Lifter
Item Part No. Description
1 0866801000 Spring
2 9938138400 Set Screw, 1-14 x 3/4, Flat Point
3 9938228300 Bushing, 7/8 x ½ x 1
4 9938228400 Bushing, 1-3/4 x 1-3/8 x 1
5 9938431100* Coupling, 85197-2
6 9938431400 Ball Screw, 6" Stroke
9938431401 Ball Screw, 12" Stroke
7 9968253100 Snap Ring, Internal, 42mm
8 9938938000 Motor, Step
9 0868612300 Receptacle
10 0868642800* Capacitor, 5 MFD
11 0868630900* Resistor, 50 OHMS, 25 Watt
12 ZS61106 Torch Support
13 0868544100 Adapter Hub
B-20
SECTION 6
OPTIONAL ACCESSORIES
The following pages show a variety of different torch holders and adjusters.
To order accessories:
a. Provide part number, description and quantity of the part.
b. Indicate any special shipping instructions.
B-21
50 mm
Figure 6.1 Short Torch Support (ZS61106)
105 mm
Figure 6.2 Long Torch Support (ZS60200)
B-22
Figure 6.3 Manual Torch Holder, Small Handle (ZS61108)
Figure 6.4 Manual Torch Holder, Large Handle (ZS60201)
B-23
Figure 6.5 Manual Torch Holder, 1-3/8” Oxy/Fuel or Plasma (0866842800)
Figure 6.6 Torch Fore-Aft Adjuster (ZS61100)
B-24
APPENDIX C
PULSE IGNITION
October, 1999
Revision 0
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS ......................................................... C-3
Section 1.1 General Safety, Oxy/Fuel Cutting ................................................ C-4
SECTION 2 INTRODUCTION .................................................................... C-5
Section 2.1 Scope .......................................................................................... C-5

Section 2.2 Installation Requirements ............................................................ C-5
Section 2.3 Description .................................................................................. C-5
SECTION 3 INSTALLATION .......................................................................... C-6
Section 3.1 Mechanical Installation ............................................................... C-6

Section 3.2 Electrical Installation.................................................................... C-6
Section 3.3 Operation..................................................................................... C-6
Section 3.3.1 Manual......................................................................................... C-6
Section 3.3.2 CNC .......................................................................................... C-6
SECTION 4 MAINTENANCE .......................................................................... C-7
Section 4.1 Daily .......................................................................................... C-7

Section 4.2 Monthly........................................................................................ C-7
Section 4.3 Adjustment .................................................................................. C-7
Section 4.3.1 Adjust Airflow............................................................................... C-7
Section 4.3.2 Spark Gap Adjustment ................................................................ C-7
Section 4.3.3 Fine Tuning ................................................................................. C-7
SECTION 5 REPLACEMENT PARTS ............................................................ C-9
C-1
MI0549A
Figure 4.1 Air Flow/Electrode Adjustment Location ................................ C-7

Help Flow Chart Troubleshooting ..................................................................... C-8
Figure 5.1 Pulse Ignition ......................................................................... C-9
C-2
MI0549A
SECTION 1
SAFETY PRECAUTIONS
request for service be made to the Koike Aronson, Inc. Authorized Distributor from whom
purchased or directly to the Koike Aronson, Inc. Service Department.
malfunction, which results from improper use, faulty maintenance, damage, improper
repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike
Aronson.


machine and offers advice to avoid or rectify the situation.
WARNING

C-3
MI0549A
1.1 GENERAL SAFETY, OXY/FUEL 12. Coil excess hose and place it out of
CUTTING the way to prevent damage and to
eliminate tripping danger.
Operation of oxy/fuel torches involves
oxygen and flammable gases under 13. Maintain all pressure regulators in
pressure, open flames, flying slag and hot proper working condition.
metal, fumes and combustion products.
14. Never, use a regulator for any gas
Follow the precautions in this General other than that for which it is intended.
Safety Section as well as those throughout
this manual for your personal safety and 15. Never, use a regulator that leaks,
the safety of people in the area that may creeps excessively or is physically
be affected. damaged in any way.
1. Check gas and electrical connections
for tightness after installation and on a 16. Never, attempt to lubricate a regulator
regular basis thereafter. with oil or grease.
2. Keep combustibles away from the work 17. Wear filter-lens safety eye protection.
area or protect them from sparks and Wear gauntlet gloves, safety shoes, flame
flames. retardant clothing, and no cuff trousers.
Do not wear loose clothing around this
3. Check for proper function of check machinery as they can catch on the
valves regularly. Do not remove or bypass machine.
check valves.
18. Shut off power and gas supplies
4. Always open gas valves slowly. whenever leaving machine unattended or
before servicing.
5. Never use oxygen to ventilate the area
or clean off clothing. 19. Keep equipment clean and in good
6. Keep oil, grease, and combustible dust
away from all oxygen equipment. 20. Read and understand further detailed
safety precautions throughout this manual.
whenever combustible mixtures in the 21. Also, refer to the latest revisions of the
lines are suspected. following sources of safe practices in
welding and cutting.
8. Never, use the oxygen hose for any
other gas than oxygen. A. National Fire Protection Association
Standard 51B CUTTING AND WELDING
9. Replace hose that is damaged by PROCESS, obtainable from NFPA,
physical abuse or by sparks, heat or open Batterymarch Park, Quincy, MA 06269.
flame.
B. NFPA Standard 51, OXYGEN/FUEL
10. Examine hoses at regular intervals for GAS SYSTEMS FOR WELDING AND
leaks, wear, loose connections or other CUTTING, obtainable same as item A.
hazards.
C. American Welding Society publication
11. Examine hoses at daily intervals for C4.2-90, OPERATOR'S MANUAL FOR
leaks, wear, loose connections or other OXY/FUEL GAS CUTTING.
hazards.
C-4
MI0549A
SECTION 2
INTRODUCTION
2.1 SCOPE
This appendix provides a step-by-step At the torch station, a solenoid, high

guide for installation, operation, voltage transformer, a venturi tube with
adjustment and a troubleshooting guide nozzle and mounting hardware are
for the pulse ignition system. Follow all provided for assembly at the torch.
steps in order and obey all safety Mounted on the top of the tube is the air
precautions. flow adjustment and the spark adjustment.
Between the high voltage transformer and
2.2 INSTALLATION REQUIREMENTS the electrode is a noise suppressor
installed with the ignition cable. The
Pulse ignition requires a supply pressure suppressor is used for reducing RF noise
of 15psi. Propane is used as its primary generated by the transformer.
gas only; Acetylene cannot be used. If
you are using acetylene as the machine Once the ignite signal is generated, the
gas, a separate supply of propane must manifold supply solenoid opens allowing
be provided for ignition. fuel to flow to the torch station solenoid.
The torch station solenoid is pulsed
2.3 DESCRIPTION (turned on and off) at a rate programmed
to the territorial location of the machine.
Pulse ignition uses propane as its primary The rate is adjusted for proper airflow.
fuel gas. Do not use acetylene. Inlet The high voltage transformer is on steady
supply for the ignition system is supplied throughout the ignition cycle. The
from the preheat fuel manifold. A separate electrode ignites the fuel as it passes
manifold is provided with a supply through the flow tube. Since the gas is
solenoid. Outlet bushings are located on pulsed, the venturi of the tube pulls the
the manifold for each torch station. Caps gas through the tube and out the nozzle.
are installed for unused outlets. A flame about four to six inches long is
produced igniting the selected oxy-fuel
torch.
C-5
MI0549A
SECTION 3
INSTALLATION
3.1 MECHANICAL
3.2 ELECTRICAL
WARNIN
Before performing electrical

WARNING maintenance, machine electrical
Fuel gas is highly flammable.
power must be OFF.
Care must be taken working
with this system.
Connect the ignition supply solenoid to

the main electrical enclosure. Follow the
WARNING associated electrical drawings for
Purge all oxygen and fuel supply lines. reference. Connect the high voltage
transformer and the solenoid wires to the
appropriate connector on the J-box. The
Move the standard preheat manifolds J-box is located on the back of the slave
(fuel, preheat oxygen and cut) to as low station. The ignition wire is connected to
on the support brackets as possible. the high voltage transformer to the noise
Locate the ignition manifold towards the suppressor to the electrode. Be sure to
top of the support brackets, centering the place the insulated sleeve over the
manifold between them. Install the connection at the electrode and the
manifold clamps. Remove the cap on the rubber insulator at the high voltage
fuel preheat tee and install the hose to transformer.
connect the two manifolds. The long red
hose is connected to the outlet bushing 3.3 OPERATION
and is routed through the flexible cable
3.3.1 MANUAL
carrier to the oxy-fuel station. Install the
igniter tube with the torch clamps. The Pressing the ignite button on the touch
tube nozzle must face the torch tip and be panel will turn on the ignition cycle for four
located approximately one inch above the (4) seconds. This allows sufficient time for
tip. The tube and solenoid must also be the torch to ignite. You must have an
clear of all other parts and accessories. oxy-fuel station selected.
Connect the hose to the top of the
solenoid inlet fitting. Position the 3.3.2 CNC
adjustment collar so it is convenient to
make airflow and electrode adjustments. Using CNC programming the ignition
Tighten all hardware and hose cycle is started automatically with the
connections. selected torch or torches.
C-6
MI0549A
SECTION 4
MAINTENANCE
4.0 MAINTENANCE 4.3.2 SPARK GAP ADJUSTMENT
This section includes preventative and
routine maintenance using the pulse Locate the pilot block and the Phillips
ignition system. This section also contains screw with the nut attached to it. Adjust
a set-up and troubleshooting guide for the nut so it touches the head of the
problems that may occur. screw. Turn the screw clockwise so it just
touches the electrode. Turn counter-
4.1 DAILY clockwise five (5) complete turns. This
sets the spark gap of the electrode to the
Clean the nozzle from the blow back from ignition block.
piercing the plate. Ensure the clamps
holding the tube are tight. 4.3.3 FINE TUNE
4.2 Monthly The airflow and spark gap may have to be

adjusted depending on gas being used.
Perform a leak test on the hoses and The flame should be bluish in color. If it is
fittings. Before making, any corrections not some adjustment in the air may be
ensure the system is purged. Check all necessary.
hoses for wear and pinch points. If there
are any, replace the hose or correct the
routing.
4.3 ADJUSTMENT
Ensure the ignition system is installed

properly. Ensure the gas supply is set to
15psi. Select an oxy-fuel station and
press ignite. Wait a few seconds to allow Air Flow Adjustment
the fuel to fill the hose and fittings.
4.3.1 ADJUST AIRFLOW
Locate the adjusting slide assembly, using Electrode Adjustment

a Phillips screwdriver; adjust the air intake
holes on the slide until they are inline with
intake holes on the ignition block.
Figure 4.1
C-7
MI0549A
4.0 HELP FLOW CHART
Select an oxy-
fuel station
(Press button) Check gas flow
Check flow
orifice for
obstructions
Close manual
valves on the
torch
(Fuel, oxygen
and cut) Check electrical WARNING
circuit. If the Is the solenoid TURN OFF GAS
No
electrical is ok, pulsing? SUPPLY.
replace solenoid Remove igniter
Press assembly. Press the
ignition ignition button and
button check for spark. If
the spark is not
present check the
high voltage circuit. If
the spark is weak
Light Check for adjust the gap using
Did ignition take Did ignition take
with plugged nozzle the adjustment
place and a blue 4 No place and a blue 4 No
manual assembly, clean screw.
in. flame appear? in. flame appear?
striker if necessary.
Yes
Check for
corrosion on the
WARNING electrode,
TURN OFF GAS remove cover,
SUPPLY. clean if
Remove igniter necessary.
Yes assembly. Press the
ignition button and
check for spark. If
the spark is not
present check the
high voltage circuit. If
the spark is weak
adjust the gap using
the adjustment
screw.
Adjust the air flow Adjust the air flow
for the bluest flame for the bluest flame
possible. possible.
The ignition system should now be operational
C-8
MI0549A
SECTION 5
REPLACEMENT PARTS
4
1
5
12
6
7
8
13
14
15
10
11
Figure 5.1
Note: Only Major Components Are Listed.

1115-7933-00 Pulse Ignition
1 *ZS60287 Ignition Transformer 1
2 *1138-3078-00 Check Valve, Fuel 1
3 *0866-8550-00 Solenoid Valve, Fuel 1
4 *1115-7925-00 Pilot Orifice 1
5 1115-7931-00 Adjusting Collar 1
6 1115-7926-00 Mixing Pipe,1/2” Dia. X 2-1/4 1
C-9
MI0549A
Part Listing Continued
7 1115-7927-00 Pilot Block, 3/4Dia. X1.25x1.75 1

8 1115-5245-01 Clamp 1
9 1115-7924-00 Tube, Copper 1
10 1115-5246-00 Clamp 1
11 *1115-7934-00 Pilot Nozzle, 3/4Dia.x1.56 1
12 *1115-7932-00 Electrode 1
13 1138-8906-00 Noise Suppressor 1
14 ZM62972 Glass Fiber Tube, Igniter 1
15 ZM62973 Teflon Tube, Igniter 1
C-10
MI0549A
This page left intentionally blank

MI0549A
APPENDIX D
HI/LO Gas Control Panel
JULY, 2000
Revision 0
MI0549A
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS ...............................................................D-2
Section 1.1 General Safety, Oxy/Fuel Cutting......................................................D-3
SECTION 2 INTRODUCTION ..........................................................................D-4
Section 2.1 Scope ...............................................................................................D-4

Section 2.2 Installation Requirements..................................................................D-4
Section 2.3 Specifications ....................................................................................D-4
Section 2.4 Specifications ....................................................................................D-4
Section 2.5 Installation Connections ....................................................................D-5
Section 2.6 Optional Ease-On..............................................................................D-5
SECTION 3 OPERATION.....................................................................................D-7
Section 3.1 Overview ..........................................................................................D-7
SECTION 4 MAINTENANCE................................................................................D-8
Section 4.0 40 Hours ...........................................................................................D-8

Section 4.1 Help Flow Chart ................................................................................D-8
SECTION 5 REPLACEMENT PARTS..................................................................D-9
Figure 2.1 Connections/Flow Diagram ...............................................................D-6

Figure 5.1 HI/LO Panel ......................................................................................D-9
Figure 5.2 Optional Ease-On............................................................................D-10
Figure 5.3 Optional Ease-On............................................................................D-11
D-1
MI0549A
SECTION 1
SAFETY PRECAUTIONS
USER RESPONSIBILITY - This equipment will perform in conformity with the
description thereof in this manual and accompanying labels and/or inserts when
installed, operated, maintained and repaired in accordance with the instructions
provided. This equipment must be checked periodically. Defective equipment should
not be used. Parts that are broken, missing, plainly worn, distorted or contaminated
should be replaced immediately. Should repair or replacement become necessary,
Koike Aronson recommends that a request for service be made to the Koike
Aronson, Inc. Authorized Distributor from whom purchased or directly to the Koike
Aronson, Inc. Service Department.
This equipment or any of its parts should not be altered without prior written
approval of Koike Aronson. The user of this equipment shall have sole responsibility
for any malfunction, which results from improper use, faulty maintenance, damage,
improper repair or alteration by anyone other than Koike Aronson or a facility,
designated by Koike Aronson.

situations that require additional information. The following formats are used for
each:

WARNING

D-2
MI0549A
1.1 GENERAL SAFETY, OXY/FUEL 13. Maintain all pressure regulators in

CUTTING proper working condition.
Operation of oxy/fuel torches involves 14. Never use a regulator for any gas
oxygen and flammable gases under other than that for which it is intended.
pressure, open flames, flying slag and hot
metal, fumes and combustion products. 15. Never use a regulator that leaks,
creeps excessively or is physically
Follow the precautions in this General damaged in any way.
Safety Section as well as those
throughout this manual for your personal 16. Never attempt to lubricate a regulator
safety and the safety of people in the area with oil or grease.
that may be affected.
17. Wear filter-lens safety eye protection.
1. Check gas and electrical connections Wear gauntlet gloves, safety shoes,
for tightness after installation and on a flame retardant clothing, and no cuff
weekly basis. trousers. Do not wear loose clothing
around this machinery as they can
2. Keep combustibles away from the catch on the machine.
work area or protect them from sparks
and flames. 18. Shut off power and gas supplies
whenever leaving machine unattended
3. Check for proper function of check or before servicing.
valves regularly. Do not remove or
bypass check valves. 19. Keep equipment clean and in good
4. Always open gas valves slowly.
20. Read and understand further detailed
5. Never use oxygen to ventilate the area safety precautions throughout this
or clean off clothing. manual.
6. Keep oil, grease, and combustible dust 21. Also, refer to the latest revisions of the
away from all oxygen equipment. following sources of safe practices in
welding and cutting.
7. Purge oxygen and fuel lines
individually whenever combustible A. National Fire Protection Association
mixtures in the lines are suspected. Standard 51B CUTTING AND
WELDING PROCESS, obtainable
8. Never use the oxygen hose for any from NFPA, Batterymarch Park,
other gas than oxygen. Quincy, MA 06269.
9. Replace hose that is damaged by B. NFPA Standard 51, OXYGEN/FUEL
physical abuse or by sparks, heat or GAS SYSTEMS FOR WELDING AND
open flame. CUTTING, obtainable same as item A.
11. Examine hoses at daily intervals for C. American Welding Society publication
leaks, wear, loose connections or C4.2-90, OPERATOR'S MANUAL
other hazards. FOR OXY/FUEL GAS CUTTING.
12. Coil excess hose and place it out of
the way to prevent damage and to
eliminate tripping danger.
D-3
MI0549A
SECTION 2
INTRODUCTION
2.1 SCOPE high preheat pressures and the
pressures regulated at the HI\LO
This appendix provides a step-by-step manifold are the low preheat
guide for operation, adjustment and a pressures. The system allows a
troubleshooting guide for the HI/LO gas very hot flame for preheating the
system. The HI/LO system provides for plate quickly while also regulating
smooth transitions between the Hi preheat the supply to a lower preheat flame
setting to the low preheat setting during necessary when the actual cutting
the actual cut. is taking place.
2.2 INSTALLATION REQUIREMENTS When the preheat output is turned

on through a CNC program or by a
Two separate oxygen supply lines of manual switch, the preheat
three-eighths of an inch inside diameter. solenoid valves on the inlet of the
One fuel line of three-eighths of an inch manifolds and on the HI\LO gas
inside diameter. Two short supply lines, panel energize. All four valves
one oxygen and one fuel to the manifold being normally closed valves now
assembly. open and allow gas to enter into
the HI\LO panel around the pilot
2.3 SPECIFICATIONS regulator, out of the gas panel
without any restriction into the
Maximum input supply pressure: Cutting manifold, and then flow to the
Oxygen: 100psig torch.
Preheat Oxygen: High preheat setting is Once the cutting oxygen is turned
dependent on the tip chart setting for on the preheat valves on the HI\LO
selected tip. panel are turned off. The preheat
gases are then forced into the inlet
Preheat Fuel: High preheat setting is of the pilot regulators, which are
dependent on the tip chart setting for used to adjust the desired flow to
selected tip. Note: Do Not Exceed 15psig the torch. This is the low preheat
for any type of fuel gas. setting. It is important to note that
the low preheat cannot be adjusted
2.4 THEORY OF OPERATION unless the cut signal is activated.
Theory of operation: 2.5 INSTALLATION CONNECTIONS.
The gas and oxygen main supply Refer to Figure 2.1 for the proper hook up
lines connect directly to the gas connections.
panel inlet and the cutting oxygen
supply is a separate connection 2.6 OPTIONAL EASE-ON ASSEMBLY
directly to the cutting oxygen
manifold inlet. The optional ease-on assembly controls
the rate at which cutting oxygen is
The preheat pressures set at the pressurized. This valve allows for smooth
supply tanks are referred to as the starts during piercing.
D-4
MI0549A
Note: Turning the valve clockwise slows

the time, rate at which the cut oxygen
comes on. Turning the valve counter
clockwise increases the, rate at which the
cut oxygen comes on.
D-5
MI0549A
Note: Cut Oxygen Pressure

Setting Not To Exceed 100psig
To Manifold
Note: Oxygen Pressure

Setting Set To Tip Chart
Note: Fuel Gas Maximum

Pressure Setting: 15psig
HI/LO PANEL
Individual Solenoid Control

(Typical per Oxy-fuel Station)
Preheat Fuel Manifold
Preheat Oxygen Manifold
Figure 2.1 Cut Oxygen Manifold
Cut Oxygen Blow-off Solenoid
Individual Cut Oxygen Solenoid
CV
CV
CV
Typical Oxy-fuel Torch Station
D-6
MI0549A
SECTION 3
WARNING OPERATION
h. At the torch, open the torch fuel
ENSURE ALL HOSE FITTINGS AND preheat valve slightly by turning
TANK FITTINGS ARE TIGHT counter clockwise ¼ turn.
BEFORE PROCEEDING. PERFORM i. Ignite the torch and open slightly the
A LEAK TEST ON ALL FITTINGS. preheat oxygen valve.
j. Adjust the flame for the hottest high
preheat flame setting necessary for
3.1 OVERVIEW the thickness of steel plate you are
cutting at the tank regulators
Note: This procedure must be done (preheat fuel and oxygen).
before using the CNC operation or the k. Place the CUT switch to the on
manual cut function of the manual position. The switch is located on
controls. the drive unit box.
l. At the torch, open the torch cut
The following gives a general procedure valve all the way by turning counter
for using the HI/LO panel. When all clockwise.
connections are made and leak tested, m. At the HI/LO panel adjust the
select the proper tip for the steel plate to settings for a neutral flame at the
be cut. torch. Manually open and close the
a. Place the selected tip in the desired torch cutting oxygen valve several
torch for cutting. times, adjusting the fuel valve if
b. Make sure the tip nut is tight. necessary to achieve: satisfactory
c. Open the cutting oxygen tank preheat flame when cutting oxygen
regulator and adjust the pressure for is off; and a neutral flame around
100psi. the cutting oxygen stream for
d. Open the High Preheat oxygen tank several inches from the tip face
regulator and adjust the pressure for when the cutting oxygen is on. Note:
the HI tip chart setting. Note: This is The cutting oxygen stream within
a course setting adjustment. Note: A the neutral flame should be straight
slight increase in pressure may be and several inches long.
required do to the length of the n. The flame should now be properly
incoming supply hose to the adjusted for cutting.
machines’ HI/ LO panel.
e. Open the Fuel tank regulator and Note: THIS SETUP IS FOR ONE TORCH
adjust the pressure for the tip chart ONLY. WHEN USING MULTIPLE
setting. Note: This is a course TORCHES, ADJUSTMENT OF THE
setting adjustment. TORCH VALVES MAY BE NECESSARY
f. Place the selected TORCH switch in (TRIMMING).
the on position.
g. Place the PREHEAT switch to the
on position. The switch is located on
the drive unit box.
D-7
MI0549A
SECTION 4
MAINTENANCE
4.0 40 HOURS
After 40 hours of operation, perform a

leak test on all connections and fittings.
4.1 HELP FLOW CHART
Cannot adjust low

Low preheats do
preheatflame at
not work
the HI/LO Panel
Make sure the

supply lines are
connected properly
The OFF/BOOST/
AUTO switch not
placed in AUTO
Make sure the

supply pressure is
set correctly Solenoids at the
HI/LO panel not
Turning Off
HI/LOW GAS PANEL WORKING CORRECTLY
D-8
MI0549A
SECTION 5
REPLACEMENT PARTS
1 2
6 5
Figure 5.1

1115-0742-06 HI/LO GAS PANEL
1 1138-3004-00 Gauge, Fuel 1
2 1138-3005-00 Gauge, Oxygen 1
3 1138-5506-01 SOL. 2
Valve,1/4",Fuel,2way,NC,CGA,
ASCO #SC8262G78
120 Volt
4 1138-5500-00 Solenoid Valve, Preheat 2
Oxygen,
2-Way, 1/4"NPT, NC
Parker #04F20C2210ACF-
PH05-O
5 201-1105 Regulator, Oxygen 1
6 201-1106 Regulator, Fuel 1
D-8
MI0549A
Figure 5.2

1112-0051-11 Distribution Unit
SOL. Valve,1/4",Fuel,2way,NC,CGA,
1 1138-5506-01 ASCO #SC8262G78 1
120 Volt
Solenoid Valve, Preheat Oxygen,
2 1138-5500-00 2-Way, 1/4"NPT, NC 1
Parker #04F20C2210ACF-PH05-O
Solenoid Valve, Cut Oxygen,
3 1138-5503-00 2-Way, 1/4"NPT, NC 1
Parker #04F25C2222CAF-PH05-O
Solenoid Valve Assembly, Blow Oxy,
4 1138-5501-01 2way, 1/4" NPT, NO, 1
Parker Valve, Hirchmann Connector
Breather Vent Brass Schrader
5 9938-4463-00 1
#4704-004
D-10
1
To Dome Regulator
From Supply
To Ease-on Valve (supply )
Cut Oxygen Manifold

From Ease-on Valve
Figure 5.3 Optional Ease-On Assembly

1115-0425-05 AUTO EASE-ON ASSEMBLY
Valve, Flow Control, 1/8 NPT,
1 0834-3547-00 1
Ace Control
2 0866-8742-00 Regulator, Dome 1
D-11
APPENDIX F
PNEUMATIC AIR SCRIBE MARKER
May 2002
Revision 0
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS ................................................................F-2
SECTION 2 INTRODUCTION
Section 2.1 Scope ................................................................................................F-3

Section 2.2 Installation Requirements ..................................................................F-3
SECTION 3 OPERATION
Section 3.1 Manual ..............................................................................................F-4

Section 3.2 CNC /Automatic Operation ................................................................F-4
SECTION 4 MAINTENANCE
Section 4.1 Changing the stylus ...........................................................................F-6
SECTION 5 REPLACEMENT PARTS ..................................................................F-7
Figure F-1 Scribe............................................................................................... F-5

Table F-1 Troubleshooting ............................................................................... F-6
Figure F-2 Parts................................................................................................. F-7
F-1
SECTION 1
SAFETY PRECAUTIONS
request for service be made to the Koike Aronson, Inc. Authorized Distributor from whom
purchased or directly to the Koike Aronson, Inc Service Department.
malfunction, which results from improper use, faulty maintenance, damage, improper
repair or alteration by anyone other than Koike Aronson or a facility, designated by Koike
Aronson.


WARNING

F-2
MI0548A
SECTION 2
INTRODUCTION
2.1 SCOPE
This appendix provides a step-by-step guide

for operation, adjustment and a
troubleshooting guide for the scribe marking
station. The station consists of a model G
torch lifter (a six or twelve inch lifter) with a
four-inch stroke air cylinder. Air solenoids
control the up and down movement of the
cylinder while another controls the on and off
operation. A course adjustment to the plate
is made by the Model “G” torch lifter.
2.2 INSTALLATION REQUIREMENTS
There are no requirements for this station

when ordered at the time of machine
purchase. When the situation arises that a
torch station be added to the existing
machine, Koike Aronson must be notified as
to how many existing stations are currently
on the machine. The electrical assembly
consists of the cables and software for the
options ordered with the station. The Air
supply should be at least 90psi and a Filter-
Lubricator-Regulator with good quality
spindle oil is recommended. The FLR should
be adjusted so there is a slight oil mist in the
exhaust.
F-3
MI0548A
SECTION 3
OPERATION
3.1 OPERATION
Refer to the operation section of the

KARCNC manual section 2.2.9, 2.2.12 for
details on manual and cnc operation.
F-4
MI0548A
SECTION 4
MAINTENANCE
Model G Torch Lifter
Air Cylinder, 4” Stroke
Scribe Assembly
Figure F-1 Scribe
F-5
MI0548A
WARNING
Disconnect the air supply before performing any maintenance on the scribe assembly.
TROUBLESHOOTING GUIDE
Trouble Probable Cause Solution
Low power Low pressure at the inlet Check the air supply. For top performance,
the air pressure must be 90 psig (6.2
bar/62OkPa) at the inlet.
Internal dirt accumulation Pour about 3 cc of a clean, suitable cleaning
solution into the air inlet and operate the tool
for a few seconds. Immediately, pour a few
drops of the recommended oil into the air
inlet and operate the tool for about 30
seconds to lubricate the internal parts.
Worn Piston and/or Cylinder Replace the Piston and/or Cylinder.

Lack of adequate lubrication Check the lubricator to make sure it is
working properly. If a lubricator is not used,
pour a few drops of the recommended oil into
the air inlet after every two hours of
operation.
Leaky Throttle Sleeve Warn Housing Seals Replace the Housing Seals.
Air cylinder will not raise or Check the I/O to ensure the Check the I/O fuses for integrity.
lower output for the solenoids is
coming on.
Ensure CNC program is Correct the posted program.
correct.
4.1 CHANGING THE STYLUS
a. Carefully, place the housing in copper-covered or leather-covered vise jaws, inlet side
down.
b. Using a wrench on the flats of the nosepiece unscrew (turn counterclockwise) and
remove the nosepiece.
c. Remove the stylus spring and the stylus.
d. Install the stylus spring onto the new stylus and insert the stylus into the housing.
e. Screw the nosepiece into the housing and tighten securely. (Turn clockwise to install)
Reference: Figure F-2
F-6
Table F-1
MI0548A
SECTION 5
REPLACEMENT PARTS
Inlet
Throttle Sleeve
Housing
Housing Seal
Piston Stop
Piston
Cylinder
O-Ring
Cylinder Spacer
1138417904 Stylus
Stylus Spring
Nosepiece
Figure F-2 Scribe Assembly
F-7
KOIKE ARONSON, INC.
635 W. Main St., Arcade NY, 14009-0307(585) 492 2400, Fax (585) 457 3517
Visit us at www.koike.com
ATM-MI0549A PRINTED IN U.S.A.

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ARONSON TECHNICAL MANUAL

KOIKE ARONSON, INC.

SECTION 1 SAFETY PRECAUTIONS .......................................................... 1

Section 1.1 General Safety ........................................................................... 4

SECTION 2 General Introduction .............................................................. 11

Section 2.1 Scope....................................................................................... 11

SECTION 3 Pre-installation Requirements .............................................. 14

Section 3.1 Pre-installation Safety .............................................................. 14

SECTION 4 Installation .............................................................................. 18

Section 4.1 Installation Safety Precaution................................................... 18

SECTION 6 Maintenance ........................................................................... 24

Section 6.1 Safety Precautions ................................................................... 24

SECTION 7 Replacement Parts................................................................. 28

LIST OF ILLUSTRATIONS /TABLES

Figure 1.1 Machine Safety Frame ............................................................. 10

Appendix A List of Terms and Abbreviations...............................................A1

NOTES, CAUTIONS & WARNINGS

ELECTRICAL SHOCK CAN KILL

DO NOT WATCH THE ARC

GROUND THIS EQUIPMENT

EYE PROTECTION REQUIRED

USE AN APPROVED RESPIRATOR

WEAR APPROVED EAR PROTECTION

INSULATED GLOVES REQUIRED

INSULATED FOOTWARE REQUIRED

HOT SURFACE DO NOT TOUCH

DO NOT REMOVE GUARDS

WEAR PROPER EYE PROTECTION WHEN PLASMA CUTTING

WEAR PROTECTIVE CLOTHING

11. Replace hoses that are damaged by

13. Coil excess hose and place it out of the

16. Never use a regulator that leaks,

28. Shut off power and gas supplies

24. Never expose cylinders to excessive

2. Provide radiation protection for the

9. The plasma operation should be located

4. The operator must use in addition to

22. Conform to all local codes for primary

24. Inspect the torch leads. Replace if

26. Do not pick up the work piece,

20. Maintain proper insulation against

30. Be sure the power cord is plugged into

2. Check that the machine voltage and

3. Never operate this machine unless all

5. Never touch torch tip when lit, or you

11. Take care not to climb on or over the rail

12. There is no pressure relief valve in the

8. During the piercing operation on heavier Maximum supply pressures are:

Cutting Machine Fence

2.15 STEEL BAND ASSEMBLY

The steel band assembly consists of a single

3.2 SITE LOCATION

3.4 ELECTRICAL REQUIREMENTS copper, 4.5M (14’) in length. If you cannot

During an installation of this type, care

Station drops should be installed on a wall or A locally supplied pressure booster is

The burning table, fabricated enclosed or

b. Keep in mind the pre-installation

Note: DO NOT ANCHOR TO THE FLOOR AT Outboard Rail

c. Using a manometer (water level), locate

Suspend the cutting machine assembly by