SOP-EQ-011 Rev 2 — Koike IK-12 Beetle Portable Automatic Gas Cutter — Safe Operation (UA46 120V, acetylene, standard tips)

Equipment: Koike IK-12 Beetle Portable Automatic Gas Cutter (EQ-011)

Location:

Approved by: Marty Howe, Welding Instructor

Approval date: 2026-05-25

Linked records: HA-EQ-011 · ·

Standards basis: OHSA s.25 (general duty); O.Reg 851 s.24 (machine safety), s.42 (electrical), s.79 (compressed gas), s.85 (lockout — multiple energy sources), s.105 (PPE); CSA W117.2 Section 5 (oxy-fuel cutting safety, gas hoses, regulators), Section 6 (flashback prevention), Section 11 (fire prevention in cutting operations); CSA Z460-13 (cord/plug + gas-supply LOTO — dual-energy isolation); CSA Z94.3 (eye/face — shade requirement for cutting); CSA Z94.2 (hearing); CGA E-9 (flashback arrestors); CGA P-1 (cylinder safe handling); NFPA 51 / NFPA 51B (hot work — UA46 shop functions as designated hot work area per shop policy); manufacturer manual Koike IK-12 BEETLE.

Machine Specs

Specification	Value
Manufacturer	Koike Sanso Kogyo Co., Ltd. (Japan)
Model	IK-12 BEETLE Portable Automatic Gas Cutter (BCA00B15)
Drive	Single cone speed changer (mechanical non-stage variable speed)
Voltage (UA46)	120V AC, 3-prong grounded plug
Frame material	Aluminum alloy (lightweight; NOT impact-resistant — handle carefully)
Direction control	FWD-NEUTRAL-REV switch (return to NEUTRAL between direction changes; never reverse mid-travel)
Fuel gas (UA46)	Acetylene ONLY (NOT propane — would require 106-type tips, not stocked)
Tip type (UA46)	102 STANDARD speed ONLY — 6-preheat-cone (NOT 102-D7 high-speed which needs 100 psi O2)
Tip sizes (102)	#00 (1/8" plate) through #4 (2" plate) per Cutting Data Reference
Torch valves	Three independent: cutting O2, preheat O2, fuel gas
Cutting capacity	1/8" to 2" mild steel plate (per mfr Cutting Data)
O2 pressure range (102 STANDARD)	20-45 psi (NEVER exceed; high-speed D7 NOT configured at UA46)
Acetylene pressure	2.8 psi typical; NEVER exceed 15 psi
Energy sources to control	Electric (120V cord-and-plug) AND gas (O2 + acetylene cylinders)
Manual reference	Koike IK-12 Beetle Operation Manual (21st printing, April 2024)

⚠ Danger Aluminum alloy frame is NOT impact-resistant — drop will damage machine AND injure operator (heavy on foot). NEVER move machine while preheat flame is on (mfr rule). Backfire/flashback hazard: tip must be torqued correctly with TWO wrenches; damaged tip taper causes backfire. NEVER use outdoors in wet weather — fatal electric shock risk.

PPE Required

⊙ Cutting goggles with Shade 5 lens (CSA Z94.3 / ANSI Z87.1) — MANDATORY for oxy-acetylene flame work

⊙ Welding/cutting gauntlet gloves — leather (Koike-specified for handling hot tips/heat shield)

⊙ CSA Z94.2 hearing protection (motor + cutting jet noise)

⊙ Cutting jacket or leather apron (slag spatter protection)

⊙ CSA Z195 Grade 1 safety footwear with metatarsal guard (machine weight + slag drop)

Pre-Use Inspection

Confirm cabtyre cord intact, three-prong grounded plug; verify 120V circuit at work location
Inspect aluminum machine body for cracks, impact damage, loose components (alloy NOT impact-resistant)
Inspect oxygen and acetylene hoses for cuts, kinks, oil contamination; verify no twisting
Confirm tip is correctly torqued using TWO wrenches; verify tip taper undamaged (damaged taper = backfire hazard)
Verify oxygen and acetylene regulators set per Cutting Data (typical 20-45 psi O2, 2.8 psi acetylene for 102-STANDARD)
Leak-test ALL hose connections, distributor, torch with soapsuds (NEVER oil or grease on oxygen fittings)
Set rail on workpiece — verify rail extends beyond cut start AND end; machine slides smoothly along rail
Confirm direction switch is NEUTRAL (stop), speed adjuster at minimum, all three torch valves CLOSED

Operation

Pre-Operation Setup

Place IK-12 on rail GENTLY (aluminum frame — drop damages machine and operator)
Select tip per Cutting Data Reference (UA46 uses 102 STANDARD acetylene only — NOT 102-D7 high-speed)
Install tip in torch using TWO wrenches simultaneously; verify nut snug (not over-torqued; over-torque causes seizing when heated)
Confirm blue hose (oxygen, right-hand thread) and red hose (acetylene, left-hand thread) routed correctly to torch
Open cylinder valves slowly: oxygen first, then acetylene (acetylene max 1.5 turns open, leave wrench on valve)
Set regulator pressures per Cutting Data Reference for plate thickness; acetylene NEVER exceed 15 psi
Plug cabtyre cord into 120V grounded outlet; verify direction switch NEUTRAL, speed at minimum

Lighting & Adjusting the Torch (3-Valve System)

Place torch on torch holder before igniting (mfr safety rule — never light off-machine)
Open fuel gas valve (acetylene) on torch slightly; ignite IMMEDIATELY with friction striker (NEVER lighter/match)
Increase acetylene until flame stops smoking and pulls slightly from tip
Open PREHEAT oxygen valve slowly; adjust to neutral flame — inner cones sharp, no feather, no excess oxygen sound
Open CUTTING oxygen valve momentarily to verify cutting jet is straight and centered through preheat flames
Close cutting oxygen valve — preheat flame should return to neutral; if disturbed, re-adjust preheat
Position torch over cut start point; verify direction switch still NEUTRAL before moving to cutting step

Cutting Data Reference — 102 STANDARD (Acetylene)

UA46 uses 102 STANDARD speed tips ONLY. 102-D7 high-speed tips require 100 psi (7.0 kg/cm²) oxygen pressure — UA46 oxygen supply is NOT configured for this. Do not attempt high-speed cuts.

Plate thickness	Tip size	Cutting speed	O2 cutting (psi)	O2 preheat (psi)	Acetylene (psi)	Kerf (in)
1/8"	#00	27 ipm	20	20	2.8	0.04
1/4"	#0	24 ipm	30	30	2.8	0.05
3/8"	#0	22 ipm	30	30	2.8	0.06
1/2"	#1	21 ipm	40	40	2.8	0.07
3/4"	#2	18 ipm	45	45	2.8	0.08
1"	#2	17 ipm	45	45	2.8	0.08
1-1/2"	#3	14 ipm	45	45	2.8	0.09
2"	#4	12.5 ipm	45	45	3.6	0.11

Data per Koike IK-12 Beetle Operation Manual, Section 11 (Cutting Data — 102 Standard Speed for Acetylene). Adjust within range based on observed cut quality.

Performing the Cut

Thoroughly preheat the cut-start point until white hot — DO NOT shortcut preheat (insufficient preheat causes poor pierce/cut quality)
Open CUTTING oxygen valve to pierce or start kerf (tip 15-20 mm above plate for piercing — prevents slag damage to tip)
IMMEDIATELY engage motor direction switch (FWD or REV); machine travels at set speed
STAY WITH MACHINE through full cut; monitor for hose snag, rail-end approach, and cut quality
Adjust speed with speed adjuster if needed (clean kerf = correct; top-edge melting = too slow; slag = too fast)
Approaching end of cut: turn off motor direction switch (return to NEUTRAL)
Shutdown sequence per mfr: close cutting O2 → close fuel gas (acetylene) → close preheat O2

Prohibitions

NEVER operate without operator qualification confirmed (instructor sign-off interim; TR_Register entry future)
NEVER use oil or grease on ANY oxygen connection, regulator, valve, or fitting — oxygen + oil = explosion
NEVER use a cracked, deformed, or out-of-test cylinder

Emergency Stop

Emergency Response SEQUENCE MATTERS — gas first, then motor, then power: (1) CLOSE the cutting oxygen valve on the torch — this stops the cut immediately. (2) CLOSE the preheat oxygen valve. (3) CLOSE the fuel gas (acetylene) valve on the torch. (4) STOP the travel motor — flip the on/off switch to OFF. (5) Once travel stopped, close cylinder valves at the cylinders (oxygen first, then acetylene). (6) If electrical emergency: unplug the cabtyre cord at the wall outlet. DO NOT shut off the motor before stopping gas flow — moving torch with active flame can drag fire across the workpiece and ignite nearby materials. DO NOT shut off cylinder valves while flames are still active at the torch — pressure release through hoses with active flame can cause flashback. For flashback (flame inside torch/hose): close acetylene valve at torch IMMEDIATELY, then oxygen valve at torch. Then cylinder valves. Do NOT attempt to extinguish externally. The IK-12 has no emergency stop button. Manufacturer-installed flashback arrestors and check valves at the torch are the engineering controls for gas-side emergencies.

Scenario	Immediate response	Notify
FLASHBACK (hissing sound in torch — flame retreating)	Per Koike mfr sequence: close PREHEAT OXYGEN first, then FUEL GAS, then CUTTING OXYGEN. Do NOT relight. Tag torch out of service pending inspection.	Instructor immediately
Backfire (single pop — preheat flame extinguishes)	Close all 3 torch valves; allow tip to cool; check for: overheated tip, slag-clogged tip, damaged tip taper, improper gas pressure. Replace tip if taper damaged.	Instructor
Machine dropped or struck (aluminum frame impact)	Power off; close gas cylinder valves; inspect machine for cracks, bent components, electrical damage; tag out of service if any damage	Instructor + first aid if struck
Machine falls off rail end / workpiece edge	Power off; do NOT approach until movement stops; close gas cylinder valves before inspecting	Instructor + first aid if struck
Hose snag tips machine over during travel	Power off; close gas cylinder valves at source; do NOT right machine until verified gas is OFF	Instructor
Cylinder valve fails / uncontrolled gas leak	EVACUATE area; ventilate space; close cylinder valve from safe distance if possible; NO open flames near area	Instructor + 911 if leak uncontrolled
Operator clothing ignites from sparks/spatter	STOP-DROP-ROLL; smother with fire blanket; NO water near energized machine	Instructor + 911 + first aid
Electric shock symptoms or visible cord damage during operation	Do NOT touch machine; power off at wall breaker; check for wet conditions causing shock path	Instructor immediately

Power Isolation

Cord-and-Plug Control Before servicing, cleaning, or accessory change — unplug the unit and maintain exclusive control of the plug. Per CSA Z460-20 cl. 4.3.5.

Set direction switch to NEUTRAL; turn power OFF; unplug cabtyre cord at outlet
Close oxygen and acetylene cylinder valves AT THE CYLINDER; bleed both regulators to zero
Apply personal lock+tag at electrical plug AND verify gas pressure at zero before service >5 min (per CSA Z460-20 cl. 4.3.5)

Post-Use

Turn power OFF; unplug cabtyre cord at outlet
Close cylinder valves: oxygen first, then acetylene; bleed both regulators to ZERO
Place torch on torch holder; allow tip to cool fully before handling (tip operating temp is very high)
Wipe machine and rail clean of slag and debris; inspect tip for clogs, taper damage (replace if damaged — backfire risk)
Coil hoses without twisting (mfr rule); inspect along full length; tag for service if any damage
Return machine GENTLY to case (aluminum frame — drop damages); secure cylinders upright

Related Resources

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ELIM

Cannot eliminate; oxy-fuel track cutting is the equipment's purpose. Substitute plasma cutting (SOP-PROC-PLASMA-001) where plate thickness, material, and cut-edge quality permit (plasma is rarely used at UA46 — see that SOP). Mechanical cutting (saws — Baxter Verticut, cold-cut) substitutes for straight cuts within machine capacity.

SUB

Within oxy-fuel cutting category, the IK-12 substitutes for handheld torch cutting on long straight cuts (rail-mounted travel is more consistent and safer than handheld). Sibling unit Victor VCM-200 (SOP-EQ-VICTOR) is the alternate track cutter at UA46.

ENG

Manufacturer-installed check valves and flashback arrestors at torch; rail-mounted tractor eliminates handheld torch hazards; grounded three-prong cord (120V single-phase); cylinder station chains (SOP-PROC-CYLINDER-001) that supply the tractor; regulator-controlled pressure (manufacturer max specs — 20-45 psi cutting oxygen standard 102 tip range).

ADM

Operator qualification per manufacturer §QUALIFICATIONS — interim enforcement via instructor sign-off (TR_Register reference for future standardization); pre-use leak test of all gas connections (soap-and-water); rail clearance check before motor engaged; UA46 shop is designated hot work area (no per-cut permit, no fire watch required by shop policy); shutdown sequence enforced (gas → motor → power); cylinder hydrostatic test verification at delivery; standard tips only (102-series for acetylene; preheat cone count 4 or 6 by plate thickness); cross-reference SOP-PROC-CYLINDER-001 for cylinder handling.

PPE

CSA Z94.3 cutting goggles or welding helmet with appropriate shade — STUDENT-SUPPLIED at UA46; shade compatibility is student responsibility (shade 5 for tips up to size 0, shade 6 for sizes 1-2, shade 7 for sizes 3-4 per ANSI Z49.1 / CSA W117.2 cl. 7); fire-resistant clothing (FR cotton or leather); leather gauntlet gloves; CSA Z94.2 hearing protection; CSA Z195 Grade 1 footwear; cotton or leather (NEVER synthetic — melts) clothing; head covering for any reach-in work; respiratory protection consideration for galvanized or coated plate (zinc fume hazard).

Before you sign off on this machine

On the next page you will confirm you have:

Read this entire SOP
Received instructor demonstration of the procedure
Demonstrated competent operation to the trainer
Understood the prohibitions and the emergency stop
Had the opportunity to ask questions

If you are unsure about any step or any control on this machine, stop and ask the instructor before you sign off.

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SOP-EQ-011

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