G.B.C BOILER K Instruction Manual Download Page 1

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BOILER K

INSTRUCTION MANUAL

G.B.C. Industrial Tools S.p.A.

Via Sandro Pertini 41/43 –

25065

Cazzago San Martino (Bs) –

Italia –

Tel. + 39 030 7451154 –

Fax. + 39 030 73 56 629

sio

. 2

Range

Ø 28 / 76 mm

(1,10”

—

2,99”)

Summary of Contents for BOILER K

Page 1: ...BOILER K INSTRUCTION MANUAL G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Versione 02 2016 Range Ø 28 76 mm 1 10 2 99 ...

Page 2: ...d Use Of The Machine 5 Technical Data 6 Machine Configuration Models 7 Machine Standard Equipment 8 Optional Equipment 9 Safety Prescriptions 10 Transport recommendations 11 Machine Stability 12 Workplace 12 Emergency Stop Installation Exemption 12 Machine Setup For Beveling 13 Reduced Shaft Kit Assembly 20 Elbow Shaft Kit Assembly 30 Pneumatic Locking System Assembly 39 Reduced Shafts Kit with Pn...

Page 3: ...e with the quality system regulations UNI EN ISO 9001 SGS ITALIA S R L N IT 96 088 1996 This Manual is supplied together with the machine it makes reference to The customer may apply for fur ther copies to G B C Industrial Tools S p a Our company owns the copyright of this document and any partial or complete copy or distribution to natural persons or to corporate bodies is strictly forbid den unl...

Page 4: ... G B C Industrial Tools S p A and MSS obligations will cover the defect resolution the general maintenance and the inspection of the parts subject of the claim only The component replacement is at G B C Industrial Tools S p A discretion only The shipmen to costs from and to the MSS as well as the direct and indirect costs rising from repair of the product are at user s charge Any warranty repair o...

Page 5: ...IALIZED OPERATORS WHO HAVE BEEN DULY TRAINED ON THE UNIT FOLLOWING TO A SPECIFIC FORMATION WE DO NOT ENVISAGE ANY REASONABLY PREDIC TALBE MISUSE OF THE UNIT The machine shown in the drawing is intended to be used for prepping pipes for the welding It works while inserted and locked into the ID of the pipe It works while inserted and locked into the ID of the pipe The bevel is obtained by bevelling...

Page 6: ...07 74 44 Torque Nm Nm 27 6 bar 82 8 bar 124 116 Feeding Stroke mm inches 40 1 57 40 1 57 40 1 57 Pneumatic Motor Power Hp W 1 07 800 Air Consumption Nl min cfm 1000 35 31 Air Pressure Bar psi 6 8 87 116 Air Hose Connection Pollici inches 1 2 1 2 Electric Motor Power W 1300 720 Tension Volt 110 230 18V 4 0 Ah Frequency Hz 50 Maximum Acoustic Emission Db 75 75 75 Machine Weight Kg 8 9 9 MACHINE DIME...

Page 7: ...compliance with the paragraph 1 7 4 of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 BOILER K BOILER K E BOILER K with autolock ...

Page 8: ...an Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine is supplied with Locking jaws complete kit from 28 to 76 mm one measure of which is already mounted on the unit 4 mm Allen Key 24 mm Double Ended Hexagon Tubular Socket Wrench 19 mm wrench Case Instruction Manual And Exploded Drawings Pipe Beveling Machine Service Tools Case Instruction Manual And Exploded Drawings ...

Page 9: ...Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 INTERCHANGEABLE REDUCED SHAFTD FOR ID PIPES FROM 20mm to 30mm INTERCHANGEABLE ELBOW SHAFTS FOR CURVED ID PIPES FROM 46mm to 79mm ...

Page 10: ... are qualified to operate the unit Strictly attain to the indications given by the international symbols applies on the ma chine and or on its case Do not perform any maintenance operation when the machine is plugged to the power supply Before every use ensure the power supply connections to be conform to the specs given by our manual alle caratteristiche specificate nel manuale G B C alle caratte...

Page 11: ...ight kg 24 Under 25 Kgs no lifting machines are required 1 Always wear gloves and goggles during every operation 2 Any adjustment or inspection of the machine shall be done with the unit unplugged from the power source 3 During the operations the hands shall be kept on the security valve and on the hand wheel 4 The Use and Maintenance Manual as well as the drawings will always supply quick and ade...

Page 12: ...7451154 Fax 39 030 73 56 629 Considering the mass of the machine no particular problem has been detected in regard to the operator safety By always using both hands for operating the machine the operator is unable to reach the bevelling tools as the unit would suddenly stop motor brake As provided for the paragraph 1 2 4 3 of the attachment 1 of the Machinery Di rective portable machines are exemp...

Page 13: ...1 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Ensure the vane expansion nut is not abutted then unscrew the vane abutment cap and the vane abutment bush WARNINIG DO NOT MOVE THE EXPANSION SHAFT The expansion shaft can be moved by the vane expansion nut after having replaced the locking jaws Remove the locking jaws you want to replace ...

Page 14: ...n Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Select the LOCKING JAWS according to the diameter of the pipe and install them on the expansion shaft as shown in the picture While holding the three LOCKING JAWS you have just mounted unscrew the VANE E XPANSION NUT in order to let them enter their seat If the procedure is correctly made the locking jaws should have a little play ...

Page 15: ...ols S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw back on clockwise the vane expansion bush all way down and then the vane expansion nut While keeping the machine in axis with the pipe insert the SHAFT in the pipe about 15 20mm Firmly screw clockwise the VANE EXPANSION NUT ...

Page 16: ... S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Select the BEVELLING TOOL in regard to the bevel you need to perform and insert it on the CHUCK locking it with the two grub screws by using the Allen key You will want to use two paired cutting tools and one facing tools when required ...

Page 17: ...rective 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Connect the machine to the air hose Press the button lever upwards to actuate the machine WARNING You will need to apply a constant pressure on the lever ...

Page 18: ...ial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine feeding is actuated by turning the hand wheel clockwise as shown in the picture Maintain a constant and continuous action to obtain a uniform feeding The motor will automatically stop by releasing the lever ...

Page 19: ...Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 WARNING DURING THE OPERATIONS PAY ATTENTION NOT TO TOUCH THE LOCKING JAWS WITH THE TOOLS AS THESE MAY GET DAMAGED 1 2 REMOVING THE MACHINE FROM THE PIPE 1 Unscrew the vane expansion nut using the wrench supplied with the machine 2 Remove the machine ...

Page 20: ...ph 1 7 4 of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Unscrew the vane abutment cap and the vane abutment bush counter clockwise Remove the locking jaws ...

Page 21: ... Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw the vane expansion nut until it is butte to the machine Use a pair of long nose pliers rotate clockwise the expansion shaft until it comes out ...

Page 22: ...achinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Remove the grub screw cap and the grub screw from the cover case in order to release the guiding shaft ...

Page 23: ...C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the shaft by rotating the hand wheel clockwise Take the guiding shaft from the reduced shaft kit and mark the groove of the lap joint as well as the far end of the shaft as shown in the picture ...

Page 24: ...l Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the expansion shaft in the machine and align it s lap joint with the hole of the cover case where you will want to insert the two grub screws previously removed Rotate the hand wheel to get the shaft in the machine ...

Page 25: ...of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Re assemble the grub screw and the grub screw cover locking them tight Screw in all way down the vane expansion nut ...

Page 26: ... Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the reduced expansion shaft Insert a set of long nose pliers in the vane expansion nut screw the vane expansion shaft until it is positioned 2mm inside from the end of the reduced guiding shaft as shown in the picture ...

Page 27: ...embly in your machine you will have to follow the same proce dure described in the pages 20 21 22 23 24 and 25 After that you will have to follow a different procedure as described below Insert the standard VANE EXPANSION SHAFT and screw it inside the VANE GUIDING SHAFT until the gap between the VANE GUIDING SHAFT and the thread of the VANE ABUTMENT CAP is 2mm as shown in the photo 1 When the corr...

Page 28: ...0 7451154 Fax 39 030 73 56 629 3 Install the LOCKING JAWS selected for the next job and screw the VANE ABUTMENT BUSH on the VANE GUIDING SHAFT thread and also in this case you will want to leave about 1mm gap between the parts Screw on the VANE ABUTMENT CAP while holding still the VANE ABUTMANT BUSH so that it will not touch the shaft once the CAP is abutted to it 4 Fasten the VANE LOCKING CAP wit...

Page 29: ...ertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Select the correct locking jaws according to the ID of the pipe you need to work and place them in the shaft as shown in the picture Pull back the locking jaws unscrew the vane abutment cap and screw back on the vane expansion nut using the wrench supplied with the machine ...

Page 30: ... Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Ensure the vane expansion nut is not abutted then unscrew the vane abutment cap and the vane abutment bush counter clockwise Remove the locking jaws ...

Page 31: ...4 of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw back on the vane expansion nut all the way Rotate the shaft clockwise with long nose pliers and extract it ...

Page 32: ...he Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Remove the grub screw cap and the grub screw from the cover case in order to release the shaft ...

Page 33: ...ery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the shaft by rotating the hand wheel clockwise Extract the tool abutment chuck by using the special tool not supplied with the machine ...

Page 34: ...al Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the tool abutment bush supplied with the elbow locking kit Take the shaft from the reduced shaft kit and use a marker to mark the groove of the lap joint as well as the far end of the shaft as shown in the picture ...

Page 35: ...ial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the elbow shaft in the machine and align its lap joint with the hole of the cover case where the two grub screws should then be screwed back in Rotate the hand wheel in order to get the shaft inside the machine ...

Page 36: ...the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw back in all way down the vane expansion nut Screw back in the grub screw and the grub screw cover locking them tight ...

Page 37: ...achinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Slide in the elbow shaft Screw in the elbow shaft using a screwdriver until it extends 20mm from the head as shown in the picture 20 ...

Page 38: ...y Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Slide the selected locking jaws in the expansion shaft Fix the cover with the special screws supplied with it The machine is now ready to be used ...

Page 39: ... Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Ensure the vane expansion nut is not abutted then unscrew the vane abutment cap and the vane abutment bush counter clockwise Remove the locking jaws ...

Page 40: ...the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw back on the vane expansion nut all the way Rotate the shaft clockwise with a set of long nose pliers and extract it ...

Page 41: ...06 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Unscrew the vane expansion nut In replacement of the vane expansion nut you will need to screw the counter nut and then the pneumatic lock ing device as shown in the picture ...

Page 42: ...ve 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 screw the locking device and fix it in position with the counter nut As shown in the picture Unscrew the nipple and install the air connector supplied with the kit ...

Page 43: ...ry Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 After having supplied the pneumatic locking device with air move the lever downward to move the locking piston forward Plug the air supply tube ...

Page 44: ...e 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Slide the vane expansion shaft into the guiding shaft and screw it counter clockwise until you will obtain a gap of 0 5 1 mm by screwing back on the vane abutment cap ...

Page 45: ...4 Fax 39 030 73 56 629 After having supplied the pneumatic locking device with air keep the locking jaws pressed with your hand and move the lever upward to get the expansion shaft withdrawn in the machine If the assembling has been correctly executed the locking jaws should a little play in their seat Select the LOCKING JAWS according to the diameter of the pipe and install them on the expansion ...

Page 46: ... Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 In the rear part of the locking device you shall now insert the stem and the two grub screws as shown in the picture making sure not to move the expansion shaft Screw back on the vane abutment bush and the vane abutment cap counter clockwise 2 1 3 ...

Page 47: ...ith the paragraph 1 7 4 of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw the grub screws and the knobs supplied with the locking device ...

Page 48: ...ph 1 7 4 of the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Unscrew the vane abutment cap and the vane abutment bush counter clockwise Remove the locking jaws ...

Page 49: ...ry Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw the vane expansion nut until it is butte to the machine By using long nose pliers rotate clockwise the expansion shaft until it comes out ...

Page 50: ...achinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Remove the grub screw cap and the grub screw from the cover case in order to release the guiding shaft ...

Page 51: ...C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the shaft by rotating the hand wheel clockwise Take the guiding shaft from the reduced shaft kit and mark the groove of the lap joint as well as the far end of the shaft as shown in the picture ...

Page 52: ... 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the expansion shaft in the machine and align its lap joint with the hole of the cover case where you will want to insert the two grub screws previously removed Rotate the hand wheel to get the shaft in the machine Re assemble the grub screw and the grub screw cover locking them tight ...

Page 53: ...dustrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 In replacement of the vane expansion nut you will need to screw the counter nut and then the pneumatic lock ing device as shown in the picture Fix the reduction inside the locking device as show in here above ...

Page 54: ...f the Machinery Directive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 screw the locking device and fix it in position with the counter nut As shown in the picture Plug the air supply tube ...

Page 55: ... 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 After having supplied the pneumatic locking device with air move the lever downward to move the locking piston forward Slide the vane expansion shaft into the guiding shaft and screw it counter clockwise until you will obtain a gap of 0 5 1 mm by screwing back on the vane abutment cap ...

Page 56: ...4 Fax 39 030 73 56 629 Select the LOCKING JAWS according to the diameter of the pipe and install them on the expansion shaft as shown in the picture After having supplied the pneumatic locking device with air keep the locking jaws pressed with your hand and move the lever upward to get the expansion shaft withdrawn in the machine If the assembling has been correctly executed the locking jaws shoul...

Page 57: ... Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 1 2 3 Screw back on the vane abutment bush and the vane abutment cap counter clockwise In the rear part of the locking device you shall now insert the stem and the two grub screws as shown in the picture making sure not to move the expansion shaft ...

Page 58: ...C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the screws from the motor flange Hold the motor and pull it applying a little rotating movement until it comes off N B While performing this operation ensure that the pinion remains in its seat ...

Page 59: ...6 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25065 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the electric drive device making sure that the key on its shaft fits the seat on the pinion placed into the machine After a successful positioning fix the flange screws ...

Page 60: ...d is supplied by G B C Industrial Tools S p A only Perform a compressed air periodical cleaning on the threaded part of the guid ing shaft and in the rear part of the machine Always ensure that the seats of the tools on the chuck are clean Every 20 30 hours ensure the security valve has no air leaks Ensure no air leaks are present on the air supply system nearby the connection between the machine ...

Page 61: ...he machine does not run properly Check the condition of the shaft and verify it to perfectly spins around its axis of rotation The machine does not bevel Check the beveling tools condition and en sure that the pipe you are working does not require special bevelling tools due to its composition Always ask suggestions to your referent in G B C as we are at your com plete disposal The acoustic emissi...

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