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SUPERBOILER T5

 

Original Instructions—rev.2011—

 

In compliance with the step 1.7.4 of the Machinery Direc-

tive 2006/42/CE 

 

G.B.C. Industrial Tools S.p.A.

 

Via Sandro Pertini 41/43 –

 25046 

Cazzago San Martino (Bs) –

 

Italia –

 

Tel. + 39 030 7451154 –

 

Fax. + 39 030 73 56 629

 

Remove the vane abutment nut and the vane abutment bush with a counter

-

clockwise movement

 

Screw all the way down the vane expansion nut

 

Summary of Contents for SUPERBOILER T5

Page 1: ...SUPERBOILER T5 INSTRUCTION MANUAL G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Versione 04 2018 ...

Page 2: ...arranty General Clauses 4 Intended Use Of The Machine 5 Technical Data 6 Machine Configuration Models 7 Machine Standard Equipment 8 Optional Equipment 9 Safety Prescriptions 10 Machine Stability 12 Workplace 12 Emergency Stop Installation Exemption 12 Machine Setup For Beveling 13 Elbow Shaft Kit Assembly 25 Pneumatic Locking Device Assembly 33 Converting The Machine Fron Pneumatic to Electric 44...

Page 3: ...ance 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 ...

Page 4: ...id 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 prod uct are at user s charge Any warranty repai...

Page 5: ...ECIALIZED OPERATORS WHO HAVE BEEN DULY TRAINED ON THE UNIT FOLLOWING TO A SPECIFIC FORMATION WE DO NOT ENVISAGE ANY REASONABLY PREDICTALBE 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 bevellin...

Page 6: ...26 Chuck Maximum Torque Nm 70 6 bar 210 8 bar 467 395 Stroke mm 40 40 40 Pneumatic Motor Power Hp W 1 74 1300 Air Consumption Nl min 1300 Air Pressure Bar psi 6 8 87 116 Air Hose Connection Inches 3 4 Electric Motor Power Hp W 2 58 1900 Tension Volt 110 230 Frequency Hz 50 60 Hydraulic Motor Power Hp W 1 36 1000 Hydrsulic Power Pack Max Pressure Bar 80 Oil Flow l min 30 Max Acoustic Emission Db 75...

Page 7: ...with the step 1 7 4 of the Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 SUPERBOILER T5 SUPER BOILER T5 E SUPERBOILER T5 Auto Lock SUPERBOILER T5 F ...

Page 8: ...azzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine is supplied with Locking jaws complete kit from 49 to 207 mm one measure of which is already mounted on the unit 5mm Allen Key 24mm Double Ended Hexagon Tubular Socket Wrench Case Instruction Manual And Exploded Drawings Pipe Beveling Machine Service Tools Case Instruction Manual And Exploded Drawings ...

Page 9: ... with the step 1 7 4 of the Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 INTERCHANGEABLE ELBOW SHAFT KIT FROM 98mm TO 207mm ID FLANGE KIT 60 400mm ...

Page 10: ...the regulations and all the instructions and that they 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 The autho...

Page 11: ...nder 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 adequate explan...

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 Directi ve portable machines are exem...

Page 13: ...ndro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 A Ø range 50 103 mm Plug Extension Jaw Screw M4 x 8 Locking Jaw Select the option A B or C according to the pipe ID Plug Extension Jaw B Ø range 102 155 mm Screw M4 x 8 Locking Jaw Plug Extension Jaw C Ø range 154 207 mm Plug Extension Jaw Screw M4 x 8 Locking Jaw ...

Page 14: ...dustrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 OPTION A Ø 50mm 103mm Remove the 3 screws fixed on the expansion unit of the machine Insert the 3 locking jaws you have selected in function of the ID of the pipe you need to prep and fix them with their screws ...

Page 15: ...andro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 OPTION B Ø 102mm 155mm Remove the 3 screws fixed on the expansion unit of the machine Insert the plug extension jaw and subsequently insert the le 3 locking jaws you have selected in function of the ID of the pipe you need to prep and fix them with their screws ...

Page 16: ...6 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane abutment nut and the vane abutment bush with a counter clockwise movement OPTION C Ø 154mm 203mm Take out the 3 extension jaws one by one as shown in the picture ...

Page 17: ... p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Get the widest extension jaws from the case and insert them one by one in the slots where from you have pre viously removed the smaller extension jaws Assemble back on the vane abutment nut and the vane abutment ring with a clockwise rotation ...

Page 18: ...ini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Now insert the locking jaws you have selected in function of the ID of the pipe you have to prep and fix them with their screws WARNING In order to achieve the perfect positioning and locking the jaws will have to be inserted in the ID for at least 15 20 mm as shown in the picture ...

Page 19: ... Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Keep the machine aligned with the axis of the pipe and fasten tightly the vane expansion nut with a wrench turning it clockwise ...

Page 20: ...C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Now select the beveling tool according to the operation you need to do insert it in the appropriate seat in the chuck and lock it tight with the grub screws using the Allen key supplied with the machine ...

Page 21: ...1 In compliance with the step 1 7 4 of the Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Correct position of the beveling tool NO YES ...

Page 22: ...B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Connect the air hose to the machine and the to the air system Actuate the machine by pressing the lever as shown by the arrow in the picture WARNING YOU WILL NEED TO APPLY A CONSTANT PRESSURE ON THE ...

Page 23: ...Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine feeding is achieved by acting on the hand wheel as shown in the picture For a perfect result it is important you to maintain a constant feeding rate When the job is finished release the security lever and the machine will automatically stop ...

Page 24: ...Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 WARNING DURING THE OPERATION THE BEVELING TOOL SHOULD NEVER COME IN CON TACT WITH THE LOCKING JAWS AS THESE MAY BE DAMAGED 1 2 To remove the machine from the pipe 1 Unscrew the vane expansion nut using the wrench supplied with the machine 2 Remove the machine from the pipe ...

Page 25: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane abutment nut and the vane abutment bush with a counter clockwise movement Screw all the way down the vane expansion nut ...

Page 26: ...c tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Using a long nose pliers rotate the expansion shaft counter clockwise until you can take it out Remove the 3 extension jaws one by one as shown in the picture ...

Page 27: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Loose the grub screw of the stop run bush but do not unscrew it completely then unscrew the stop run bush ...

Page 28: ... C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Take off the guiding shaft by rotating the hand wheel counter clockwise as shown int the picture Take off the vane abutment bush with the extractor and the special pliers Not supplied as STD optionals ...

Page 29: ...ve 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the tool abutment bush supplied with the elbow shaft kit The bush must be placed into position as per the above picture where the minor diameter faces outwards ...

Page 30: ...43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the guiding shaft in the machine until it marche the internal groove Rotate the shaft until it is centered with the groove rotate the hand wheel clockwise and insert the guiding shaft Screw back on the stop run bush positioninig it on one of the three seats and fix it with the grub screw ...

Page 31: ...tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw the vane expansion nut all the way down Insert the expansion shaft and screw it counter clockwise until its tip extends 20mm outside as shown in the picture ...

Page 32: ...dustrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Select the 5 locking jaws in relation to the ID of the elbow you need to work and insert them as shown in the picture Mount the cover as shown in the picture and fix it with the 10 screws supplied with the kit ...

Page 33: ...t stem between the chuck and the gripping jaws hub Insert the jaws hub in the elbow ID until the positioner adheres to the elbow wall as shown in the picture Now feed the machine forward until the positioner is packed between the elbow and the chuck At this stage the ma chine is squared G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax...

Page 34: ...the Expansion Nut to lock the machine with a stedy grip Move back the machine with the hand wheel and remove the positioner Now you can install the required bevel tools and perform the bevel operation G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 ...

Page 35: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane abutment nut and the vane abutment bush with a counter clockwise movement Screw all the way down the vane expansion nut ...

Page 36: ...c tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Using a long nose pliers rotate the expansion shaft counter clockwise until you can take it out Remove the 3 extension jaws one by one as shown in the picture ...

Page 37: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Loose the grub screw of the stop run bush but do not unscrew it completely then unscrew the stop run bush ...

Page 38: ...ial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Screw the nut M22x1 5 supplied with the kit and install the pneumatic locking device as shown in the picture Screw the pneumatic locking device all the way down and fix it in position with the nut as shown in the picture ...

Page 39: ...C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Unscrew and remove the nipple and install the air connector between the nipple and the security switch Connect the air tube to the air connector and the pneumatic locking device as shown in the picture ...

Page 40: ...ec tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 After having suppkied air to the pneumatic locking device move the red level upwards or downwards in order to move the pneumatic piston all the way forward ...

Page 41: ...E G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the expansion shaft inside the guiding shaft screw it counter clockwise until you will obtain a 0 5 1 mm gap when inserting the vane abutment nut as clearly shown in the above picture ...

Page 42: ...x 39 030 73 56 629 After having supplied air to the pneumatic locking device keep the locking jaws firmly pressed with your hand and move the red lever upwards or downwards so that the expansion shaft will withdraw into the ma chine body Se il montaggio è corretto le tre alette devono avere un leggere gioco nella propria sede Select the locking jaws in function of the ID of the pipe you will have ...

Page 43: ... A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Assemble back on the vane abutment nut and the vane abutment ring with a clockwise rotation In the rear part of the locking device you shall now insert the stem and the grub screw as shown in the pictur making sure not to move the expansion shaft ...

Page 44: ... 1 7 4 of the Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Lock the machine body into a vice with aluminium jaws as shown in the picture and remove the 3 screws ...

Page 45: ...ls S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Grab the motor and pull it out with a rotatory motion until it comes off N B While extracting the drive unit the pinion assembly might come off together with it Should this happen you will want to follow this procedure I CASE II CASE ...

Page 46: ... tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 I CASE The pinion assembly remains attached to the pneumatic motor Separate the pinion assembly from the motor Install the pinion assembly on the electric motor ...

Page 47: ...i 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 II CASE The pinion assembly remains inside the machine body Get an M6x60 screw or a longer one and screw it in the pinion so that it extends out of the machine body as shown it the picture Now pull in until the pinion assembly comes off Install the pinion assembly on the electric motor ...

Page 48: ...ols S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the electric drive device all the way down making sure that the pinion and the crown teeth are matching perfectly Once the motor is correctly installed screw back on the 3 screws to lock it The machine is now ready to be used ...

Page 49: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane abutment nut and the vane abutment bush with a counter clockwise movement Screw all the way down the vane expansion nut ...

Page 50: ...c tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Using a long nose pliers rotate the expansion shaft counter clockwise until you can take it out Remove the 3 extension jaws one by one as shown in the picture ...

Page 51: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the vane expansion nut Loose the grub screw of the stop run bush but do not unscrew it completely then unscrew the stop run bush ...

Page 52: ... Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the 4 screws that hold the chuck in position Take off the guiding shaft by rotating the hand wheel counter clockwise as shown int the picture ...

Page 53: ...A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Gently hit the chuck extremities with a rubber hammer to remove it easily Take the flange kit match the key notch and install it helping yourself with a rubber hammer Ensure also that the protection ring is aligned with the attachment of the handle ...

Page 54: ...hinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert and fasten the 4 screws and ensure the kit is able to freely rotate in both ways Fix the two grub screws as shown in the picture ...

Page 55: ...p 1 7 4 of the Machinery Direc tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 NB Put back together the expansion unit following in reverse all the operations previously described ...

Page 56: ... B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 After having selected the locking jaws in function of the ID of the pipe insert the machine inside the flange until the locking jaws are 5 mm inside the pipe as clearly shown in the above picture ...

Page 57: ...ec tive 2006 42 CE G B C Industrial Tools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 By using the wrench supplied with the machine lock tight the vane expansion nut and fixing the machine to the flange Insert the tool and lock it in position ...

Page 58: ...able the automatic feeding by polling the Knob A Rotate the Knob B to position the tool in the initial position Before engaging back again the automatic feeding pushing the Knob A forward rotate the flange kit body very slowly to ensure that the tool you have just installed does not touch the surface of the flange Knob A Knob B To increase the pace depth turn the hand weel clockwise To obtain opti...

Page 59: ...ed is supplied by G B C In dustrial Tools S p A only Perform a compressed air periodical cleaning on the threaded part of the gui ding 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 machin...

Page 60: ...The 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 ensure 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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