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G.B.C SUPERMAXI 7-24, Instruction Manual

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G.B.C SUPERMAXI 7-24 Instruction Manual Download Page 2

2

 

                       

SUPERMAXI 7

-

24

 

Original Instructions 

-

 Rev.1 

-

 2016 

-

 In 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 –

 25046 

Cazzago San Martino (Bs) –

 

Italia –

 

Tel. + 39 030 7451154 –

 

Fax. + 39 030 73 56 629

 

 

Presentation of the company and introduction to the Instruction Manual 

 

 

 

3

 

 

Warranty 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

 

 

Transport advices 

 

 

 

 

 

 

 

 

 

 

 

11

 

 

Machine Stability 

 

 

 

 

 

 

 

 

 

 

 

12

 

 

Workplace

 

 

 

 

 

 

 

 

 

 

 

 

12

 

 

Emergency Stop Installation Exemption

 

 

 

 

 

 

 

 

12

 

 

Machine Setup For Bevelling 

 

 

 

 

 

 

 

 

 

13

 

 

Tools Setup

   

 

 

 

 

 

 

 

 

 

 

17

 

 

 

Drive Kit Replacement

 

 

 

 

 

 

 

 

 

 

20

 

 

24” 

Extension Kit Installation

 

 

 

 

 

 

 

 

 

23

 

 

Ordinary maintenance 

 

 

 

 

 

 

 

 

 

 

26

 

 

Troubleshooting and Acoustic Emissions 

  

 

 

 

 

 

 

28

 

Summary of Contents for SUPERMAXI 7-24

Page 1: ...SUPERMAXI 7 24 INSTRUCTION MANUAL V 01 2016 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 2: ...nd introduction to the Instruction Manual 3 Warranty 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 Transport advices 11 Machine Stability 12 Workplace 12 Emergency Stop Installation Exemption 12 Machine Setup For Bevelling 13 Tools Setup 17 Drive Kit Replacement 20 24 Extensi...

Page 3: ...mpliance 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 ...

Page 4: ...e void 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 r...

Page 5: ...SPECIALIZED OPERATORS WHO HAVE BEEN DULY TRAINED ON THE UNIT FOLLOWING TO A SPECIFIC FORMATION WE DO NOT ENVISAGE ANY REASONABLY PRE DICTALBE 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 in serted and locked into the ID of the pipe The bevel is obtained by beve...

Page 6: ...RIC ID Locking Range 180 504 7 08 19 84 180 504 7 08 19 84 180 504 7 08 19 84 Mm inches Idle Speed 11 14 10 gg min Rpm Max Chuck Torque 1342 6bar 2508 8bar 2709 1640 Nm Nm Stroke 50 1 96 50 1 96 50 1 96 Mm inches Pneumatic Motor Power 4 2 3100 Hp W Air Consumption 2800 99 Nl min cfm Air Pressure 6 8 87 116 Bar psi Air Hose Connection 3 4 3 4 Pollici inches Hydraulic Motor Power 4 76 3500 Hp W Max ...

Page 7: ... 1 2016 In 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 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Pneumatic Hydraulic Electric ...

Page 8: ...San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine is supplied with Locking jaws complete kit from 180 to 504 mm one measure of which is already mounted on the unit 5 mm Allen Key 6 mm Allen Key 12 mm Long Allen Key Tx 20 Screwdriver 38 mm Wrench Wooden Case Instruction Manual And Exploded Drawings SM7_24 Service Tools Wooden Case Instruction Manual And Exploded Drawings ...

Page 9: ...th 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 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 24 EXTENSION KIT FOR WEDGE LOCKING TOOLS 24 EXTENSION KIT FOR STANDARD TOOLS ...

Page 10: ...l 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 aut...

Page 11: ...o richiesti mezzi di sollevamento diversi dalla forza umana di un unico operatore 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 al...

Page 12: ...030 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 e...

Page 13: ... S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Install the selected locking jaws in their seats Measure the pipe ID and select the correct locking jaws size before proceeding with the setup Use the allen key part of the service tool kit to lock the locking jaws in position with the 4 screws ...

Page 14: ... Directive 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 Use the wrench to rotate the central nut clockwise to allow the locking jaws to expand locking the machine inside the pipe Insert the machine in the pipe ID ...

Page 15: ...ustrial 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 compressed air hose to the machine pneumatic motor The machine can be started by rotating the lever as shown in the above picture WARNING THE MACHINE WILL START RUNNING THE VERY MO MENT THE LEVER IS TURNED ...

Page 16: ...ools S p A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 The machine can be moved closer to the pipe or away from the pipe by turning the handwheel N B To execute the bevel you will want to move the machine towards the pipe by turning the hand wheel with a continuous and constant paced motion ...

Page 17: ...y Directive 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 Fix the tip to the tool holder by using the appropriate screwdriver Select the most appropriate wedge locking kit in relation to the specific job required ...

Page 18: ...Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Position the kit making sure that the blade of the tip is in correspondence with the pipe wall thickness and lock it in position by fastening the screw with the appropriate Allen key Insert the kit you have just assembled into the T shaped slot on the slide ...

Page 19: ...ia Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 WRONG position Select the most appropriate wedge locking kit in relation to the specific job required fasten the grub screws present for the whole length of the tool to lock it in position N B THE TOOL MUST BE LOCKED BY AT LEAST 2 GRUB SCREWS CORRECT position ...

Page 20: ...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 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the 4 screws and washers as shown in the above picture Pull out the drive kit ...

Page 21: ...ective 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 Install the flange supplied with the hydraulic drive kit and install it in the motor seat Fix the flange with the four screws supplied with the hydraulic drive kit ...

Page 22: ... Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert the hydraulic motor making sure that the key located on its pinion matches the slot present on the ID of the toothed pinion installed in the machine Secure in place the hydraulic motor by fastening the 4 screws supplied with the hydraulic drive kit ...

Page 23: ...ertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 As already explained for the hydraulic motor the electric drive kit should be installed making sure that the key of its pinion is matching with the slot of the toothed pinion installed in the machine Secure the electric drive kit by fastening the four screws supplied along with it ...

Page 24: ... A Via Sandro Pertini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Remove the tool holder from the mandrel by removing the fixing screws with an Allen key as shown in the above picture Get the 2 2 extensions of the 24 kit and secure them on the mandrel by using the same screws of the tool holders you have just removed ...

Page 25: ...ini 41 43 25046 Cazzago San Martino Bs Italia Tel 39 030 7451154 Fax 39 030 73 56 629 Insert and tighten the stiffening screws 1 for each extension supplied with the 24 kit as shown in the picture N B The installation of the 24 kit will be complete by mounting the extension plugs in function of the pipe diameter you have to work See page 13 for the assembling instructions ...

Page 26: ...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 and the hose Introduce some drops of gas...

Page 27: ... AND TO GREASE THE THRUST BEARING REGU LARLY DEPENDING ON THE USE OF THE MACHINE The greases normally employed are lithium based Ep and correspond to the standards DIN 51825 K2K 20 ISO L X BCHA2 It is possible to use equivalent greases The working temperatures are included between 20 C and 120 C Special greases are necessary for the use of the machine at lower temperatures In the below chart are l...

Page 28: ...on 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 bevelling 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 complete disposal The acoustic emi...

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