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GULLCO KBM-18, Parts List & Operating Instructions, Page: 2 / 60

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Summary of Contents for KBM-18

Page 1: ...ustable bevel head produces bevel angles from 22 5º through 55º Supplied with angle bevel pin for 30º Other bevel angle pins are available upon request NOTE Machine shipped with the 30º bevel pin in place PARTS LIST OPERATING INSTRUCTIONS Website www gullco com Distributed by ...

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Page 3: ...in such instances As the bevelling capacity of the machine is reduced on higher tensile materials no more than 50 of the machines total bevelling capacity should be bevelled in a single pass when bevelling high tensile steel and stainless steel TABLE OF CONTENTS SAFETY INSTRUCTIONS 1 KBM 18 PLATE EDGE BEVELLING MACHINE DETAILS 3 MACHINE SPECIFICATIONS 3 BEVELLING CAPACITY 5 GENERAL DESCRIPTION 6 I...

Page 4: ...INSPECTIONS 33 PERIODIC INSPECTION MAINTENANCE 33 STORAGE 34 SHIPPING 34 TROUBLESHOOTING GUIDE 35 KBM 18 100 GENERAL ASSEMBLY BREAKDOWN 38 CLAMP ROLLER ASSEMBLY BREAKDOWN 40 PIVOT ARM ASSEMBLY BREAKDOWN 41 SLIDE BASE ASSEMBLY BREAKDOWN 42 MAIN ROLLER ASSEMBLY BREAKDOWN 43 SUPPORT ROLLER ASSEMBLY BREAKDOWN 44 STARTER ASSEMBLY BREAKDOWN 45 MANUAL STARTER ASSEMBLY BREAKDOWN 46 KBM 18 MAIN GEARBOX BRE...

Page 5: ...tch assembly that features short circuit and motor load protection There is also an under voltage release device that will reset the switch to an off state and will not allow it to be switched on until the power has been re established and the Start push button is manually activated This provides protection against unwanted restart after a power failure etc The Stop push button is the red raised m...

Page 6: ...e if ill or drowsy from medication or fatigue Avoid horseplay around this machine Keep positioning handles dry clean and free from oil and grease Do not try to lift the machine by the positioning handle bars or wheel handles refer to the appropriate section of the manual for correct lifting technique Keep hands away from the cutting area and any possible pinch points when there is the slightest po...

Page 7: ...ximum Bevel Depth 0 61 15 6 mm at standard 30 bevel angle on material with a tensile strength of 64 000 lb in 45 Kg mm multiple passes Minimum Plate Thickness 1 4 6 3 mm Bevel Speed 13 4 m per minute Motor 2 H p 3 phase available for 230 460 and 575 V at 60 Hz and also 380 and 400 415 V at 50 Hz supply Gearbox Oil 1 US Gallon 4 Litres of Shell Tivela S 320 See section Periodic Inspection Maintenan...

Page 8: ...4 KBM 18 080 UNDERCARRIAGE ...

Page 9: ...55 14 0 mm 0 39 9 9 mm 0 47 11 9 mm 0 33 8 4 mm 55º 0 59 15 0 mm 0 34 8 6 mm 0 55 14 0 mm 0 32 8 0 mm 0 47 11 9 mm 0 27 6 8 mm The bevelling capacity is based on the bevel width W which corresponds to the amount of material removed by the cutter If the maximum bevel width is exceeded overloading of the machine and cutter may result In general as the tensile strength of the material increases the b...

Page 10: ... through the cutter The adjustable bevelling head enables the bevelling of angles 22 5 through 55 The KBM 18 is available for use with the following power supplies 230 460 and 575 V at 60 Hz and also 380 and 400 415 V at 50 Hz The supply to be used must be specified at the time of order Gullco can also provide machines for use with supplies that are not listed above please consult Gullco for more ...

Page 11: ...e bars or by the wheel adjusting handles or any other such component s that could result in machine damage and or bodily injury due to mechanical failure during the lifting hoisting process IMPORTANT To prevent air from entering the hydraulic system it is important that the scissor mechanism is not allowed to open during lifting of the KBM 18 equipped with the hydraulic undercarriage Holes are pro...

Page 12: ...he same as that specified on the product label If in doubt DO NOT SUPPLY POWER TO THE MACHINE Copies of the possible product labels are listed below The F L A ratings referenced in the above labels represent the maximum values to which the adjustable overload setting of the starter switch must be set to and are based on the Full Load Amp rating of the motor for the voltage being used This equipmen...

Page 13: ...alls below an acceptable level This protects against the machine from accidentally starting up when power is re applied Note The Emergency stop push button latches when activated and requires a counter clockwise twist to release WARNING As shown in the accompanying drawing the cutter rotation MUST be clockwise as viewed from the front IT IS IMPORTANT THAT THIS ROTATION DIRECTION BE CORRECT OTHERWI...

Page 14: ...al operation All of the necessary hardware will be provided with the machine Refer to the parts list drawings later in this manual for more assembly details 1 The Starter Switch Assembly may need to be re orientated or re attached 2 The handle bars may need re attaching 3 The Clamp Roller Assembly may need re attaching 4 The Chip Pan may need re inserting into the optional undercarriage assembly 5...

Page 15: ...d board and foam spacer that are used to retain the cutter shaft collar during shipping Install the cutter onto the shaft do not apply excess force if the cutter does not slide on to the shaft easily there may be burrs or damage on the cutter if it s been excessively used Reinstall the cutter nut washer complete the assembly by firmly tightening the cutter nut Cutter nut 27mm and washer Cardboard ...

Page 16: ...then loosen the Slide Base Clamping Bolt 3 Lower the Slide Base Assembly by turning the Slide Base Adjusting Bolt counter clockwise 4 Loosen the nut of the Angle Alignment Bolt 5 Loosen the Wing Screw 6 Tilt the Pivot Arm Assembly upward 7 Unscrew and remove the Angle Pin 8 Screw in the correct Angle Pin to match the desired bevel angle to be produced 7 8 ...

Page 17: ...er Shaft Housing adjust the Angle Alignment Bolt up or down so that the notched mark on the end of the Angle Alignment Bolt lines up with the appropriate mark engraved on the side of the Cutter Shaft Housing The Alignment Bolt must be adjusted equally from both sides of the Cutter Shaft Housing to prevent the bolt from twisting Note the alignment is the same for the 37 5º 45º bevel angles 10 11 11...

Page 18: ... the front of the Tilting Base Frame The weight of the main body of the machine will result in undesirable motion forward or backwards depending on the tilt angle if it is not properly supported first Slightly loosen the two 2 bolts one 1 on each side of the Tilting Frame Base so that there is still enough clamping tension to prevent undesirable tilting motion of the main body of the machine but s...

Page 19: ...ct the accuracy of the Root Face Angle Reference Scales Therefore these scales should only be used as approximate reference guides and a test run is recommended to check the actual root face setting The Angle Reference Scale is slotted to allow the operator to recalibrate based on an actual bevel The Root Face Scale is reversible with inch markings on one side and millimetres on the other side 17 ...

Page 20: ... that the machine is level Using the hydraulic pump on the optional hydraulic lift undercarriage adjust the working height of the machine to suit the height of the work table the top of the Main Roller after adjusting to desired bevel depth is to be the same height as the underside of the plate to be bevelled To lower the working height of the machine slowly turn the release valve located on the p...

Page 21: ...e Guide Roller Bracket For plates with straight edges the Guide Rollers should be slightly in front of the face of the Guide Roller Bracket by approximately 0 020 0 5 mm For plates with concave edges i e bevelling the inside diameter of a large disk the Guide Rollers will need to be set further back in towards the machine For plates with convex edges i e bevelling the outside diameter of a large d...

Page 22: ...e the upper rear set screw 4 and the upper front set screw 5 to position and pinch the guide roller shoulder bolt 6 so that the Guide Rollers are in the desired position Both of the upper set screws 4 5 should be applying captive pressure to the guide roller shoulder bolt 6 19e Re tighten the guide roller clamp nut 1 19f Screw in the lower set screw 3 so that it rests against the guide roller shou...

Page 23: ...19 22 5º 30º 22 5º BEVEL ARRANGEMENT 30º BEVEL ARRANGEMENT ...

Page 24: ...20 37 5º 45º 37 5º BEVEL ARRANGEMENT 45º BEVEL ARRANGEMENT ...

Page 25: ...21 55º 55º BEVEL ARRANGEMENT ROOT FACE SCALE EXAMPLES ...

Page 26: ...eight above the floor or runway for the angle of bevel to be performed See the table below for minimum plate heights KBM 18 MINIMUM WORKING HEIGHT when used with KBM 18 069 Undercarriage Assembly DEGREES TABLE HEIGHT 22 5º 21 7 8 556 mm 30º 21 533 mm 37 5º 20 508 mm 45º 18 3 4 476 mm 55º 17 1 4 438 mm KBM 18 MINIMUM WORKING HEIGHT when used with KBM 18 080 Undercarriage Assembly DEGREES TABLE HEIG...

Page 27: ...f the bevelling machine to allow the work pieces to remain in a flat horizontal plane It is not recommended to bevel heavy or large work pieces that are difficult to manually handle with bench mounted machines If a heavy or large piece must be bevelled with a bench mounted machine support the material with a suitable arrangement of rollers or casters to allow free movement of the material Ensure t...

Page 28: ...mp rollers should not be screwed down too tightly on the plate material This will cause feeding difficulties The material should be able to move freely under the clamp rollers 5 Remove the material 6 It is recommended that the corners of the leading and trailing edges of the plate material be ground prior to bevelling The notched corners should be at least the depth of the final bevel depth This p...

Page 29: ...he Slide Base Clamping Bolt 3 Lower the Slide Base Assembly by turning the Slide Base Adjusting Bolt counter clockwise 4 Disengage the cutter from the plate being bevelled 5 Draw the machine back from the plate and grind off any projections from the bevelled surface 6 Rectify the problem that caused the interruption i e worn cutter too large of a cut incorrect height adjustment etc 7 Readjust the ...

Page 30: ...city The following are recommendations for bevelling high tensile plate 1 Bevelling tougher materials should always be performed on the conservative side in terms of smaller bevel cuts and increased number of passes 2 Always use a sharp cutter The need for re grinding replacing cutters depends on the amount of use and work involved however it is always advisable to closely monitor the cutter as wo...

Page 31: ...RESISTANCE KBM 18 X1A EXCELLENT FAIR LOW HARD AGGRESSIVE CUTTER PERFORMS WELL UNDER PERFECT CONDITIONS BUT WILL FAIL IF NOT PROPERLY SETUP OPERATED CUTTER LIFE KBM 18 cutters are subject to wear under normal working conditions and should be re ground at regular intervals as per the procedure described later in this manual The service life of the cutter before resurfacing or replacement is necessar...

Page 32: ...ormally up to 10 re grinds can be performed before the cutters 0 110 2 8 mm recess is ground flat When resurfacing GBM 18 KBM 18 cutters the following instructions will help to provide the maximum cutter life 1 The cutter should be surface ground until all of the burred and dulled edges of the flutes are removed 2 The recommended grinding wheel is a Carborundum S G Medalist 461 Grit or equivalent ...

Page 33: ...cutter thickness be made and appropriate spacers installed behind the cutter to bring the total thickness as close as possible to the 0 991 25 2 mm NOTE Cutter spacers are available in two 2 nominal thicknesses 0 02 0 5 mm thick and 0 04 1 0 mm thick For Example Cutter thickness after several sharpenings L1 0 964 24 5 mm Add one spacer L2 0 020 0 5 mm Total Thickness L3 0 984 25 0 mm CUTTER DETAIL...

Page 34: ...r during operation P2 External force pulling material away from the cutter P3 Downward moment onto material P4 Upward moment onto material P5 External force interfering with feeding force F2 P6 Poor Main Roller rotation L1 Material extension from the cutter The cutter rotation F1 material feeding force F2 and the material pulling force to the cutter P1 are generated by the KBM 18 machine itself Un...

Page 35: ...s or plates with a long extension L1 2 Use a pinch roller and roller conveyor to improve the feeding force F2 and minimize the interference force P5 bench mounted operation with large heavy plate 3 Use a caster assembly to minimize the pulling force P2 away from the cutter self propelled operation When the KBM 18 is used as a bench mounted unit to bevel the short sides of rectangular plates such a...

Page 36: ...ivot Arm Assembly components and possibly cutter and drive line components will result IMPORTANT Ensure that no contamination has been trapped behind the Slide Base before retightening It is essential that the clearance between the Slide Base and the Pivot Arm Block be zero If even a slight clearance is present due to chips etc it could result in significant damage to Pivot Arm Assembly components...

Page 37: ...height adjustment assemblies and replace worn damaged parts as necessary Apply general purpose grease to lubricate the spring loaded mechanisms as needed All cables and conduits should be inspected for breaks abrasions and security PERIODIC INSPECTION MAINTENANCE NOTE The following inspection maintenance should be performed with greater frequency if conditions and usage requires Periodically clean...

Page 38: ...n of the oil For storage periods of over 60 days all machined surfaces should be protected with a suitable anti oxidation product For storage periods of over 6 months it is recommended that in addition to the points above the gearbox should be filled with extra oil requiring draining to the correct amount before re use It is also recommended that the rotor be turned every 1 to 2 months and to take...

Page 39: ...y tighten the Slide Base Locking Bolt Overload Check bevel width relative to the plate tensile strength Take smaller cuts per pass Refer to Bevelling Capacity earlier in the manual Burrs in sheared edge of plate interfere with feeding Grind off all burrs and irregularities before bevelling The cutter edge extension is not far enough beyond the edge of the plate The bottom dead centre of the cutter...

Page 40: ...ghtly higher than the appropriate mark engraved on the side of the Cutter Shaft Housing If the bevelled plate looks similar to the adjacent image Stop bevelling with the machine immediately Serious component damage will result after a very short period of use under these conditions Perform the same checks as listed next to the image above If the bevelled plate looks similar to the adjacent image L...

Page 41: ...e bevel thereby providing a more constant bevel across the whole edge of the plate It may also be necessary to move the Support Rollers to the inner holes of the Support Roller Plate when bevelling malleable material especially thin malleable plate This will provide support to the plate closer to where the material is being sheared thus reducing plate deformation and improving the starting feed Mo...

Page 42: ...38 KBM 18 100 GENERAL ASSEMBLY BREAKDOWN Drawing Number KBM 18 100 ...

Page 43: ...39 KBM 18 100 GENERAL ASSEMBLY BREAKDOWN Drawing Number KBM 18 100 ...

Page 44: ...HAFT SUPPORT PLATE 1 6 KBM 18 058 SLIDE SHAFT RETAINING PLATE 1 7 KBM 18 052 SCREW SHAFT 1 8 KBM 18 057 HAND WHEEL 1 9 KBM 18 053 BEARING WASHER 4 10 KBM 18 054 THRUST BEARING 2 11 KBM 18 110 REVOLVING HANDLE 1 12 GK 111 094 WASHER 6mm BOLT x 12 OD x 1 6 1 13 GK 112 130 M6 1 0 x 14mm BHCS 1 14 GK 107 123 M8 1 25 x 16mm SHCS 2 CLAMP ROLLER ASSEMBLY BREAKDOWN Part Number KBM 18 024 ...

Page 45: ...41 PIVOT ARM ASSEMBLY BREAKDOWN Part Number KBM 18 213 ...

Page 46: ...42 SLIDE BASE ASSEMBLY BREAKDOWN Part Number KBM 18 212 ...

Page 47: ...43 ITEM PART NUMBER DESCRIPTION QTY 1 KBM 18 067 MAIN ROLLER 1 2 KBM 18 05759 MAIN ROLLER BEARING 1 3 KBM 18 05230 80mm INTERNAL RETAINING CLIP 1 MAIN ROLLER ASSEMBLY BREAKDOWN Part Number KBM 18 026 ...

Page 48: ... 1 KBM 18 066 SUPPORT ROLLER PLATE 1 2 KBM 18 108 SUPPORT ROLLER 2 3 GK 111 095 WASHER 12mm BOLT x 24 OD x 2 5 2 4 GK 109 069 M12 1 5 HEX NUT 2 5 GK 136 070 LOCK WASHER 12mm BOLT 2 SUPPORT ROLLER ASSEMBLY BREAKDOWN Part Number KBM 18 029 ...

Page 49: ...45 STARTER ASSEMBLY BREAKDOWN Drawing Number KBM 18 214 ...

Page 50: ...46 MANUAL STARTER ASSEMBLY BREAKDOWN Drawing Number KBM 18 215 1 2 3 ...

Page 51: ...ot Sold Individually Output Shaft 1 5202 KBM 18 5202 Key 6x6x25 C 1 5301 KBM 18 5301 Bearing 32007X 1 5303 KBM 18 5303 Bearing 6213 2 5305 KBM 18 5305 Circlip 120 2 5307 KBM 18 5307 Bevel Pinion Washer 35 3x48x1 1 5308 KBM 18 5308 Output Shaft Washer 100x120x1 R 1 5851 KBM 18 5851 Oil Seal 65x120x13 DL 2 5854 Not Sold Individually Key 20x12 1 Note Provide all nameplate details from gear box label ...

Page 52: ...dditional Gear Module 1 103 KBM 18 142 Gear 1 105 KBM 18 143 Bearing Retainer 1 5102 KBM 18 144 Bearing 3206 2RS 1 5104 GK 119 072 External Retaining Clip 30 1 5112 GK 108 122 Bolt T E M6x16 3 5105 If component damage occurs Gullco strongly recommends replacing the KBM 18 201 Gear Module Assembly as it is more readily available and has been precision assembled adjusted Special tooling and procedur...

Page 53: ...tems 1 151 5001 5005 KBM 18 203 B 575V Motor Assembly KBM 18 100 E Includes items 1 151 5001 5005 1 KBM 18 207 Cover 1 151 Not Sold Individually Pinion Gear 1 5001 KBM 18 5001 Oil Seal 1 5002 KBM 18 5002 Bolt 6 x 20 10 5005 KBM 18 5005 Gamma Seal 1 203 1 Note Provide all nameplate details from gear box label when ordering spare parts ...

Page 54: ...50 OPTIONAL HYDRAULIC UNDERCARRIAGE ASSEMBLY BREAKDOWN Part Number KBM 18 080 ...

Page 55: ...51 OPTIONAL HYDRAULIC UNDERCARRIAGE ASSEMBLY BREAKDOWN Part Number KBM 18 080 ...

Page 56: ...52 OPTIONAL UNDERCARRIAGE ASSEMBLY BREAKDOWN Part Number KBM 18 069 ...

Page 57: ...53 KBM 18 WIRING SCHEMATIC Drawing Number KBM 18 215 SCH ...

Page 58: ...atings General Changed references of 415V to 400 415V January 2008 Title Page Updated Gullco contact details Page 7 Revised the S C Rating on the Product labels Page 32 Inserted additional Troubleshooting page resulted in page numbering changes General Revised to reflect optional undercarriage February 2008 Page 44 Added KBM 18 Gearbox Input Assembly Breakdowns page March 2008 Page 43 Added Part N...

Page 59: ...oducts are subject to change without notice KAT Moggy Sam KATBAK KBM are registered trademarks of Gullco International Enterprises Ltd Only use genuine authorized replacement parts May 2018 Pgs 45 46 53 Updated starter details and part numbers ...

Page 60: ...www GULLCO com ...

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