G.B.C G400 User manual

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 – email: sal[email protected]
Versione 01 2017
ELECTRONIC GRINDER G400

2
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sal[email protected]
Index Pag. 02
Preliminary Information Pag. 03
Warranty General Clauses Pag. 04
Intended Use Of The Machine Pag. 05
Safety Prescriptions Pag. 06
Specific Safety Prescriptions Pag. 07
Machine Standard Configuration Pag. 08
Machine Technical Specifications Pag. 09
Grinding Disc Specifications Pag. 10
Control Panel Functions Pag. 11
Grinding Disc Mounting and Removal Pag. 13
Head Position Adjustment Pag. 14
Head Horizontal Travel Pag. 15
Head Perpendicular Travel Pag. 16
Head Tilting for Backgouging Pag. 17
Left/Right Head Rotation for a Correct Positioning Pag. 18
Gouging the Groove Pag. 19
Reference Charts for Groove Dimensions Pag. 20
Machine Start-up Sequence Pag. 22
Ordinary Maintenance Pag. 27

3
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
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
unless our prior approval to do so is obtained. G.B.C. Industrial Tools S.p.a.
informs its customers that any operation carried out on the machines which is not prescribed in this manual
entails the automatic invalidation of the warranty. G.B.C. Industrial Tools S.p.a.
recommends to contact the Maintenance Service in Cazzago San Martino– Italy prior to proceed with any
modi-fication on the machine.
You are invited to scrupulously adhere to the information written on the identification tag.
For any further information you are invited to contact us at the telephone number or email below:
Tel. +39 - 030 -7451154
email: [e-mail]

4
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
G.B.C. Industrial Tools S.p.a. guarantees the reliability of the machine and its con-
formity to the specifications herewith reported. The warranty covers the machine in its whole
for a time period of one year from the shipment date (ref. Delivery Note) for any flaw not imput-
able to the user.
The parts subject to wear are excluded from the warranty at sole discretion of G.B.C. Indus-
trial Tools S.p.a.
In case of any operational malfunction arising during the warranty period, G.B.C. Industrial
Tools S.p.a.
And its Maintenance Service, hereinafter called MSS, will remedy this inconvenient free of char-
ge , both for handwork and for eventual replaced parts, except when the malfunction is di-rectly
or indirectly imputable to misuse or alteration. In any case the machine must not be disas-
sembled or altered before the shipment. The warranty is valid only when the warranty document
is duly signed by G.B.C. Industrial Tools S.p.a. and by a G.B.C. official distributor con-
nected with the MSS maintenance service.
The shipment of the defective material must be performed within 8 (eight) days from the notifica
-tion of the defect and/or the claim and/or the request of technical assistance. On the contrary the
warranty will be 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 repair or extraordinary repair must be executed by G.B.C.
Industrial Tools S.p.A. and MSS, otherwise the warranty will be void.
Any ordinary maintenance performed by the customer/user or by any service centre non recog-
nized or approved by G.B.C. Industrial Tools S.p.A. will not be refunded and will make the
warranty void. The warranty is not valid for cases not listed in this certificate or for damage cau-
sed by a misuse of materials, power supply, negligence, unauthorized modifications, atmos-
pheric events, acts of vandalism, incautious handling and/or transport, use of non original G.B.C.
Industrial Tools S.p.A. parts and damage for causes not specified by G.B.C. Industrial Tools
S.p.A. and for which G.B.C. Industrial Tools S.p.A. declines any responsibility. G.B.C. Indus-
trial Tools S.p.A. reserves the right to modify and to improve its products without any obligation
to modify equipment and components already supplied. Nobody is authorized to modify the con-
ditions herewith contained or to issue any on behalf of G.B.C. Industrial Tools S.p.A. The
claim terms for defects and/or damages in the material or of the ordered quantities, are those pre-
scribed by the Civil Code; the goods acceptance entails the buyer to automatically accept the
above mentioned warranty clauses.

5
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
THE GRINDER G400 MUST BE USED ONLY BY OPERA-
TORS WHO HAVE RECEIVED AN APPROPRIATE TRAI-
NING
PROPERLY TRAINED PERSONNEL RULES OUT THE
POSSIBILITY OF MISUSE OF THE UNIT
The grinder G400 represents a revolutionary method of executing grinding processes in the
boiler industry granting the following advantages:
− Sensible reduction of the working time in comparison with the existing manual grin-
ders;
− High material removal rate
− No thermal alteration on the welding area
− Consistency of the groove
− Vibrations free
− Requires only one operator
− Improvement of the working conditions and safety of the operator.
− Sensible reduction of injury risks ( flying shrapnels, tendinitis and distortions, stress
fractures) deriving from an extended use of angle grinders.

6
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
• Read ALL the following regulations and instructions;
• Ensure that the foreman that is using the machine is fully aware of all the regulations and instruc-
tions and that is qualified to operate the unit.
• Strictly attain to the indications and the international symbols portrayed in the present manual;
• Do not perform technical maintenance while the machine is plugged to the power source.
• Before every use ensure that the connection to the power source is in compliance with the specifica-
tions provided by the G.B.C. manual.
The authorized operator should not in any case disregard the basic safety regulation such as:
• Using gloves and goggles (safety gear supplied by the company responsible for the
site or for the building)
• To properly illuminate the working area;
• Ensure you are operating in an area which grants free movements (at least 2 metres
around the operator);
• Do not replace the control system and do not replace worn parts with non-genuine
GBC parts
• Do not use water jets on the machine;
• Do not get near the machine while it is running.
G.B.C. Industrial Tools S.p.A. recommends that for any particular case not mentio-ned in
this manual, the manufacturer’s authorization is necessary

7
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
- WEAR PROTECTIVE EYEWEAR AGAINST UTRAVIOLET RAYS
- WEAR HEARING PROTECTIONS
- WEAR A FACE SHIELD FOR SPARKS AND FUMES
- The unit must carry a tag indicating the maximum speed of the grinding disc (65 m/s)
which shall always be inferior to the speed sustainable by the grinding disc itself as spe-
cified by the manufacturer ( 80 m/s)
- The protection arount the grinding disc must cover at least 2/3 of the disc surface

8
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The machine is supplied with:
• Control Panel
• Wired Control
• 80-120mm Hook Wrench
• 8mm Allen Key
• 24mm Socket Wrench
• 24mm Open End Wrench
• 17mm Socket Wrench
• 6mm Allen Key
• 13mm Open End Wrench
• Instruction Manual
• Drawing of machine
G400 Wired Control
Control Panel
Tools
Trolley
Instruction Manual

9
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
FEATURES AND PERFORMANCES UNIT
MEASURE VALUES NOTES
Power Supply Tension (V) 400 -
Main Motor Power (KW) 9-
Push Motor Power (KW) 0.37 -
Horizontal Motor Power (KW) 0.37 -
Total Power (KW) 10 -
Head Horizontal Stroke (mm) 160 -
Head Push Stroke (mm) 140 -
Grinding Disc Speed (RPM) 3200 -
Grinding Disc Maximum diameter (mm) 410 -
Grinding Disc Flange Seat (mm) 60 -
Grinding Disc Allowed Thickness (mm) 8÷10
12÷14÷16 -
Grinding Disc Peripheral Speed (m/s) 65 With Intact Grinding Disc
Head Rotation Left-Right (°) 5With Intact Grinding Disc
Head Lateral Tilt (°) 5On the Left Side
Head Tilt on Trolley (°) 0÷45 Head Installed on the
Trolley
Gouging Depth (mm) 0÷120 With Intact Grinding Disc
Gouging Force (N) 150
Rotation Speed of the Positioners min/max (mm/min) 500÷2000 Optimal Speed between
1000 and 2000
Grinding Disc Productivity (Carbon Steel) Kg/min 0.080 In Optimal Conditions
Constant Noise at 2mt from the Grinding Disc
Noise Peak at 2mt from the Grinding Wheel
(dB A)
(dB B)
80÷85
110÷120
See the Note on the Next
Page
Weight of the Head (Kg)
180
Weight of the Head + Trolley (Complete Unit) (Kg)
500

10
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
NOTE:
G.B.C. Industrial Tools S.p.A, declares that every machine is tested on steels commonly user in mechani-
cal and metal work fabrication with 50mm wall thickness. The figures listed in the above chart, are de-
tected by a phonometer certified by an acoustic calibrator mod. DELTA HOM HD 9102 certified by
LAT (former SIT) N. SIT 03229/09 and we confirm such figures are in compliance with the regulation
EN 60745.
Therefore according to the evaluation of the environmental risk of the workplace, regulated by the Law
Decree.81/08 and following variations, actuating the directive2003/10/CE, according to the Art. 190 of
the above mentioned Decree, the staff responsible of the G400 must be formed and educated in renard to
the above said regulation , and must be equipped with the (DPI) and acoustic control upon request of the
worker, when deemed opportune by the doctor in charge.
EXAMPLE OF A GRINDING DISC IDENTIFICATION TAG
THE ABRASIVE DISC MUST HAVE THE FOLLOWING FEATURES:
Max. Ø 410
Thickness: 8 ÷16 mm
Flange Seat : Ø60
RPM max.3810/min
Max.80m/s
Reference Code: EN 12413 ÷ ANSI B7.1
Expiry Date and binder features are clearly stated on the abrasive wheel.

11
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
1 - Absortion Digital Display
2 - Switch Grinding Wheel / Grinding Tape
3 - Circuit Breaker Indicator
4 - Tension Indicator
5 - ON-OFF General Switch
6 - Emergency Stop
7 - Grinding Wheel Motor STOP
8 - Grinding Wheel Motor START
9 - Cycle Start
10 - Grinding Disc Absorption Adjustment
11 - Grinding Tape Absorption Adjustment
1
8
9
25
6
7
34
11 10

12
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
WIRED CONTROL FUNCTIONS:
1– Emergency Stop
2– Grinding Disc Motor START
3– Head Feeding
4– Head Left Translation
5– Tension Indicator
6– Grinding Disc Motor STOP
7– Head Return
8– Head Right Translation
6
7
5
8
1
2
3
4

13
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The replacement of the grinding disc and the replacement of the rubber wheel (for the grin-
ding tape) are operations that require the same procedure which is described below:
- Insert the hexagonal tubular wrench in the flange seat and engage the grinding disc loc-
king nut. At the same time use the hook wrench on the flange back plate on the opposite
side to hold it in place.
- Turn the nut and remove the flange.
- Replace the grinding disc, reposition the flange and the nut and use the hexagonal tubular
wrench to secure the parts in place again using the hook wrench to hold the back plate on
the opposite side.
− Due to the allowed manufacturing tolerances you may note that the grinding disc
might slightly in and out of the center line. This phenomena tends to fade away after
about 10 minutes of usage therefore during this limited period of time the machine
will have to work on light workload
− Replace the grinding wheel when its diameter is reduced to less than 275mm.
Wrenches Positioning for the
grinding disc REMOVAL
procedure
Wrenches Positioning for the
grinding disc MOUNTING
procedure

14
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The head tilt adjustment is achieved by rotating the handwheel in one way or another. This will
cause the head to tilt accordingly.
N.B. It is advisable that the head tilt does not exceed 10°÷45° and possibly that the head
axis is lined up with the workpiece to be worked.

15
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The head of the G400 can be translated on the horizontal axis by pushing the buttons indi-
cated by the arrows below.
N.B. The stroke of the head is 0÷160mm (0÷ 6 5/16")

16
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The head of the G400 can be translated on the perpendicular axis (moved towards or away
from the workpiece) by pushing the buttons indicated by the arrows below..
N.B. The stroke of the head is 0÷140mm (0÷5 1/2
“)

17
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
The procedure described below is the correct one to perform a perfect groove back gou-
ging:
1) Using the Allen key supplied with the machine, loose the screw that locks the joint as
shown in the picture below.
2) Use the socket wrench supplied with the machine and rotate the threaded pin in the di-
rection indicated by the arrow until you reach the deisred tilting.
N.B. The max tilting achievable is 5°
1
2

18
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
During the positioning of the machine it is possible to rotate the head left and right in order
to achieve a perfect alighment of the head with the workpiece to back gouge.
The procedure to do so is the following:
1) Use the Allen key supplied with the machine loose the screw pointed by the big arrow in
the below picture.
2) Use the open end wrench supplied with the machine and turn the tie rod in the direction
required until the head reaches the desired position.
3) Tight the screw to lock the head i position as shown in the picture below.
N.B. The maximum rotation is + 5° and – 5°
1
23

19
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]
Back gouging impure welding material between the edges of two parts (generally rolled
plates) partially welded together is a typical application for which this machine is devised.
For a perfect execution it is absolutely vital that the workpiece rotates without drifting
(lateral movements) and if it does you will want to eliminate the problem using some coun-
ter rollers on which the edge of the workpiece can lean against having the counter roller to
act as an end-stop device or you can find other expedients that grant the same result.
Sometimes the grinding disc is not parallel to the welding groove longitudinal axis you ha-
ve to gouge and needs therefore to be slightly tilted so that you can achieve a perfect “U-
shaped” groove.
The correct degree is defined by specific charts listed in the following pages, in which are
listed values in relation to the surface width and the desired depth to achieve. Approxima-
tely the value is included between 3° and 8°. In any case it is essential that during the gou-
ging process such angle remains unchanged or that at least is does not increase otherwise
this may generat friction between the grinding disc and the walls of the groove.

20
GRINDER G400
Original Instructions Rev.01-2017 in compliance with the § 1.7.4 of the Machines 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 – email: sale[email protected]