G.B.C CHALLENGE 12 User manual

CHALLENGE 12
INSTRUCTION MANUAL
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
Versione 00 . 2012

2
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
INDEX
Presentation of the Company and Introduction to the Instruction Manual 3
Warranty General Clauses 4
General Safety Regulations 5
Safety Prescriptions 7
Transport Recommendations 8
Intended Use Of The Machine 9
Technical Data 10
Machine Standard Equipment 12
Machine Stability 13
Workplace 13
Emergency Stop 13
Machine Setup 14
Plate Beveling 18
Short Plate Beveling 19
Milling Tools Replacement 21
Roller Kit for Optional Angles 22
Pipe Beveling With Challenge 12 23
Ordinary Maintenance 24
Periodical Checks 24
Troubleshooting And Acoustic Emissions 50

3
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
PRESENTATION OF THE COMPANY AND
PRESENTATION OF THE COMPANY AND
PRESENTATION OF THE COMPANY AND
INTRODUCTION TO THE INSTRUCTION MANUAL
INTRODUCTION TO THE INSTRUCTION MANUAL
INTRODUCTION TO THE INSTRUCTION MANUAL
G.B.C. Industrial Tools S.p.A. is known worldwide for the quality of its machines and accessories
for pipe cutting and beveling procedures of any sort and plate beveling machines..
The Headquarters are located in Torbiato di Adro (BS) where are currently operanting the General
Management, the sales de-department, as well as the main workshop and the shipping de-
partment.
QUALITY STANDARD—All our machines are assembled acording to the highest quality stan-
standard. Since 1996 G.B.C. In-dustrial Tool S.p.a. has implemented management procedures in
compliance 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 docu-
ment 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 Torbiato di Adro –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 these numbers:
Tel. +39 - 030 -7451154
Fax +39 - 030 –7356629

4
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
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. Indu-
strial 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 war-
ranty void. The warranty is not valid for cases not listed in this certificate or for damage caused
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. Indu-
strial 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 he-
rewith 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.
WARRANTY GENERAL CLAUSES
WARRANTY GENERAL CLAUSES
WARRANTY GENERAL CLAUSES

5
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
The following list of safety regulations is a complementary attachment of the instruction manual
of all the plate beveling machines manufactured by G.B.C. Industrial Tools S.p.a. and it is its inte-
gral part.
G.B.C. Industrial Tools S.p.A. designs and manufactures its machines according with the safety
regulations provided by the EC (89/392 and additional) and the Italian law in force.
G.B.C Industrial Tools S.p.A. is not liable for an eventual improper use of the machines and for
their use when not in conformity with the regulations listed below and of the instructions attached
hereto.
1) Accurately read all the following regulations and the attached instructions before starting
any operation. Ensure that the operator and the foreman using the machine have full
knowledge of all the regulations and instructions.
2) All the setting and maintenance operations shall always be performed with the machine
unplugged from any power source.
3) Do not get you hands close to the moving milling tool.
4) In case of replacement of the milling tool, the afore said milling tool should be handled
carefully in order to avoid to hurt yourself with the edges.
5) Any intervention on the control box shall be performed by qualified personnel and only
when the machine is unplugged from any power source.
6) Especially when working on short plates, be careful where you put your hands.
7) When the machine is working off the ground ensure it to be always
attached to a security cable.
GENERAL SAFETY REGULATIONS
GENERAL SAFETY REGULATIONS
GENERAL SAFETY REGULATIONS

6
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
8) Do not try to remove chips or burr with your hands. Always help yourself with a tool
9) The machine should always be lifted by the lifting hoop and never
by the side handles.
10) Do not exceed the single passes figures shown in the chart.
11) In case of flame cut or burred plates, we suggest to clean the edge with grinder before
starting the beveling procedure.

7
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
G.B.C. Industrial Tools S.p.A. designs and assembles its machines in strict compliance with
the safety regulations provided by the applicable EC directives and by the Italian laws regulat-
ing this matter.
G.B.C. Industrial Tools S.p.A. declines any responsibility for misuse of its machines and their
use when in contrast with the regulation listed hereinafter and with the use and maintenance
instructions hereto.
Carefully read ALL the following regulations and the instructions herewith attached
before starting any operation.
Carefully ensure that the operator and the foreman using the machine are fully aware of
all 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 authorized operator in any case will not have to disregard the basic safety rules 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 1,5 metres
around the operator)
Do not replace the control system and do not replace parts with non original spare
parts, and do not project violent water squirts on the machine
Keep the hands away from hot and sharpened parts.
G.B.C. Industrial Tools S.p.A. remarks that for any non specified circumstances it is
necessary to obtain the authorization of the manufacturer.
SAFETY PRESCRIPTIONS
SAFETY PRESCRIPTIONS
SAFETY PRESCRIPTIONS

8
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
TRANSPORT RECOMMENDATIONS
Weight of the Machine kg 95
Shipping Dimensions mm 95x65x75
Shipping Weight kg 100
No lifting devices are required under 25 Kgs.
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 explanations.
Using properly the safety gear entails the only risks to be generated by the user’s
system and not by inborn defects of our machines.

9
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
THE MACHINE SHOULD BE OPERATED ONLY BY SPECIALIZED 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
INTENDED USE OF THE MACHINE
INTENDED USE OF THE MACHINE
INTENDED USE OF THE MACHINE
The machine shown in the
drawing is intended to be
used for prepping plates
for the welding.
It works while applied and
and locked on both sides of
the plate.
The bevel is obtained by a
low speed moving toothed
grinding wheel which en-
gages the plate and bevels
it while rotating

10
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
TECHNICAL DATA
Electrical Power System Volt/Hz/Phase 380 / 50 / 3
Bevelling Speed m/min 2,6
Electric Motor Power Kw 2,2
Plate Thickness mm (inches) 6-40 (0,23-1,57)
Std Bevelling Angle - 30°
Plate Minimum Length Mm (inches) 60 (2,36)
Machine Weight Kg. 65
MACHINE DIMENSION
A mm 416
B mm 426
C mm 530
OPTIONALS AVAILABLE ON REQUEST
Different Voltage
Roller Kit for bevelling angles 35° - 37°30’ - 45°
Milling Tools For Stainless Steel

11
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629

12
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
MACHINE STANDARD EQUIPMENT
MACHINE STANDARD EQUIPMENT
MACHINE STANDARD EQUIPMENT
The machine is supplied with:
22-24 mm wrench
Allen Key
Instruction Manual And Exploded Drawings
Plate Bevelling Machine Service Tools
Instruction Manual And Exploded
Drawings

13
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
MACHINE STABILITY
MACHINE STABILITY
MACHINE STABILITY
Considering the mass of the machine no particular problem has been detected in regard to
the operator safety.
WORKPLACE
WORKPLACE
WORKPLACE
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 –
EMERGENCY STOP
EMERGENCY STOP
EMERGENCY STOP
The Emergency Stop Button is located on the Control Panel of the machine as shown
ini the below picture.

14
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
MACHINE SETUP
MACHINE SETUP
MACHINE SETUP
Ensure the knob “A” is positioned on “0” and that the button “B” is NOT engaged. Now plug the machine to
the electric power supply.
Move the selector “A” on the position “1” or “2”. Press the button “B” and verify the direction of rotation of
the milling tool.
Should the direction be counter-clockwise you will need to rotate the selector on the correct position.
Turn off the machine with the emergency red button.
WARNING!
In order to bevel the plate correctly, the milling tool shall always rotate CLOCKWISE.
CONTROL PANEL

15
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
The plate shall always be feeded into the machine from right to left.
The machine is delivered with a standard bevelling angle of 30°

16
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
Measure the exact thickness of the plate you need to bevel and the length of the diagonal bevel you want
to obtain.
The formula written below will give you the number to set on the vernier of the machine
S - L = X
S = WALL THICKNESS
L = BEVEL LENGTH
X = RESULT (To be set on the vernier)

17
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
Example
S - L = X
S = Wall Thickness = 20
L = Bevel Length = 10
X = 20 - 10 = 10
The vernier setting is achievable by loosing the
nut on the roller kit Now act on the regulation screw to move
up or down the mobile part.

18
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
Press the button lever upwards to actuate the machine.
WARNING!
You will need to apply a constant pressure on the lever.
PLATE BEVELING
PLATE BEVELING
PLATE BEVELING
Set the bevel
angle only whan
the machine is
turned off. Adjust the roller plate
using a small plate ha-
ving the same thickness
of the plate you are
going to work on.
Hoist the machine with a security cable and
position it at the same height of the plate.
Connect the plug.
Turn on the machine
with teh start button
“B”.
Push the machine towards the plate until
the milling tools begins the bevel.
Now let the machine run by itself along the
plate.

19
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
SHORT PLATE BEVELING
SHORT PLATE BEVELING
SHORT PLATE BEVELING
Secure the machine over a steady
base at head height.
Set the bevel an-
gle only whan the
machine is turned
off.
Adjust the roller plate using a small
plate having the same thickness of
the plate you are going to work on.
WARNING!
The plate must be in straight line with the roller
and the roller case must touch it as shown in the
picture.
Connect the plug.

20
CHALLENGE 12
Original Instructions—rev.2011—in compliance with the paragraph 1.7.4 of the Machinery
Directive 2006/42/CE
G.B.C. Industrial Tools S.p.A.
Via Artigiani,17 –25030 Torbiato di Adro (Bs) –Italia –Tel. + 39 030 7451154 –Fax. + 39 030 73 56 629
Move the selector “A” on the position “1” or “2”. Press the button “B” and verify the direction of
rotation of the milling tool.
Should the direction be counter-clockwise you will need to rotate the selector on the correct position.
Turn off the machine with the emergency red button.
WARNING!
BE VERY CAREFUL WHERE YOU HOLD YOUR HANDS.
NO! YES !
Now place the plate in correspondence of the milling tool and push it into the machine.