G.B.C HYPERMAXI 20 User manual

HYPERMAXI 20_40
INSTRUCTION MANUAL
Versione 01 . 2017
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

2
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
Index
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 recommendations 11
Machine stability 12
Workplace 12
Emergency stop installation exemption 12
Machine setup for beveling 13
Wedge locking tools setup 17
Standard tools setup 19
Drive kit replacement 20
Installation of the hydraulic feeding device 24
Installation of the pneumatic feeding device 27
Copie tool holders 30
Ordinary maintenance 34
Troubleshooting and acoustic emission 36

3
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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 Cazzago San Martino (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 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 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 machi-
nes 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 these numbers:
Tel. +39 - 030 -7451154
Fax +39 - 030 –7356629

4
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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 pe-
riod 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. Industrial
Tools S.p.a.
In case of any operational malfunction arising during the warranty period, G.B.C. Industrial To-
ols 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 connected 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. 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 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 men-
tioned warranty clauses.
WARRANTY GENERAL CLAUSES
WARRANTY GENERAL CLAUSES
WARRANTY GENERAL CLAUSES

5
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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 PRE-
DICTALBE 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
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 bevelling
tools of various shape and materi-
als, depending by the nature of the
material to be bevelled.

6
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
TECHNICAL DATA
PNEUMATIC HYDRAULIC
ID Locking Range mm
(inches)
465-997
(18.30-39.25)
465-997
(18.30-39.25)
OD workable Range mm
(inches)
508-1016
(20-40)
508-1016
(20-40)
Idle Speed gg/min (Rpm) 6 14
Stroke Mm (inches) 100 (3.93) 100 (3.93)
Pneumatic Motor Power Hp (W) 4.21 (3100) -
Max Torque Nm 2492 (6bar)
4658 (8bar) 6200
Air Consumption Nl/min (cfm) 2800 (99) -
Air Pressure Bar (psi) 6 ÷ 8 (87÷116) -
Air Hose Connection Pollici (inches) 3/4” (3/4”) -
Hydraulic Motor Power Hp (W) - 12.92 (9500)
Hydraulic Unit Max Pressure Bar (psi) - 140 (2030)
Oil Flow L/min (cfm) - 64 (14.1)
Max Acoustic Emission Db 75 75
Machine Weight Kg 870 870

7
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
MACHINE CONFIGURATION MODELS
MACHINE CONFIGURATION MODELS
MACHINE CONFIGURATION MODELS
Pneumatic
Hydraulic

8
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
MACHINE STANDARD EQUIPMENT
MACHINE STANDARD EQUIPMENT
MACHINE STANDARD EQUIPMENT
The machine is supplied with :
 Serts of locking jaws from 465 to 997 mm
 5 mm Allen Key
 6 mm Allen Key
 10 mm Long Allen Key
 Tx20 Screwdriver
 38 mm Open Ended Wrench
 Wooden Box
 Instruction Manual and Drawings
Hypermaxi20_40 Service Tools
Wooden Box Instruction Manual and Drawings

9
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
OPTIONAL EQUIPMENT
OPTIONAL EQUIPMENT
OPTIONAL EQUIPMENT
PNEUMATIC AUTOMATIC FEEDING DEVICE
HYDRAULIC AUTOMATIC FEEDING DEVICE
COPIER TOOL HOLDER
EXTENSION KIT 40‖

10
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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 neces-
sary to obtain the authorization of the manufacturer.
SAFETY
SAFETY
SAFETY PRESCRIPTIONS
PRESCRIPTIONS
PRESCRIPTIONS

11
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
TRANSPORT RECOMMENDATIONS
TRANSPORT RECOMMENDATIONS
TRANSPORT RECOMMENDATIONS
Weight of the Machine kg 870
Shipping Dimensions mm 1180 x 1650 x 1670
Shipping Weight kg 990
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.

12
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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 INSTA
EMERGENCY STOP INSTA
EMERGENCY STOP INSTALLATION EXEMPTION
LLATION EXEMPTION
LLATION EXEMPTION
As provided for the paragraph 1.2.4.3. of the attachment 1 of the Machinery Direc-
tive, portable machines are exempt to have this feature.

13
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
MACHINE SETUP
MACHINE SETUP
MACHINE SETUP FOR
FOR
FOR BEVELING
BEVELING
BEVELING
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.

14
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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.

15
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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

16
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
The machine can be moved closer to the pipe or away from the pipe by turning the hand wheel .
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.
Position the tool holder plates according to the above drawings.
Pipes from 20” to 28” Pipes from 28” to 36”

17
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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.
WEDGE LOCKING TOOLS SETUP
WEDGE LOCKING TOOLS SETUP
WEDGE LOCKING TOOLS SETUP

18
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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.

19
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
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.
STANDARD TOOLS SETUP
STANDARD TOOLS SETUP
STANDARD TOOLS SETUP
CORRECT position.

20
HYPERMAXI 20_40
Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 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
DRIVE
DRIVE
DRIVE KIT
KIT
KIT REPLACEMENT
REPLACEMENT
REPLACEMENT
Remove the 6 screws and washers as shown in the above picture.
Pull out the drive kit.