G.B.C MINI K LEVER User manual

INSTRUCTION MANUAL
Versione 01 . 2016
MINI K LEVER
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
MINI K LEVER
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
Indice
Presentation of the company and introduction to the Instruction Manual 3
Warranty General Clauses 4
Intended Use Of The Machine 5
Technical Data 6
MINI K A LEVER Models 7
Machine Standard Equipment 10
Optional Equipment 11
Safety Prescriptions 12
Shipping Details 13
Machine Stability 14
Workplace 14
Emergency Stop Installation Exemption 14
Machine Setup For Beveling 15
Use Instructions 20
Mini K Lever Removal Operation 22
Reduced Shaft Kit Assembly 23
Shaft Assembly with Automatic Locking Device 30
Elbow Shaft Kit Assembly 39
Pneumatic Locking Device Assembly 46
Converting The Machine From Pneumatic to Electric 54
Ordinary Maintenance 58
Troubleshooting And Acoustic Emissions 59

3
MINI K LEVER
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. 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 operating the General Manage-
ment, the sales de-department, as well as the main workshop and the shipping department.
QUALITY STANDARD—All our machines are assembled according to the highest quality standard. Since
1996 G.B.C. Industrial 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 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 these numbers:
Tel. +39 - 030 -7451154
Fax +39 - 030 – 7356629

4
MINI K LEVER
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 conformity 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 imputable 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 Tools
S.p.a.
And its Maintenance Service, hereinafter called MSS, will remedy this inconvenient free of charge ,
both for handwork and for eventual replaced parts, except when the malfunction is directly or indi-
rectly imputable to misuse or alteration. In any case the machine must not be disas-sembled or al-
tered 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 notification
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 product 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 recognized
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 caused by a mis-
use of materials, power supply, negligence, unauthorized modifications, atmospheric 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. Industrial Tools S.p.A. reserves the
right to modify and to improve its products without any obligation to modify equipment and compo-
nents already supplied. Nobody is authorized to modify the conditions 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
MINI K LEVER
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 Mini K Lever is used
for beveling pipe ends pre-
paring them for the subse-
quent welding.
The Mini K Lever has to be
locked in the pipes ID
The bevel is obtained by
bevelling tools of various
shape and materials, de-
pending by the type of fin-
ishing required and by the
nature of the material to be
beveled.
THE MACHINE SHOULD BE USED ONLY BY SPECIALIZED OPERATORS WHO HAVE
BEEN DULY TRAINED ON THE UNIT.
FOLLOWING TO A SPECIFIC FORMATION THERE IS NO REASONABLY PREDICTALBE
MISUSE OF THE UNIT

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MINI K LEVER
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 FEATURES
PNEUMATIC ELECTRIC
ID Locking range mm (inches) 20 - 42 (0.78-1.65) 20 - 42 (0.78-1.65)
Idle Speed gg/min (Rpm) 180 305
Max Chuck Torque Nm (Nm) 6 (6 bar)/18 (8 bar) 17
Axial Feeding mm (inches) 20 (0.78) 20 (0.78)
Pneumatic Motor Power Hp (W) 0.59 (435)
Air Consumption Nl/min (cfm) 615 (21.7)
Air Pressure Bar (psi) 6 ÷ 8 (87 ÷ 116)
Air Hose Connection Pollici (inches) 1/2” (1/2”)
Electric Motor Power W720
Tension Volt 110 / 230
Frequency Hz 50 / 60
Max Acoustic Emission Db 75 75
Machine Weight Kg 4.8 5.5
MACHINE DIMENSION
PNEUMATIC ELECTRIC
Amm (inches) 365 (14.37) 450 (17.71)
Bmm (inches) 300 (11.81) 300 (11.81)
Ø C mm (inches) 67 (2.63) 67 (2.63)
Ø C (Optional) mm (inches) 60 (2.36) 60 (2.36)

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MINI K LEVER
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
MINI K LEVER PNEUMATIC

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MINI K LEVER
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
MINI K LEVER ELECTRIC

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MINI K LEVER
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
MINI K LEVER “PLD”
“PNEUMATIC LOCKING DEVICE”
Modelli della serie MINI K A LEVA

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MINI K LEVER
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 is supplied inclusive of the following equipment:
• Series of locking jaws from 20 to 42 mm (One set is already mounted on the unit)
• 3 mm Allen Key
• 14-17mm wrench
• Machine Case
• Instruction Manual And Exploded Drawings
Machine Case
Mini K Lever
Service Tools
Instruction Manual And Exploded
Drawings

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MINI K LEVER
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
INTERCHANGEABLE REDUCED SHAFTD FOR ID PIPES FROM 12,5mm to
21mm.
INTERCHANGEABLE ELBOW SHAFTS FOR CURVED ID PIPES FROM
25mm to 51mm.
OP- TIONAL

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MINI K LEVER
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 mainte-
nance 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.

13
MINI K LEVER
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
SHIPPING DETAILS
Model
Pneu. Elet.
Weight of the Machine kg 65
Shipping Dimensions mm
370x430x120 370x480x120
Shipping Weight kg 12 11
Under 25 Kgs no lifting machines are required.
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.
Proper use of the safety gear entails the only risks to be generated by the user’s
system and not by inborn defects of our machines.

14
MINI K LEVER
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
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 exempt to have this feature.

15
MINI K LEVER
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
Unscrew the VANE ABUTMENT CAP and remove it.
Screw the VANE ABUTMENT NUT for the full stroke

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MINI K LEVER
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
WARNING!!!! DO NOT MOVE THE EXPANSION SHAFT!!!!
You will be able to move it by acting on the VANE EXPANSION NUT only
AFTER the docking jaws have been put back in position.
Remove the three LOCKING JAWS previously mounted.

17
MINI K LEVER
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
Select the LOCKING JAWS according to the diameter of the pipe and install them on the
expansion shaft as shown in the picture.
While holding the three LOCKING JAWS you have just mounted, unscrew the VANE E-XPANSION
NUT in order to let them enter their seat. If the procedure is correctly made the locking jaws should have a
small backlash.

18
MINI K LEVER
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
Put back the VANE EXPANSION NUT and torque ir.
While keeping the machine in axis with the pipe, insert the SHAFT in the pipe (about 15-20mm)
Firmly screw clockwise the VANE EXPANSION NUT.
This will cause the expansion of the locking jaws and will have the machine to achieve a stable grip.

19
MINI K LEVER
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
Select the BEVELING TOOL according to the required finishing and place it on any of the CHUCK slots
locking it with the two grub screws by using the Allen key .
Using two beveling tools simultaneously (placed opposite to each other as shown below) will help preserving
their life.
The remaining free slots can be used for a facing tool and an ID beveling tool if necessary.
TOOL
CORRECT POSITIONING
TOOL
WRONG POSITIONING

20
MINI K LEVER
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
To start the machine, push the black security lever forward/up and press the metal lever
WARNING!!!!
The starting mechanism is a “Dead Man Switch” therefore it requires a constant push by the
operator.
Releasing the lever will stop the machine immediately.
Connect the machine to the AIR HOSE.