G.B.C SUPERMAXI 7-24 User manual

SUPERMAXI 7-24
INSTRUCTION MANUAL
V. 01 . 2016
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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
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 advices 11
Machine Stability 12
Workplace 12
Emergency Stop Installation Exemption 12
Machine Setup For Bevelling 13
Tools Setup 17
Drive Kit Replacement 20
24” Extension Kit Installation 23
Ordinary maintenance 26
Troubleshooting and Acoustic Emissions 28

3
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
G.B.C. Industrial Tools S.p.A. is known worldwide for the quality of its machines and ac-
cessories for pipe cutting and bevelling procedures of any sort and plate bevelling ma-
chines..
The Headquarters are located in Cazzago San Martino (BS) where are currently operating the
General Management, the sales de-department, as well as the main workshop and the ship-
ping 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
modifications 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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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
charge , 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
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.
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 men-
tioned warranty clauses.

5
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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
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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
MACHINE DIMENSIONS
PNEUMATIC HYDRAULIC ELECTRIC
Ø A mm 550 (630 opt.) 550 (630 opt.) 550 (630 opt.)
Bmm 880 830 800
TECHNICAL DATA
PNEUMATIC HYDRAULIC ELECTRIC
ID Locking Range
180-504
(7.08-19.84)
180-504
(7.08-19.84)
180-504
(7.08-19.84)
Mm
(inches)
Idle Speed 11 14 10gg/min (Rpm)
Max Chuck Torque
1342 (6bar)
2508 (8bar)
2709 1640Nm (Nm)
Stroke 50 (1.96) 50 (1.96) 50 (1.96)Mm (inches)
Pneumatic Motor Power 4.2 (3100) - -Hp (W)
Air Consumption 2800 (99) - -Nl/min (cfm)
Air Pressure 6 ÷ 8 (87-116)) - -Bar (psi)
Air Hose Connection 3/4” (3/4”) - -Pollici (inches)
Hydraulic Motor Power - 4.76 (3500) -Hp (W)
Max GBC Power Pack Pressu-
re
- 130 (1885) -Bar (psi)
Oil Flow - 30 (1.05) -L/min (cfm)
Electric Motor Power - - 3,2 (2400)Hp (W)
Tension - - 110 / 230Volt
Frequency - 50 / 60Hz
Max Acoustic Emission 75 75 75Db
245 245 245Machine Weight Kg

7
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
Pneumatic
Hydraulic
Electric

8
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
The machine is supplied with :
• Locking jaws complete kit from 180 to 504 mm one measure of which is already mounted on the
unit;
• 5 mm Allen Key
• 6 mm Allen Key
• 12 mm Long Allen Key
• Tx 20 Screwdriver
• 38 mm Wrench
• Wooden Case
• Instruction Manual And Exploded Drawings.
SM7_24 Service Tools
Wooden Case Instruction Manual And Exploded
Drawings

9
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
24” EXTENSION KIT FOR
WEDGE LOCKING TOOLS
24” EXTENSION KIT FOR
STANDARD TOOLS

10
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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.

11
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
Weight of the Machine kg 245
Shipping Dimensions mm 1100x980x900
Shipping Weight kg 350
Al di sotto dei 25 Kg non sono richiesti mezzi di sollevamento diversi dalla forza umana di
un unico operatore
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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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.

13
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
The machine can be moved closer to the pipe or away from the pipe by turning the handwheel .
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.

17
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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.

18
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – 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.
CORRECT position.

20
SUPERMAXI 7-24
Original Instructions - Rev.1 - 2016 - In compliance with the paragraph 1.7.4 of the Machinery 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 – Fax. + 39 030 73 56 629
Remove the 4 screws and washers as shown in the above picture.
Pull out the drive kit.