G.B.C BOILER K User manual

BOILER K
INSTRUCTION MANUAL
G.B.C. Industrial Tools S.p.A.
Via Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Versione 02 . 2016
Range Ø 28 / 76 mm (1,10” — 2,99”)

2
BOILER K
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 Sandro Pertini 41/43 – 25065 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
Reduced Shaft Kit Assembly 20
Elbow Shaft Kit Assembly 30
Pneumatic Locking System Assembly 39
Reduced Shafts Kit with Pneumatic Locking System assembly procedure 48
Converting The Machine From Pneumatic to Electric 58
Ordinary Maintenance 60
Troubleshooting And Acoustic Emissions 61

3
BOILER K
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 Sandro Pertini 41/43 – 25065 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
Management, 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
modification 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
G

4
BOILER K
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 Sandro Pertini 41/43 – 25065 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 direct-
ly or indirectly imputable to misuse or alteration. In any case the machine must not be disassem-
bled 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 product
are at user’s charge. Any warranty repair or extraordinary repair must be executed by G.B.C. In-
dustrial 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
BOILER K
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 Sandro Pertini 41/43 – 25065 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 PREDIC-
TALBE 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 inserted and
locked into the ID of the
pipe.
The bevel is obtained by
bevelling tools of various
shape and materials, de-
pending by the nature of
the material to be bevelled.

6
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
TECHNICAL DATA
PNEUMATIC ELECTRIC BATTERY
ID Locking Range mm (inches)
28 - 76
(1.10-2.99)
28 - 76
(1.10-2.99)
28 - 76
(1.10-2.99)
Idle Speed gg/min (Rpm) 107 74 44
Torque Nm (Nm)
27 (6 bar)
82 (8 bar)
124 116
Feeding Stroke mm (inches) 40 (1.57) 40 (1.57) 40 (1.57)
Pneumatic Motor Power Hp (W) 1.07 (800)
Air Consumption Nl/min (cfm) 1000 (35.31)
Air Pressure Bar (psi) 6 ÷ 8 (87 ÷ 116)
Air Hose Connection Pollici (inches) 1/2” (1/2”)
Electric Motor Power W1300 720
Tension Volt 110 / 230 18V 4.0 Ah
Frequency Hz 50
Maximum Acoustic Emission Db 75 75 75
Machine Weight Kg 899
MACHINE DIMENSION
PNEUMATIC PN. + LOCK ELECTRIC BATTERY
Amm (inches) 400 (15.74) 400 (15.74) 450 (17.71) 450 (17.71)
Bmm (inches) 395 (15.55) 575 (22.63) 395 (15.55) 395 (15.55)
Ø C mm (inches) 80 (2.03) 80 (2.03) 80 (2.03) 80 (2.03)

7
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
BOILER K
BOILER K “ E”
BOILER K “ with autolock”

8
BOILER K
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 Sandro Pertini 41/43 – 25065 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 28 to 76 mm one measure of which is already mounted on the unit
• 4 mm Allen Key
• 24 mm Double Ended Hexagon Tubular Socket Wrench
• 19 mm wrench
• Case
• Instruction Manual And Exploded Drawings
Pipe Beveling Machine Service Tools
Case Instruction Manual And Exploded
Drawings

9
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
INTERCHANGEABLE REDUCED SHAFTD FOR ID PIPES FROM 20mm to 30mm.
INTERCHANGEABLE ELBOW SHAFTS FOR CURVED ID PIPES FROM
46mm to 79mm.

10
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
.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 regulating
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.
alle caratteristiche specificate nel manuale G.B.C.
alle caratteristiche specificate nel manuale G.B.C.
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
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
TRANSPORT RECOMMENDATIONS
Weight of the Machine kg 12
Shipping Dimensions mm
670x480x240
Shipping Weight kg 24
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.
Using properly the safety gear entails the only risks to be generated by the user’s system and not by inborn de-
fects of our machines.

12
BOILER K
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 Sandro Pertini 41/43 – 25065 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
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Ensure the vane expansion nut is not abutted, then unscrew the vane abutment cap, and the vane abutment
bush.
WARNINIG : DO NOT MOVE THE EXPANSION SHAFT!
The expansion shaft can be moved by the vane expansion nut after having replaced the
locking jaws.
Remove the locking jaws you want to replace

14
BOILER K
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 Sandro Pertini 41/43 – 25065 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 little play.

15
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Screw back on clockwise the vane expansion bush all way down and then the vane expansion nut.
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.

16
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Select the BEVELLING TOOL in regard to the bevel you need to perform and insert it on the CHUCK locking
it with the two grub screws by using the Allen key .
You will want to use two paired cutting tools and one facing tools when required.

17
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Connect the machine to the air hose.
Press the button lever upwards to actuate the machine.
WARNING!
You will need to apply a constant pressure on the lever.

18
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
The machine feeding is actuated by turning the hand wheel clockwise as shown in the picture.
Maintain a constant and continuous action to obtain a uniform feeding.
The motor will automatically stop by releasing the lever.

19
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
WARNING! DURING THE OPERATIONS PAY ATTENTION NOT TO TOUCH THE LOCKING JAWS
WITH THE TOOLS AS THESE MAY GET DAMAGED.
12
REMOVING THE MACHINE FROM THE PIPE:
1. Unscrew the vane expansion nut using the wrench supplied with the machine.
2. Remove the machine.

20
BOILER K
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 Sandro Pertini 41/43 – 25065 Cazzago San Martino (Bs) – Italia – Tel. + 39 030 7451154 – Fax. + 39 030 73 56 629
Unscrew the vane abutment cap and the vane abutment bush counter clockwise.
Remove the locking jaws.