GBC BOILER 1-4 K User manual

BOILER 1-4 K
INSTRUCTION MANUAL
Versione 01 . 2016
Range Ø 23 / 108 mm (0,90” — 4,25”)
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
BOILER 1”-4” K
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 9
Optional Equipment 10
Safety Prescriptions 11
Transport recommendations 12
Machine Stability 13
Workplace 13
Emergency Stop Installation Exemption 13
Machine Setup For Beveling 14
Reduced Shaft Kit Assembly 21
Elbow Shaft Kit Assembly 29
Pneumatic Locking Device Assembly 38
Converting The Machine From Pneumatic to Electric 47
Ordinary Maintenance 49
Troubleshooting And Acoustic Emissions 50
EC Declaration 51
EC Label 52

3
BOILER 1”-4” K
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 the machines and accesso-
ries 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 department, as well as the main workshop and the shipping de-
partment.
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 ap-
ply for further 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 forbidden 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
Info: [email protected]

4
BOILER 1”-4” K
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 indirectly imputable to misuse or alteration. In any case the machine must not be
disassembled or altered before the shipment. The warranty is valid only when the warranty docu-
ment 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
notification of the defect and/or the claim and/or the request of technical assistance. On the con-
trary 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 ship-
men 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 misuse 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 obli-
gation to modify equipment and components 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.

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BOILER 1”-4” K
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
PREDICTALBE MISUSE OF THE UNIT
The machine shown in the
drawing is conceived for
beveling pipe ends and to
prep the for the subsequent
welding process.
It works gripped 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 beveled.

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BOILER 1”-4” K
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 ELECTRIC BATTERY
ID Locking Range mm (inches)
23 - 108
(0.9-4.25)
23 - 108
(0.9-4.25)
23 - 108
(0.9-4.25)
Idle Speed gg/min (Rpm) 87 74 44
Chuck Max Torque Nm
27 (6 bar)
82 (8 bar)
124 116
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 W- 1300 720
Tension Volt - 110 / 230 18V 4.0 Ah
Frequency Hz - 50
Max Acoustic Emission Db 75 75 75
Machine Weight Kg 910 10
MACHINE DIMENSIONS
PNEUMATIC PN. + LOCK ELECTRIC BATTERY
Amm (inches) 420 (16.14) 430 (15.53) 450 (17.71) 450 (17.71)
Bmm (inches) 425 (16.73) 575 (22.63) 425 (16.73) 425 (16.73)
Ø C (opt) mm (inches) 115 (4.52) 115 (4.52) 115 (4.52) 115 (4.52)
Ø D (opt) mm (inches) 80 (2.03) 80 (2.03) 80 (2.03) 80 (2.03)

7
BOILER 1”-4” K
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
BOILER 1”-4” KBOILER 1”-4” K “ E”
BOILER 1”-4” K “ With Autolock” BOILER 1”-4” K Ratchet

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BOILER 1”-4” K
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 with:
• Locking jaws complete kit from 23 to 108 mm one measure of which is already mounted on the unit
• 4 mm Allen Key
• 24 mm Double Ended Hexagon Tubular Socket Wrench
• 14-17 mm wrench
• Storage Case
• Instruction Manual And Exploded Drawings
Boiler 1-4 K Service Tools
Case Instruction Manual And Exploded
Drawings

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BOILER 1”-4” K
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 ELBOW SHAFTS FOR CURVED ID PIPES FROM
46mm to 103mm.

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BOILER 1”-4” K
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 here in after and with the use and mainte-
nance instructions hereto.
• Carefully read ALL the following regulations and the instructions here with 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 specifics
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 not 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 not specified circumstances it is
necessary to obtain the authorization of the manufacturer.

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BOILER 1”-4” K
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
Weight of the Machine kg 13
Shipping Dimensions mm 670x480x240
Shipping Weight kg 35
Under 25 Kgs no lifting machines are required.
1 Always wear protective gloves and eyewear.
2 Always disconnect the machine from the power source during the setup.
3 Always use both hands while operating the machine, one on the security
lever and one on the feeding hand wheel.
4 The Instruction Manual and the drawings will supply quick and easy ex-
planations.
Using properly the PPE entails the only risks to be generated by the user’s system and not by in born defects of
our machines.

12
BOILER 1”-4” K
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.

13
BOILER 1”-4” K
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
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

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BOILER 1”-4” K
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 EXPANSION 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 1”-4” K
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
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 1”-4” K
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 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 1”-4” K
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 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 1”-4” K
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 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 1”-4” K
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! DURING THE OPERTIONS 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 1”-4” K
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 the vane abutment bush counter clockwise.
Remove the locking jaws.