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G.B.C MINI K LEVER Instruction Manual

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INSTRUCTION MANUAL
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

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Summary of Contents for G.B.C MINI K LEVER

  • Page 1 INSTRUCTION MANUAL 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...
  • Page 2 Machine Stability Workplace Emergency Stop Installation Exemption Machine Setup For Beveling Use Instructions Mini K Lever Removal Operation Reduced Shaft Kit Assembly Shaft Assembly with Automatic Locking Device Elbow Shaft Kit Assembly Pneumatic Locking Device Assembly Converting The Machine From Pneumatic to Electric...
  • Page 3 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.
  • Page 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. 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.
  • Page 5 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-...

  • Page 6: Technical Features

    MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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) Max Chuck Torque Nm (Nm) 6 (6 bar)/18 (8 bar)
  • Page 7 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE MINI K LEVER PNEUMATIC 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...
  • Page 8 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE MINI K LEVER ELECTRIC 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...
  • Page 9 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Modelli della serie MINI K A LEVA MINI K LEVER “PLD” “PNEUMATIC LOCKING DEVICE” 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...

  • Page 10: Service Tools

    MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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) •...
  • Page 11 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE TIONAL INTERCHANGEABLE REDUCED SHAFTD FOR ID PIPES FROM 12,5mm to 21mm. INTERCHANGEABLE ELBOW SHAFTS FOR CURVED ID PIPES FROM 25mm to 51mm. 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...
  • Page 12 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. 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.

  • Page 13: Shipping Details

    MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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. 1. Always wear gloves and goggles during every operation 2.
  • Page 14 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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 –...
  • Page 15 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Unscrew the VANE ABUTMENT CAP and remove it. Screw the VANE ABUTMENT NUT for the full stroke 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...
  • Page 16 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the three LOCKING JAWS previously mounted. 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.
  • Page 17 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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.
  • Page 18 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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.
  • Page 19 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE 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 .
  • Page 20 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Connect the machine to the AIR HOSE. 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.
  • Page 21 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE The feeding of the machine is actuated by a LEVER. After you have started the motor push the LEVER as shown below and try to maintain a constant push in order to keep the machine working until you have reached the desired finishing.
  • Page 22 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Once the beveling operations are completed, turn counter-clockwise the VANE EXPANSION NUT using the spanner to withdraw the locking jaws and the machine will lose it grip. G.B.C. Industrial Tools S.p.A.
  • Page 23 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Unscrew the vane abutment cap and the VANE ABUTMENT CAP counter-clockwise. Screw the VANE EXPANSION NUT until it is abutted. 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...
  • Page 24 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the LOCKING JAWS By using LONG NOSE PLIERS unscrew the EXPANSION SHAFT with a clockwise rotation until it comes out. 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...
  • Page 25 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Pull the FEEDING LEVER backwards in order to expose the ø20mm HEAD of the GUIDING SHAFT as much as possible as shown below. Unscrew the ø20mm HEAD of the GUIDING SHAFT using the spanner on the flats as shown be- low.
  • Page 26 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Select the desired REDUCED HEAD and screw it on the EXTENSION with a counter-clockwise movement as shown below. Insert the REDUCED EXPANSION SHAFT and slide it inside the REDUCED HEAD.
  • Page 27 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Using a screwdriver screw the REDUCED EXPANSION SHAFT that can be reached passing through the HEXAGONAL EXPANSION NUT. Turn until the TIP of the REDUCED EXPANSION SHAFT reaches a distance of about 7.20mm from the internal side of the HEAD as shown below.
  • Page 28 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Rotate the REDUCED EXPANSION SHAFT until the flat cut on its side is in line with the hole located on the HEAD and insert the ELASTIC PIN that will act as a feeding end stop.
  • Page 29 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Select the THREE LOCKING JAWS and insert them in the seats, then apply the RINGS making sure to fix them right in the grooves of the shaft as shown in the picture.
  • Page 30 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Unscrew the VANE EXPANSION CAP and remove it. Supply air to the PLD. Keep your hand arounf the LOCKING JAWS and move the RED LEVER either up or down so that the EXPANSION SHAFT moves back inside the GUIDING SHAFT.
  • Page 31 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the THREE LOCKING JAWS. Unscrew the two GRUB SCREWS located in the rear STEM of the locking device. Using LONG NOSE PLIERS, rotate the EXPANSION SHAFT clockwise until you can remove it.
  • Page 32 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Loose the ABUTMENT NUT rotating it clockwise. Unscrew and remove the PNEUMATIC LOCKING DEVICE 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...
  • Page 33 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Pull the FEEDING LEVER backwards in order to expose the ø20mm HEAD of the GUIDING SHAFT as much as possible as shown below. Unscrew the ø20mm HEAD of the GUIDING SHAFT using the spanner on the flats as shown be- low.
  • Page 34 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Select the desired REDUCED HEAD and screw it on the EXTENSION with a counter-clockwise movement as shown below. Screw the ABUTMENT NUT and the PNEUMATIC LOCKING DEVICE all the way.
  • Page 35 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the REDUCED EXPANSION SHAFT and slide it inside the REDUCED HEAD. Using a screwdriver screw the REDUCED EXPANSION SHAFT that can be reached passing through the HEXAGONAL EXPANSION NUT.
  • Page 36 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the 4 screws and the REAR PLATE of the PLD, inserit the STROKE LIMITER as shown below.. N.B. Put the REAR PLATE back paying particular attention not to damage its seals and the seal located inside the CYLINDRICAL CHAMBER of the PLD.
  • Page 37 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Reassemble the LONG PIN, the SHORT PIN and the GRUB SCREW. 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...
  • Page 38 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Select the THREE LOCKING JAWS and insert them in the seats, then apply the RINGS making sure to fix them right in the grooves of the shaft as shown in the picture.
  • Page 39 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the VANE EXPANSION CAP. Screw the VANE EXPANSION NUT for all the feeding. 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...
  • Page 40 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the three LOCKING JAWS from the shaft. Helping yourself with LONG NOSE PLIERS rotate clockwise the EXPANSION SHAFT until it comes out. 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...
  • Page 41 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Pull the FEEDING LEVER backwards in order to expose the ø20mm HEAD of the GUIDING SHAFT as much as possible as shown below. Unscrew the ø20mm HEAD of the GUIDING SHAFT using the spanner on the flats as shown be- low.
  • Page 42 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Pull out the TOOL ABUTMENT BUSH. Replace it with the TOOL ABUTMENT BUSH supplied as par t of the ELBOW SHAFT ASSEMBLY and make sure to install it in the proper way as shown below.
  • Page 43 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the e ed avvitare in senso anti orario la SPECIAL HEAD FOR ELBOWS and screw it with a clockwise rotation to the GUIDING SHAFT EXTENSION. The assembly includes two heads : ø25mm and ø35mm.
  • Page 44 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the VANE EXPANSION SHAFT supplied with the ELBOW SHAFT ASSEMBLY and insert it inside the HEAD . screwing it with a flat head screwdriver inserted in the rear end as shown below, until the keyhole located on the VANE EXPANSION SHAFT can is detected looking through the hole of the END STOP SCREW.
  • Page 45 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the three SPRINGS in their seats located at the base of the LOCK- ING JAW SPRING Install the LOCKING JAWS in their seat, matching the hole at their bottom...
  • Page 46 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Unscrew the VANE EXPANSION CAP and remove it. Screw the VANE EXPANSION NUT for the whole stroke. 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...
  • Page 47 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the LOCKING JAWS. Helping yourself with LONG NOSE PLIERS, rotate the EXPANSION SHAFT clockwise until it comes out. 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...
  • Page 48 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Screw the ABUTMENT NUT all the way down and then screw the PNEUMATIC LOC- KING DEVICE making sure the two parts are abutted. 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...
  • Page 49 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Unscrew the nipple and install the air connector supplied with the kit. 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...
  • Page 50 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Connect the air supply tube. After having supplied the pneumatic locking device with air, move the lever downward or upward to move the locking piston forward. G.B.C. Industrial Tools S.p.A.
  • Page 51 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Slide the VANE EXPANSION SHAFT inside the GUIDING SHAFT and screw it counter- clockwise until it is about 2mm inside. Align the LOCKING JAW GROOVES as shown in the picture.
  • Page 52 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the desired LOCKING JAWS. After having supplied the pneumatic locking device with air, keep the locking jaws pressed with your hand and move the lever upward or downward to get the expansion shaft withdrawn in the machine.
  • Page 53 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE In the rear part of the locking device you shall now insert the STEM, the GRUB SCREW and the GRUB SCREW COVER locking them in position tightly. Screw back on the VANE ABUTMENT CAP, now the machine is ready for use.
  • Page 54 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Remove the FOUR SCREWS paying attention to the washers. 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...
  • Page 55 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Impugnare il MOTORE dalla parte del corpo e tirarlo verso l’esterno facendolo con- temporaneamente ruotare fino ad estrarlo From the PNEUMATIC MOTOR you will have to remove the ELASTIC RING, and the SPACER, and the SUPPORT FLANGE G.B.C.
  • Page 56 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert the ELASTIC RING in the seat located on the reducer, then insert the SPACER and the SUPPORT FLANGE previously taken from the pneumatic motor. Insert the MACHINE BODY and the REDUCER with the SUPPORT FLANGE already mounted and fix it with the four screws previously removed.
  • Page 57 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE Insert and screw the ELECTRIC MOTOR ASSEMBLY on the end of the REDUCER protruding from the MACHINE BODY. (WARNING!! The thread is inverted, therefore you will have to screw by rotating COUN-...
  • Page 58 MINI K LEVER Istruzioni originali—rev.2011—in accordo al 1.7.4 della direttiva macchine 2006/42/CE It is advisable to perform a service c/o G.B.C. Industrial Tools S.p.A. premises every 400 hours working cycles. Verify the general conditions of the machine; • Always use the filter + lubricator when using pneumatic machines •...
  • Page 59 Always ask suggestions to your referent in G.B.C. as we are at your complete disposal. The acoustic emissions are within the maximum limits provided by the current Machinery Di- rective.