Orbitalum RPG 1.0 Guide

precision.
power.
simplicity.
Operating instructions
with spare parts list
Tube Squaring Machines
RPG 1.0 Cordless
(right-angled drive)
Code 790 036 762
│Maschine-no.:
________________________________

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Duplication and reproduction in any form (print, photocopy, microfilm or electronic) require the written
permission of Orbitalum Tools GmbH.

Operating instructions RPG 1.0 Cordless (right-angled drive) Table of contents
orbitalum tools gmbh
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Table of contents
Page
0About these instructions 1
0.1 Warning messages 1
0.2 Further symbols and displays 2
0.3 Abbreviations 2
1Notes on safety 3
1.1 Proper use 3
1.2 Safety regulations 3
1.3 Working with safety in mind 4
1.4 Waste disposal / environmental protection 4
1.5 Further safety regulations 5
2Design of the product 6
2.1 RPG 1.0 Cordless 6
2.2 RPG 1.0 Cordless right-angled drive 7
2.3 Accessories 8
2.3.1 Multifunctional tool (MFW) 8
2.3.2 One-piece clamping shells 8
2.3.3 Durable storage and shipping case 9
3Features and scope of application 10
3.1 Features 10
3.2 Scope of application 10
4Technical specifications 11
4.1 Rating 11
5Commissioning 12
5.1 Scope of delivery 12
5.2 Transport 13
6Operation 14
6.1 Preparation 14
6.2 Mounting the multifunctional tool (MFW) to the tool support 15
6.3 Inserting and replacing clamping shells 16
6.4 Mounting the tube 17
6.5 Machining tubes in a cramped working area 18
6.5.1 Adjusting the feed unit 18
6.5.2 Adjusting the release handle 19
6.6 Determining the speed 19
6.7 Machining the tube 20
6.7.1 Switching the machine on 21
6.7.2 Advancing the tool 21
7Maintenance 23
8What to do if ...? 24
8.1 Trouble shooting 24
8.2 Servicing/customer service 24
9Spare parts list 25

Table of contents Operating instructions RPG 1.0 Cordless (right-angled drive)
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9.1 RPG 1.0 Cordless 25
9.2 RPG 1.0 Cordless right-angled drive 26

Operating instructions RPG 1.0 Cordless (right-angled drive) 0 About these instructions
orbitalum tools gmbh
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0 About these instructions
To allow quick understanding of these instructions and safe handling of the
machine, all the warning messages, notes and symbols used in these
instructions are presented here along with their meaning.
0.1 Warning messages
In these instructions, warning messages are used to warn you against the
dangers of injury or material damage. Always read and observe these warning
messages!
This is a warning symbol. It should warn you against dangers
of injury.
Follow all instructions which are identified with this safety
symbol in order to avoid injuries or death.
Warning
symbol Meaning
DANGER
Direct danger!
Non-observance could result in death or critical injury.
:Restrictions (if applicable).
XMeasures to prevent danger.
WARNING
Possible danger!
Non-observance could result in serious injury.
:Restrictions (if applicable).
XMeasures to prevent danger.
ATTENTION
Dangerous situation!
Non-observance could result in minor injuries.
ATTENTION
Dangerous situation!
Non-observance could result in material damage.

0 About these instructions Operating instructions RPG 1.0 Cordless (right-angled drive)
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0.2 Further symbols and displays
Symbol Meaning
Important
Note
Notes: Contain particularly important information for
comprehension.
Instruction: You must take notice of this symbol.
1.
Request for action in a sequence of actions: You have to do
something here.
X
Single request for action: You have to do something here.
ZConditional request for action: You have to do something here
if the specified condition is met.
0.3 Abbreviations
Abbr. Meaning
RPG 1.0
Cordless
Tube Squaring Machine for tubes with an outer diameter of up
to 1.0 inches, equipped with a rechargeable accumulator
RPG 1.0
Cordless
right-angled
drive
Tube Squaring Machine for tubes with an outer diameter of up
to 1.0 inches, equipped with rechargeable accumulator and
with a right-angled drive.
MFW Multifunctional Tool

Operating instructions RPG 1.0 Cordless (right-angled drive) 1 Notes on safety
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1 Notes on safety
The Tube Squaring Machine Cordless and/or with right-angled drive (in the
following referred to as RPG 1.0) is a state-of-the-art machine. Using it for
purposes other than those described in this manual may cause injury to the
user or to others. The machine or other equipment may also be damaged.
Therefore:
•Always ensure that the machine is in good working condition, and always
comply with these notes on safety.
•Keep the complete documentation close by the machine.
•Generally valid regulations for the prevention of accidents must be
observed.
1.1 Proper use
•Use the RPG 1.0 exclusively for machining thin-walled tubes (see “Scope
of application”, chapter 3.2, p. 10).
•The user will be the only person liable for damages caused by improper
use.
1.2 Safety regulations
•Only use the dimensions and materials specified in this manual. Always
consult Orbitalum Tools after-sales service personnel before using other
materials.
•Read the enclosed safety notes completely and carefully before handling
the rechargeable accumulator and the battery charger.
•Only use original Orbitalum Tools spare parts and auxiliaries.
•Inspect the RPG 1.0 every day for visible signs of damage or defects.
Any damage or defect must be repaired immediately.
•Work on the electrical equipment may only be performed by a qualified
electrician.
•Disconnect the RPG 1.0 from power supply before changing the tools,
transport or carrying out maintenance and repair work and allow the
machine to come to a stop.

1 Notes on safety Operating instructions RPG 1.0 Cordless (right-angled drive)
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1.3 Working with safety in mind
"Make your contribution to safety in the workplace."
•Report any unusual behavior of the machine to the person in charge
immediately.
•Always work with safety in mind.
•Wear safety goggles and safety gloves when working with the RPG 1.0.
•Tie up long hair (snood-type cap); do not wear any wide clothing.
Attention: jewelry and ties can get caught by rotating parts.
•Make sure that the work piece has been clamped correctly.
•Switch off the RPG 1.0 after each working cycle and allow the machine to
come to a stop.
•Disconnect the RPG 1.0 from power supply before performing any
cleaning, maintenance or repair work and allow the machine to come to a
stop.
•Keep hands away from the tools during processing.
•Pay attention to the surroundings. Do not use any electric tools or
rechargeable batteries in a damp or wet area. Make sure to have good
illumination. Do not work near combustible liquids or gases.
1.4 Waste disposal / environmental protection
•Dispose of chips and used gear lubricant oil according to the regulations.
Discarded electric tools and accessories contain a large share of
valuable raw and synthetic materials which can be recycled.
Therefore:
•Electrical (electronic) devices which are marked with the symbol to the left,
may not be disposed of with household waste in accordance to the EU
directive 2002/96/EC.
•By actively using the offered return and collection systems, you actively
contribute to the reuse, recycling and utilization of electrical (electronic)
devices.
•Electrical (electronic) used devices contain parts which must be handled
selectively according to the EU directive. Separate collection and selective
treatment is the basis for environment-friendly disposal and the protection
of human health.
•Our products that were sold to you after August 13th, 2005 are taken back
and treated according to legal standards. These products have to be send
free of charge.
•The return of used devices which pose a health or safety risk for human
beings due to soiling during use may be refused.
(RL 2002/96/EC)

Operating instructions RPG 1.0 Cordless (right-angled drive) 1 Notes on safety
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•The legally compliant disposal of electrical (electronic) devices that were
placed on the market before August 13th, 2005 are in the responsibility of
the end-user.
•Batteries which are marked with the symbol on the left may not be
disposed of together with household waste according to the applicable EU
directive 91/157/EEC.
•With batteries containing hazardous substances, the chemical symbol for
the heavy metal content is indicated below the waste bin.
1.5 Further safety regulations
Observe the regulations, norms and guidelines specific to your country.
Cd

2 Design of the product Operating instructions RPG 1.0 Cordless (right-angled drive)
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2 Design of the product
2.1 RPG 1.0 Cordless
1 Rechargeable accumulator 6 Feed Unit
2 Housing with driving motor 7 ON/OFF switch / Speed controller
3 Switch for right-handed / left-handed 9 Tool support
rotation 10 Multifunctional tool (MFW)
4 Feed with scale ring
5 Release handle for fixing the
clamping shells
1
9
8
2
7
6
5
4
3

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2.2 RPG 1.0 Cordless right-angled drive
1 Rechargeable accumulator 6 Feed with scale ring
2 ON/OFF switch / Speed controller 7 Feed Unit
3 Switch for right-handed / left-handed 8 Release handle for fixing the
rotation clamping shells
4 Hoop guard / Carrying handle 9 Multifunctional tool (MFW)
5 Housing with driving motor 10 Tool support
8
1
3
2
4
5
6
7
9 10

2 Design of the product Operating instructions RPG 1.0 Cordless (right-angled drive)
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2.3 Accessories
2.3.1 Multifunctional tool (MFW)
Contained in the standard scope of delivery. Multifunctional tool with 2 cutting
edges and high-performance coating Futura®Balinit. Usable for all tool holders
of the RPG series.
Article For tube OD [mm] For tube OD [inch] Code-no.
MFW-P-2 3.18 – 25.4 0.125 – 1 790 038 314
Torx screw – – 790 086 220
2.3.2 One-piece clamping shells
Extreme durable. Ensures accurate centering and quick clamping shell change
without any tools. Not contained in the standard scope of delivery. Other
dimensions are available upon request.
Article For tube OD [mm] For tube OD [inch] Code-no.
3.18 0.125 790 036 201
6.35 0.250 790 036 202
9.53 0.375 790 036 203
10.00 0.394
790 036 204
12.00 0.472
790 036 205
12.70 0.500
790 036 206
17.20 0.677
790 036 207
19.05 0.750
790 036 208
21.30 0.839
790 036 209
One-piece clamping
shell
25.40 1.000
790 036 210
6.00 0.236
790 036 304
6.35 0.250
790 036 301
9.53 0.375
790 036 302
10.00 0.394
790 036 305
12.00 0.472
790 036 306
One-piece clamping
shell for micro fittings
12.70 0.500
790 036 303
Please check the outer diameter of the pipe before ordering the clamping shells.
The various standards sometimes mean a special outline dimension (in particular for
pipes in accordance with DIN2430).

Operating instructions RPG 1.0 Cordless (right-angled drive) 2 Design of the product
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2.3.3 Durable storage and shipping case
High-quality blue transportation case with insert. Very sturdy design. Already
included in the standard scope of delivery of the RPG 1.0 Cordless right-
angled drive.
Article Code-no.
Durable storage and shipping case 790 036 080

3 Features and scope of application Operating instructions RPG 1.0 Cordless (right-angled drive)
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3 Features and scope of application
3.1 Features
The RPG 1.0 is suitable for squaring tube ends made of metallic materials.
It has the following features:
•Tube end preparation for welds conforming to standards
•Only one multifunctional tool is needed for:
–different tube wall thicknesses (up to 2 mm/0.079 inches)
–different tube materials (exclusively ferritic materials)
•Multifunctional tool:
–cutting geometry adapted to application
–multi-cutting tool
–only one screw is needed to fix and secure the tools
–tool coating TiN
•Machine:
–hand-operated
•Drive with rechargeable accumulator
•Quick clamping system for tubes
•Quick change system for clamping shells
•Feed with scale ring:
–total: 10 mm (0.393 inches)
–per revolution: 1.5 mm (0.059 inches)
–per pitch line: 0.05 mm (0.002 inches)
•Feed unit twistable/detachable
•Release handle adjustable
3.2 Scope of application
OD [mm] [inch]
min. 3.18 0.125
max. 25.40 1.000
The maximum machinable wall thickness is 2 mm/0.079 inches.
High-alloy steels (high-grade steel, material no. 1.40... – 1.45... in accordance
with DIN 17 455 and DIN 17 456), unalloyed and low-alloy steels, aluminum,
others on request.
Working range
Tube materials

Operating instructions RPG 1.0 Cordless (right-angled drive) 4 Technical specifications
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4 Technical specifications
4.1 Rating
RPG 1.0 Cordless RPG 1.0 Cordless
right-angled drive
Dimensions 235 x 380 x 75 mm
9.25 x 15 x 3 inch
145 x 380 x 75 mm
5.7 x 15 x 3 inch
Total weight (with accumulator; without
clamping shells)
2.1 kg / 4.63 lbs 2.2 kg / 4.85 lbs
Voltage of rechargeable accumulator 12 V 12 V
Power supply of battery charger 220 – 240 V, 50/60 Hz 220 – 240 V, 50/60 Hz
Speed (max. idling speed) 0 – 400 min–1 (rpm) 0 – 350 min–1(rpm)
Noise level at the workplace Idle running: approx. 70 dB (A)
With load: approx. 85 dB (A)
Idle running: approx. 70 dB (A)
With load: approx. 85 dB (A)
Vibration level according to EN 50144 < 2.5 m/s² < 2.5 m/s²

5 Commissioning Operating instructions RPG 1.0 Cordless (right-angled drive)
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5 Commissioning
XCheck all parts of the delivery for completeness and transportation
damage.
XReport any missing parts or transportation damage to your supplier
immediately.
5.1 Scope of delivery
•1 Tube Squaring Machine RPG 1.0 Cordless / Cordless right-angled drive
•1 Durable storage and shipping case
•2 Rechargeable accumulators
•1 Battery charger
•1 Multifunctional tool
•1 Torx T-spanner for securing the multifunctional tools (T 15)
•1 Operating instructions with Spare parts list
•Operating instructions and safety notes for the battery charger
Subject to modifications
Checking the scope
of delivery

Operating instructions RPG 1.0 Cordless (right-angled drive) 5 Commissioning
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5.2 Transport
The RPG 1.0 is a portable machine. Special transportation aids are not required.
For safe transportation, hold the machine as shown in the illustrations below.
Transport RPG 1.0 Cordless Transport RPG 1.0 Cordless right-angled drive
Danger of injury by unintended restart of the machine
During transport, the ON/OFF switch could be actuated inadvertently so that
the machine is started.
XRemove the rechargeable accumulator before transportation or workplace
change.
DANGER

6 Operation Operating instructions RPG 1.0 Cordless (right-angled drive)
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6 Operation
As the usage of both versions of the tube facing machine is identical, the
pictures shown in this chapter solely represent the essential working steps
using the RPG 1.0 cordless version.
Danger of injury by unintended restart of the machine
XRemove the rechargeable accumulator before performing any repair,
maintenance or adjustment work or tool change.
Danger of injury
Rotating tool support!
:Do not reach into the tool support while machining, keep wide clothing
away from the working area.
XOperate the machine only after the tube has been clamped.
6.1 Preparation
1. Specify the tube dimension to be processed.
2. Select the multifunctional tool and the clamping shells (for tool accessories,
see chapter 2.3, p. 8).
Note
DANGER
Specifying
dimensions

Operating instructions RPG 1.0 Cordless (right-angled drive) 6 Operation
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6.2 Mounting the multifunctional tool (MFW) to the
tool support
Danger of injury
Sharp cutting edges!
:Do not touch the cutting edges when mounting the multifunctional tool.
XWear safety gloves.
1. To detach the feed unit (1), turn the feed with scale ring (2) clockwise.
2. Screw the multifunctional tool (3) to the tool support (4) using the Torx
screwdriver.
3. Mount the feed unit (1) by means of turning the feed with scale ring (2)
counterclockwise.
The assembly of the multifunctional tool is now completed.
WARNING
3
4
1
2

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6.3 Inserting and replacing clamping shells
1. Select the appropriate set of clamping shells according to the tube dimension
(see chapter 2.3.2, p. 8).
2. Turn out the release handle (5) (the end of the release handle must be
flush with the inside of the housing).
If an already mounted set of clamping shells is to be replaced, it can now be
removed by compressing it.
3. Compress the set of clamping shells (6) slightly and insert it into the
housing.
The clamping shell is correctly inserted if it has engaged. If the clamping shell
does not engage, readjustment is possible by slightly turning the clamping shell.
The set of clamping shells has now been inserted correctly.
Removing
clamping shells
Inserting
clamping shells
Note
5
6