Orbitalum GF 4 AVM User manual

precision.
power.
simplicity.
Operating
instructions
Pipe Cutting and Beveling
Machines
GF 4 (AVM / MVM)
Code 790 142 762
│Machine-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 GF 4 (AVM / MVM) Table of contents
orbitalum tools gmbh
(01.08) MT_GF 4_BA_04_790142762_01.doc I
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 6
1.5 Returning of batteries 7
1.6 Further safety regulations 7
2Design of the product 8
2.1 Pipe cutting and beveling machine GF 4 8
2.2 Automatic Feed Module AVM 9
2.2.1 Description of the AVM buttons 9
2.3 Manual Feed Module MVM 10
2.4 Accessories 10
2.4.1 Saw blades and bevel cutters 10
2.4.2 Aluminum clamping shells 11
2.4.3 Special high-quality steel clamping jaws 11
2.4.4 Length gauge 11
2.4.5 Quick-mounting plate with screw clamps 11
2.4.6 Gear oil 11
2.4.7 Saw blade lubricant GF TOP 12
2.4.8 Saw blade lubricant ROCOL 12
3Features and scope of application 13
3.1 Features 13
3.2 Scope of application 14
3.2.1 Working range 14
4Technical data 15
4.1 GF 4 (AVM / MVM) 15
4.2 Line laser 15
5Commissioning 16
5.1 Included with the machine 16
6Transport and assembly 17
6.1 Transporting the pipe cutter 17
6.2 Fitting the pipe cutter to the workbench 18
6.2.1 Fitting the quick-mounting plate to the workbench 18
6.2.2 Fitting the pipe cutter to the quick-mounting plate 18
7Operation 19
7.1 Special functions 20
7.1.1 Multifunctional wrench 20
7.1.2 Line laser 21

Table of contents Operating instructions GF 4 (AVM / MVM)
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7.1.3 Turnable aluminum-cast clamping jaws 22
7.1.4 Swivel cable with quick-disconnect coupler 22
7.1.5 Optimized saw blade guard 23
7.1.6 Hand wheel with ratchet adjustment 23
7.2 Fitting the clamping jaws 24
7.3 Fitting the saw blade, bevel cutter, additional cutters 25
7.3.1 Inserting the saw blade or bevel cutter 25
7.3.2 Inserting additional cutters 25
7.4 Adjusting the pipe diameter 26
7.4.1 Saw blade without additional cutter 27
7.4.2 Saw blade with additional cutter 28
7.4.3 Adjusting the bevel cutter 29
7.5 Adjusting the length gauge 30
7.6 Selecting the motor speed 31
7.6.1 Standard values for spindle speed and feed force
level (AVM) 31
7.7 Processing the pipe with GF 4 AVM 32
7.7.1 Commissioning 32
7.7.2 Cutting the pipe with GF 4 AVM 33
7.7.3 Beveling the pipe with GF 4 AVM 34
7.7.4 Cutting the pipe and beveling it
simultaneously GF 4 AVM 35
7.8 Processing the pipe with GF 4 MVM 36
7.8.1 Cutting the pipe with GF 4 MVM 36
7.8.2 Beveling the pipe with GF 4 MVM 37
7.8.3 Cutting the pipe and beveling it simultaneously with
GF 4 MVM 38
7.9 Processing the pipe manually 39
7.9.1 Cutting the pipe manually 39
7.9.2 Beveling the pipe manually 40
7.9.3 Cutting the pipe manually and beveling it
simultaneously 41
8Maintenance 42
8.1 Checking the oil level of the gear and topping up 43
8.2 Cleaning the slide guide 44
9What to do if …? 45
9.1 General trouble-shooting 45
9.2 Error messages/trouble-shooting AVM 45
9.3 Servicing/after-sales service 46

Operating instructions GF 4 (AVM / MVM) 0 About these instructions
orbitalum tools gmbh
(01.08) MT_GF 4_BA_04_790142762_01.doc 1
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 GF 4 (AVM / MVM)
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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 must do
something here.
X
Single request for action: You must do something here.
ZConditional request for action: You must do something here if
the specified condition is met.
0.3 Abbreviations
Abbr. Meaning
GF 4 Pipe Cutting and Beveling Machine for up to 4 inch pipe
outer diameter
AVM Automatic Feed Module
MVM Manual Feed Module

Operating instructions GF 4 (AVM / MVM) 1 Notes on safety
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(01.08) MT_GF 4_BA_04_790142762_01.doc 3
1 Notes on safety
The Pipe Cutting and Beveling Machine (here further referred to as GF 4) 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. It may also damage
the machine or other equipment.
Therefore:
•Always ensure that the machine is in good working order and comply with
these notes on safety.
•Keep all relevant documents close by the machine.
•Generally valid regulations for the prevention of accidents must be
observed.
1.1 Proper Use
•Use the pipe cutter GF 4 only for cutting and beveling pipes.
•The Automatic and Manual Feed Module AVM/MVM may only be operated
in conjunction with the Orbitalum Tools pipe cutter GF 4.
•The user will be the only person liable for damages caused by improper
use.
•GF 4 AVM: Only the mains cable of the pipe cutter may be connected to
the socket of the AVM.
1.2 Safety Regulations
•Only use the dimensions and materials specified in these instructions.
Other materials should be used only after consulting the Orbitalum Tools
after-sales service.
•Only use original Orbitalum Tools spare parts and resources.
•Inspect the pipe cutter GF 4 daily for visible signs of damage or defects.
Have any damages or defects repaired immediately.
•Work on the electrical equipment must only be carried out by a qualified
electrician.
•Only operate the pipe cutter if the electrical restart inhibitor is working.
•Disconnect the mains plug before carrying out a tool change or
maintenance and repair work and allow the machine to run to a stop.
•Flex rotating cable: only approved for double-insulated cutter motor,
protection class II.
•GF 4 AVM: do not connect any other devices to the socket of the AVM.

1 Notes on safety Operating instructions GF 4 (AVM / MVM)
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1.3 Working with safety in mind
“Make your contribution to safety in the workplace.”
•Report any unusual response from the machine to the person responsible
immediately.
•Be aware of safety aspects at all times during work.
•When working with the GF 4, wear protective goggles, safety gloves, safety
shoes, and ear protection.
•Tie up long hair (hair-net); do not wear loose-fitting clothes.
Attention: Jewellery and ties may get caught in the rotating parts.
•Check that the work piece is correctly clamped.
•Switch on the machine only when the pipe has been clamped.
•Once the machine is running, keep hands away from the tools.
•Before changing tools, cleaning or performing any maintenance,
adjustment or repair work, disconnect the mains plug and allow the
machine to run to a stop.
•Fault current (FI) protection in the mains supply line, provided by the
customer, is required.
•When working with the AVM: in case of danger, immediately press the
EMERGENCY OFF button.
•When working with the AVM, the AVM will stop automatically after each
cutting process. If you are working manually, switch off the machine after
each working cycle (ON/OFF switch of the pipe cutter) and allow the
machine to run to a stop.
•Be aware of environmental influences: do not use electric tools in damp or
wet conditions. Ensure lighting is adequate. Do not use in close proximity to
flammable liquids or gases.
•Do not carry the machine by the cable and do not use the machine to pull
out the plug. Protect the cable from heat, oil and sharp edges (chips).
Danger of being injured by sharp cutting edges
:Keep hands away from the running tool.
XWear safety gloves.
XTie up long hair (hair-net); do not wear loose-fitting clothes.
XUse the pipe cutter only when the pipe has been clamped.
WARNING

Operating instructions GF 4 (AVM / MVM) 1 Notes on safety
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Danger of eyes and hands being injured by hot and sharp-edged chips
flying around
:Keep hands away from the running tool.
XAlways wear protective goggles.
XRemove chips only with safety gloves.
Danger of being injured by breaking tool
:Do not process the pipe while it is loose in the vice.
XClamp the pipe to be cut into the vice.
XImmediately change worn-out tools.
XSaw blade must be securely clamped in.
XPipe diameter must be set correctly. During cutting, saw blade must saw
through the entire pipe wall.
Danger of eyes and hands being injured by hot and sharp-edged chips
flying around
:Keep hands away from the running tool.
XAlways wear protective goggles and safety gloves.
XRemove chips only with safety gloves.
Danger of being injured by rotating slide housing
When switching the motor on, the pipe cutter may revolve around the pipe
automatically.
:When working with the GF 4 AVM, do not stand within swiveling distance
of the machine during an automatic revolution of the slide housing.
XMake sure that the slide housing starts from its home position.
XClamp the pipe to be cut into the vice.
XPull off the vice handle from the spindle before the slide housing starts
rotating.
:In their home position, the saw blade or bevel cutter must not touch
the pipe!
XBefore switching the motor on, make sure that the gap between the saw
blade/bevel cutter and the pipe is sufficient and that the pipe is securely
clamped in the vice.
WARNING
WARNING
WARNING
WARNING

1 Notes on safety Operating instructions GF 4 (AVM / MVM)
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Danger of death by electric shock
If the mains cable is damaged, live parts may cause death if touched directly.
:Keep the mains cable of the pipe cutter motor away from the saw blade or
bevel cutter.
:Do not let the cut-off pipe piece drop in an uncontrolled way.
XSecure the falling pipe piece.
:Do not run the machine unattended.
XDuring the machining process, always keep an eye on the position of the
mains cable.
Unintended actuation of the ON-OFF switch
XThe machine may only be operated using a fault current (FI) protect switch.
XBefore changing tools, cleaning or performing any maintenance,
adjustment or repair work, pull the mains plug and allow the machine
to run to a stop.
Danger of being injured by laser radiation!
Failure to take due care can result in the retina of the eyes being damaged and
can thereby impair sight.
:Do not look at the laser beam or view using optical instruments.
:Do not point the laser beam in the direction of others.
:Do not misuse the laser pointer and do not remove from the pipe cutter.
1.4 Waste disposal
•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 that are marked with the symbol to the left,
may not be disposed of with household waste in accordance with EU
regulations.
•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 EU regulations. 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 disposed of according to legal standards. The customer must however
bear the cost of delivery to Orbitalum Tools.
DANGER
WARNING
(RL 2002/96/EG)

Operating instructions GF 4 (AVM / MVM) 1 Notes on safety
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(01.08) MT_GF 4_BA_04_790142762_01.doc 7
•The return of used devices that pose a health or safety risk for human
beings due to contamination during use may be refused.
•The legally compliant disposal of electrical (electronic) devices that were
placed on the market before August 13th, 2005 is the responsibility of the
end-user.
•Important for Germany: our products may not be disposed of in municipal
disposal sites as they are used for industrial purposes only.
1.5 Returning of batteries
Some of our products work with batteries.
•Batteries which are marked with one of the symbols 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.
Cd = Cadmium Hg = Mercury Pb = Lead
1.6 Further safety regulations
Observe the regulations, standards and guidelines applicable in your country.

2 Design of the product Operating instructions GF 4 (AVM / MVM)
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2 Design of the product
2.1 Pipe cutting and beveling machine GF 4
1 Hand wheel 11 Rotating-speed regulator
2 Line laser 12 ON-OFF switch
3 Slide housing with cover plate 13 Ergonomic handle
4 Saw blade/bevel cutter 14 Retainer for vice handle
5 Opening for meter rule Anti-theft protection
6 Saw blade guard Holding fixture for pipe length guage bar
7 Identification plate 15 Quick mounting plate
8 Slide 16 Multifunctional wrench/vice handle
9 Motor 17 Vice
10 Rotating-speed indicator 18 Turnable clamping jaws
1
2
3
4
6
7
10
11
12
15
17
16
8
14
18
5
13
9

Operating instructions GF 4 (AVM / MVM) 2 Design of the product
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2.2 Automatic Feed Module AVM
1 Display 5 Buttons for presetting the feed force level
2 START button 6 Light barrier
3 STOP button 7 Reflector
4 EMERGENCY OFF button 8 Protective web
2.2.1 Description of the AVM buttons
If the control system is connected to the mains, the number of the current
software version will first appear on the display for approx. 1 second. If the
module is ready for operation, the currently preset feed force level will be
displayed. In case of a malfunction, this display will flash at 1-second intervals
showing F and a figure from 1 to 6. For error messages/trouble-shooting,
see chapter 9.2, p. 44.
By actuating these buttons, it is possible to preset the desired feed force in
9 levels. If the device is ready for operation, these buttons may be pressed at
any time to set the feed force level or to vary it during processing. If one of the
buttons remains pressed by the user, the display will run to the respective
direction selected by the user.
The machining process is initiated by actuating this button. After start-up, this
button serves no further function. It remains also without function during a fault
or while the software version is being displayed.
During the machining process, a stop cycle is initiated by actuating this
button, and a new start is waited for.
Before and after the machining process, the feed will run backwards as long
as the button is pressed, regardless whether the cutter motor is running or not.
During a fault, the button remains without function. For error messages/
trouble-shooting, see chapter 9.2, p. 44.
Display
PRESET buttons
/
START button
STOP button
1
2
3
4
5
8
7
6

2 Design of the product Operating instructions GF 4 (AVM / MVM)
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2.3 Manual Feed Module MVM
1 Gear 3 Gear drive with freewheel
2 Fastening screws 4 Hand wheel
2.4 Accessories
Not in product contents.
2.4.1 Saw blades and bevel cutters
All saw blades and bevel cutters are specially developed for Orbitalum Tools
pipe cutters to endure maximum strain and have a maximum tool life.
A selection of 4 different saw blades and bevel cutters are available for
various uses:
•Economy Series
for low and non-alloy steels and cast iron /casting alloys
•Performance Series
for high-alloy steels (high-quality steel)
•High-Performance Series
for high-performance materials and high-alloy steels
•Premium Series
especially for high-quality steel use with extremely long service life
Processable
pipe materials Al Non-alloy steel, Cu,
CuNi, CuZn,
CuSn
High-quality
steel, V2A,
V4A, 304,
316 (L)
Ti, Duplex,
Inconel
Economy * *
Performance * *
High-Performance * * *
Premium *
1
2
3
4

Operating instructions GF 4 (AVM / MVM) 2 Design of the product
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2.4.2 Aluminum clamping shells
Suitable for the Pipe Cutting and Beveling Machines GF 4 and RA 41 Plus.
For deformation-free clamping of thin-walled pipes. Further clamping shells are
available for various outer diameters.
Pipe OD [mm] Pipe OD [inch] Code
25.40 1.000 790 046 316
38.10 1.500 790 046 331
50.80 2.000 790 046 345
76.10 2.996 790 046 358
88.90 3.500 790 046 363
108.00 4.252 790 046 367
114.30 4.500 790 046 368
2.4.3 Special high-quality steel clamping jaws
For GF 4 and RA 4. In pairs.
Article Code
Special high-quality steel clamping jaws for GF 4 and RA 4 790 042 201
2.4.4 Length gauge
For all GF 4, RA 2, RA 4, RA 6 and RA 8 versions. Measuring range
up to 680 mm (26.77 inch).
Article Code
Length gauge 790 041 011
2.4.5 Quick-mounting plate with screw clamps
With integrated screw clamps for quick mounting of the machine on
workbenches. Ideal if changing location often.
Article Code
Quick-mounting plate for GF 4, RA 4, RA 6, RA 8, RA 41 (Plus) 790 042 027
2.4.6 Gear oil
For all Orbitalum Tools pipe cutters.
Article Code
Gear oil, bottle, 250 ml 790 041 030

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2.4.7 Saw blade lubricant GF TOP
Synthetic high-performance lubricant for cutting and beveling machines.
Increases the tool life of the saw blade. Compliant with the former food
approval USDA H2. The screwable brush guarantees an easy and uniform
application of lubricant on the saw blade.
Article Code
Saw blade lubricant GF TOP 790 060 228
2.4.8 Saw blade lubricant ROCOL
High-performance lubricant for cutting and beveling. Increases the tool life of
the saw blade.
Article Code
Saw blade lubricant ROCOL, Tube, 150 ml 790 041 016
Saw blade lubricant ROCOL, Can, 0.5 kg 790 041 013
Saw blade lubricant ROCOL, Container, 5.0 kg 790 041 019

Operating instructions GF 4 (AVM / MVM) 3 Features and scope of application
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3 Features and scope of application
3.1 Features
The pipe cutter GF 4 is distinguished by the following characteristics:
•Enhanced safety due to stationary pipe - rotating tool.
•A restart inhibit function prevents the machine from starting in an
uncontrolled way after it has been re-connected to the electric mains or
after the voltage supply has been re-established following a power failure.
•Self-centering vice.
•Low-maintenance gearbox with oil lubrication.
•Speed-controlled pipe cutter motor.
•Burr-free cutting surface and deformation-free pipe cross-section.
•Cold machining process.
•Quick cutting process.
•The ability to produce “V” and “Y” weld preps using a bevel cutter with the
option of cutting and beveling simultaneously.
•Cutting of elbows.
•Quick tool change.
•Line laser for optical identification of the cutting area.
•Locking mechanism of the slide housing prevents unauthorized usage
and theft.
GF 4 AVM:
•The intelligent control system of the AVM monitors the feed force
continuously, depending on the torque and the parameter settings.
•The operator position guarantees utmost protection against hot chips
flying around.
•Reducing the amount of physical effort for the operator.
•Manual operation is still possible.

3 Features and scope of application Operating instructions GF 4 (AVM / MVM)
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3.2 Scope of application
3.2.1 Working range
Type of machine GF 4 (AVM / MVM)
Pipe/elbow OD [mm] 12 - 120
Wall thickness [mm] (depends on material) 1 - 9
Pipe ID min. [mm] (saw blade Ø 63 mm) 21
Pipe ID min. [mm] (saw blade Ø 68 mm) 16
Pipe ID min. [mm] (saw blade Ø 80 mm) 4
•High-quality steel (any Cr and Mo content)
•High-quality stainless steel (any Cr and Mo content)
•High-quality steel (Cr < 12% and Mo < 2.5%; Cr < 20% and Mo = 0%):
–Case hardened steels
–High-speed steels
–Heat-treated steels
–Bearing steels
–Tool steels
•Black and galvanized steel pipe
•General structural steel
•Annealed cast iron pipe (GGG)
•Aluminum
•Brass
•Copper
•Plastics (PE, PP, PVDE, PVC)
Pipe materials

Operating instructions GF 4 (AVM / MVM) 4 Technical data
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4 Technical data
4.1 GF 4 (AVM / MVM)
Dimensions (l x b x h) GF 4
Dimensions (l x b x h) GF 4 AVM
Dimensions (l x b x h) GF 4 MVM
680 x 325 x 480 mm / 26.8 x 12.8 x 18.9 inch
810 x 325 x 480 mm / 31.9 x 12.8 x 18.9 inch
780 x 325 x 480 mm / 30.7 x 12.8 x 18.9 inch
Weight GF 4, approx. 55.0 kg / 121.2 lbs
Weight GF 4 AVM, approx. 64.5 kg / 142.2 lbs
Weight GF 4 MVM, approx. 60.0 kg / 132.2 lbs
Versions One-phase alternating current
220 - 240 V, 50/60 Hz
110 - 120 V, 50/60 Hz
Power GF 4 1800 W / 2.45 HP
Power AVM 50 W / 0.068 HP
Protection class GF 4, GF 4 MVM Double insulated according to class II,
DIN VDE 0740
Protection class GF 4 AVM Double insulated according to class I,
DIN VDE 0113
Tool speed 65 - 215 rpm
Speed of the slide housing 0.1 - 1.8 rpm
Torque of the slide housing 100 - 200 Nm
Sound pressure level at the
workplace*
approx. 79 dB (A)
Vibration level in accordance with
DIN EN 28662, Part 1 < 2.5 m/s2
Mains fuse by customer 16 A
* The sound pressure level was measured under normal operating conditions in accordance with EN 23741.
4.2 Line laser
Dimensions (l x b) 68 x 15 mm / 2.7 x 0.59 inch
Weight 30 g / 0.066 lbs
Power 5 mW / 0.007 HP
Beam range 1 m / 39.37 inch
Wavelength 650 nm
Operating voltage 2.8 to 4.5 V DC
Operating current 20 mA
Operating temperature -10 to 40 °C
Storage temperature -40 to 80 °C
Laser class 2M
Battery type 2 x LR44 / AG13

5 Commissioning Operating instructions GF 4 (AVM / MVM)
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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 Included with the machine
•1 Pipe Cutting and Beveling Machine GF 4 (AVM / MVM)*
•1 Transportation case
•1 Saw blade
•1 Set of clamping jaws made from cast aluminum
•1 Quick-mounting plate
•1 Tool set
•1 Tube of saw blade lubricant GF TOP (Code 790 060 228)
•1 Tube of special gear oil (Code 790 041 030)
•1 Set of operating instructions and spare parts list
* The automatic and manual feed module AVM/MVM is already fitted to the pipe cutter upon delivery.
Checking the scope
of delivery
Subject to change