Orbitalum RA 41 Plus User manual

precision.
power.
simplicity.
Operating
instructions
Pipe Cutting and
Beveling Machine
RA 41 Plus (H)
Code 790 046 773
Translation of original operating instructions
│Machine-no.:
________________________________

All rights reserved, in particular the rights of duplication and distribution as well as translation.
Duplication and reproduction in any form (print, photocopy, microfilm or electronic) require the written
permission of Orbitalum Tools GmbH.

Operating instructions RA 41 Plus (H) Table of contents
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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 5
1.5 Further safety regulations 5
2Design of the product 6
2.1 Standard 6
2.2 Accessories 7
3Features and scope of application 8
3.1 Features 8
3.2 Scope of application 9
4Technical specifications 10
4.1 Rating 10
5Commissioning 11
5.1 Scope of delivery* 11
6Transport and assembly 12
6.1 Fitting the quick-mounting plate 12
6.2 Transporting and fitting the pipe cutter 13
7Operation 14
7.1 Setting the saw position 1 15
7.1.1 Preparatory work 15
7.1.2 Fitting the saw blade or bevel cutter 16
7.1.3 Fitting the saw blade and supplementary cutter 16
7.2 Setting the saw position 2 17
7.2.1 Fitting the saw blade 17
7.3 Adjusting the pipe dimensions 18
7.3.1 "Cutting" dimension setting (at saw positions 1 and
2) 18
7.3.2 "Beveling" dimension setting (only at saw
position 1) 19
7.3.3 "Simultaneous cutting and beveling of thin-walled
metal pipes s = 1 – 2 mm" dimension setting (only
at saw position 1) 19
7.3.4 "Simultaneous cutting and beveling of metal pipes
(s = 2 – 4.5 mm)" dimension setting (only at saw
position 1) 20
7.4 Selecting speed stages 21
7.5 Cutting the pipe (saw position 1 or 2) 22

Table of contents Operating instructions RA 41 Plus (H)
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7.6 Beveling the pipe (only at saw position 1) 24
7.6.1 Bevel correction (only at saw position 1) 26
7.7 Simultaneous cutting and beveling (only at saw position 1) 27
7.7.1 Simultaneous cutting and beveling of thin-walled
pipes (s = 1 – 2 mm) 27
7.7.2 Simultaneous cutting and beveling of pipes (s = 2 –
4.5 mm) 28
7.7.3 Bevel correction (only at saw position 1) 29
8Maintenance 30
8.1 Checking the level of the gear oil 32
8.2 Topping up gear oil 32
9What to do if ...? 33
9.1 General trouble-shooting 33
9.2 Servicing/after-sales service 34

Operating instructions RA 41 Plus (H) 0 About these instructions
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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 RA 41 Plus (H)
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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
RA 41 Plus Pipe Cutting and Beveling Machine, type RA 41 Plus
RA 41 Plus (H) Pipe Cutting and Beveling Machine, type RA 41 Plus
with intermediate gear

Operating instructions RA 41 Plus (H) 1 Notes on safety
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1 Notes on safety
The Pipe Cutting and Beveling Machine (referred to as RA 41 Plus (H) in the
following) 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 complete documents close by the machine.
•Generally valid regulations for the prevention of accidents must be
observed.
1.1 Proper use
•Only use the RA 41 Plus (H) for cutting and beveling of pipes.
•For damages caused by using not according to regulations is just the user
responsible.
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.
•Only use original Orbitalum Tools spare parts and auxiliaries.
•Inspect the RA 41 Plus (H) every day for visible signs of damage or
defects. Any damage or defect must be repaired immediately.
•Work on the electrical installations may only be performed by a qualified
electrician.
•Disconnect from the mains before changing the tools, maintenance- and
repair-works and allow the machine to run a stop.
•Do not use the RA 41 Plus (H) unless all safety devices (restart inhibitor,
overload protection and saw blade guard) are working properly and the
fixtures are fitted securely on the baseplate or pipe-supply.

1 Notes on safety Operating instructions RA 41 Plus (H)
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1.3 Working with safety in mind
"Make your contribution to safety in the workplace."
•Report any unusual behavior on the part of the machine to the person in
charge immediately.
•Always work with safety in mind.
•Wear safety goggles, safety-gloves and hearing protection during working
with the RA 41 Plus (H).
•Tie up long hair (snood-type cap); do not wear any wide clothes.
Attention: jewels and ties can be grasped by the rotating parts.
•Switch the RA 41 Plus off after completing each stage of work and allow
the machine to run a stop.
•Disconnect from the mains before cleaning-, maintenance- and repair-work
the RA 41 Plus (H) and let the machine leak.
•Keep the RA 41 Plus (H) dry, do not use in the rain.
•Do not use the RA 41 Plus (H) in areas subject to explosion hazards.
Danger of death by electric shock!
If the mains cable is damaged, live parts may cause death when being touched
directly.
:Keep the mains cable of the pipe cutter motor away from the saw blade or
bevel cutter.
XSecure the falling pipe piece.
:Do not let the cut-off pipe piece drop in an uncontrolled way.
:Do not run the machine unattended.
XWhile processing the pipe, always keep an eye on the position of the mains
cable.
Danger of being injured by sharp cutting edges!
:Keep hands away from the tools during cutting or beveling.
:Never equip both sawing positions with saw blade and bevel cutter at the
same time.
XWear safety gloves.
DANGER
WARNING

Operating instructions RA 41 Plus (H) 1 Notes on safety
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Danger of being injured by the rotating slide housing!
XMake sure that the slide housing starts from its home position.
XClamp the pipe to be processed into the vice.
XPull off the vice handle from the spindle before the slide housing starts
rotating.
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.
•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.
1.5 Further safety regulations
Observe the regulations, standards and guidelines applicable in your country.
WARNING
(RL 2002/96/EC)

2 Design of the product Operating instructions RA 41 Plus (H)
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2 Design of the product
2.1 Standard
21
34
7
8
9
10
1112
13
5
6
15 16
19
14
17
18
1 Vice handle 11 On-off switch
2 Vice 12 Speed setting
3 Clamping lever for pipe dimensioning 13 Quick-mounting base plate
4 Dimension plate, to adjust the pipe 14 Mounting plate
diameter 15 Saw blade guard position 1
5 Saw blade position 2 16 Saw blade position 1
6 Saw blade guard position 2 17 Aluminum clamping jaws
7 Rotary element 18 Fixing bolt RA to quick-
8 Electric motor mounting base plate
9 Motor grip 19 Rating plate/machine number
10 Connecting lead with rotary contact

Operating instructions RA 41 Plus (H) 2 Design of the product
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2.2 Accessories
Not contained in the scope of supply:
•Cast iron clamping jaws
•Aluminum clamping shells for deformation-free clamping of thin-walled
metal tubes
•Intermediate gear (H) for cutting high-tech materials (nickel alloys, special
stainless steel)
Get further information from our current product catalogue.

3 Features and scope of application Operating instructions RA 41 Plus (H)
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3 Features and scope of application
3.1 Features
The Pipe Cutting and Beveling Machine RA 41 Plus (H) is distinguished by the
following main features:
•Increased safety due to stationary pipe and rotating tool.
•Self-centering vice.
•Low-maintenance gearing with oil-bath lubrication.
•Variable speed electric motor with restart inhibitor.
•Right-angled, burr-free, cold separating cut.
•Cold machining process.
•Quick cutting process.
•Easy and space-saving assembly.
•Fabrication of standardised welding bevels.
•Quick tool change.
•Simultaneous cutting and beveling of thin-walled metal pipes
(only at saw position 1).
•Saw position 1: saw blade and clamping jaws are close to one another to
absorb vibrations when sawing.
•Saw position 2: possibility of cutting elbows.

Operating instructions RA 41 Plus (H) 3 Features and scope of application
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3.2 Scope of application
Material Saw
position
Pipe outer
diameter OD
[mm]
Pipe inner diameter ID
[mm]
Wall
thickness
[mm]
Pipe 1 10 – 120
Elbow 2 30 – 120
16 (saw blade-Ø 68 mm)
4 (saw blade-Ø 80 mm) 0.6 – 7
Stainless steel with the following mass
fractions: Wall thickness [mm]
Cr ≤12%; Mo < 2%; Ni < 26% 1 – 7
Cr ≤20%; Mo = 0%; Ni < 13% 1 – 7
Cr ≤28%; Mo < 8%; Ni < 30% 1 – 2.5
•Unalloyed and low-alloyed steel
•High-alloyed steel
(stainless steel, material no. 1.40... – 1.45... in accordance with DIN 17455
and 17456)
•Copper
•Brass
•Annealed cast-iron pipe (nodular graphite iron)
•Aluminum
*) Consult Orbitalum Tools before using for other applications and/or materials.
Working range*
Pipe materials*

4 Technical specifications Operating instructions RA 41 Plus (H)
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4 Technical specifications
4.1 Rating
Dimensions 700 x 490 x 460 mm
27.6 x 19.3 x 18.1 inch
Weight 74 kg
163 lbs
Power 1600 W
Protection class Totally insulated in accordance with class II,
DIN VDE 0740
Speed RA 41 Plus 150 – 270 rpm
Speed RA 41 Plus (H)
(incl. intermediate gear box)
40 – 70 rpm
Versions 1-phase AC
100 – 120 V, 50/60 Hz
200 – 240 V, 50/60 Hz
Vibration level in accordance
with EN 28662, part 1
< 2.5 m/s2
Sound pressure level at
workplace*)
at idle: approx. 76 dB (A)
under load: approx. 85 dB (A)
As the noise level may also exceed 85 dB (A) under unfavorable operating
conditions, we recommend the use of suitable ear protection when the machine
is used for extended periods.
*) The sound pressure level was measured under normal operating conditions in accordance
with EN 23741.

Operating instructions RA 41 Plus (H) 5 Commissioning
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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 RA 41 Plus (H)
•1 Transportation box
•1 Saw blade (Code 790 042 064)
•1 Quick mounting plate
•1 Tool set
•1 Tube of saw blade lubricating compound GF TOP (Code 790 060 228)
•1 Tube of special gear oil (Code 790 041 030)
•1 Operating instructions with spare parts list
*) Subject to modifications
Checking the parts
of delivery

6 Transport and assembly Operating instructions RA 41 Plus (H)
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6 Transport and assembly
6.1 Fitting the quick-mounting plate
Fit the pipe cutter together with the vice, either
•to the quick-mounting plate, or
•to the quick-mounting plate with screw clamps (special accessory).
1. Mark and punch the bolt holes on the work bench. Use the quick-mounting
plate as a template.
2. Drill 13 mm Ø holes.
3. Fasten the quick-mounting plate with screws.
Mount the pipe cutter directly and without further belongings on the mounting base
plate (1) of the pipe feeder base unit (optional accessory, Code 790 068 051).
Pipe feeder base unit
1

Operating instructions RA 41 Plus (H) 6 Transport and assembly
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6.2 Transporting and fitting the pipe cutter
Danger of death caused by electric shock!
XCut off the power supply before carrying out the transportation.
Danger of being injured during transportation!
:Never carry and fit the pipe cutter alone.
XTransport and fit the pipe cutter with the aid of a crane or a similar lifting
device.
1. Clamp a suitable piece of tubing of an adequate length in the middle of the
vice.
2. Position lifting belts around the piece of pipe on both sides of the vice.
3. Use the belts to lift the pipe cutter and slide onto the fitted quick-mounting
base plate from the side.
4. Belt the pipe cutter down with the hexagon-head screw (1).
1
DANGER
WARNING

7 Operation Operating instructions RA 41 Plus (H)
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7 Operation
Use the RA 41 Plus (H) only for cutting and beveling of pipes. Please
absolutely consider the possible ways of machining of the two sawing
positions (see picture and table). For damages caused by using not according
to regulations is just the user responsible.
Saw position 1 Saw position 2
1. sawing 1. sawing
2. beveling
3. sawing and beveling simultaneous
Danger of being injured by sharp cutting edges or electric shock!
:Keep hands away from the saw blade/bevel cutter when inserting or
changing the tool.
:Never equip both saw positions with saw blade/bevel cutter
simultaneously!
XWear safety gloves.
XDisconnect the mains plug before mounting or dismounting, maintenance
or adjustment and allow the machine to run a stop.
Note
WARNING
Saw position 1
Saw position 2

Operating instructions RA 41 Plus (H) 7 Operation
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7.1 Setting the saw position 1
Damage to material
XThe saw blade or bevel cutter must be free from chips and dirt.
XOnly use Orbitalum Tools saw blades and cutters.
XWhen employing an additional cutter, only use the special Orbitalum Tools
clamp washer, not the normal clamp washer.
XThe inscription (1) on the saw blade (saw position 1) must always be facing
towards the pipe cutter. Consider the assembly sign at the saw blade guard.
7.1.1 Preparatory work
1. Swivel the pipe cutter upwards by 180° in a clockwise direction.
2. Clean the saw blade shaft (1), the contact surface of the clamp (2) and
vicinity.
1
2
ATTENTION
1

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7.1.2 Fitting the saw blade or bevel cutter
1. Fit the following on to the shaft (1):
–saw blade or bevel cutter (2)
–clamping plate (3)
2. Tighten the nut (4) counter clockwise (left-hand thread).
3. Swivel the pipe cutter down into its starting position in a clockwise direction.
1
2
3
4
7.1.3 Fitting the saw blade and supplementary cutter
1. Fit the following on to the shaft (1):
–saw blade (2), supplementary cutter (3) and clamping plate (4)
2. Tighten the nut (5) counter-clockwise (left-hand thread).
3. Swivel the pipe cutter down into the starting position in a clockwise
direction.
1
2
3
4
5