RPG 3.0 (Akku) / 4.5 (S) / 8.6 Table of Contents About these instructions....3.5.1 Multifunctional tool (MFW) ......Warning messages ....3.5.2 Tool holder (WH) for Further icons and displays ..beveling and squaring 3.5.3 Clamping shells (op- Abbreviations ......
Page 3
RPG 3.0 (Akku) / 4.5 (S) / 8.6 8.4.2 RPG 4.5 and RPG 8.6 11.6 RPG 4.5 (S): Gehäuse mit 8.4.3 RPG 4.5 S....Antrieb | RPG 4.5 (S): Main 8.4.4 Adjustment options housing with drive ....with the clamping 11.7 RPG 4.5 S: Schraubstock kom-...
RPG 3.0 (Akku) / 4.5 (S) / 8.6 About these instructions Warning messages The warnings used in these instructions warn you of injuries or damage to property. Always read and observe these warnings! This is a warning icon. It warns against dangers of injury. In order to avoid injuries or death observe the measures marked with a safety sign.
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Abbreviations ABBREVIATION MEANING RPG 3.0 (battery), RPG Tube squaring machine up to 3.0 inch, 4.5 inch or 8.6 inch outer diameter 4.5 or RPG 8.6 of the tube RPG 4.5 S Tube squaring machine up to 4.5 inch outer diameter of the tube with vice...
Scope of application of the operating instructions. • Only use dimension-specific clamping shells by Orbitalum Tools GmbH to fixate the pipes. • Only operate the machine within the voltages specified on the type plate of the drive (see chapter Technical specifications of the operating instructions).
RPG 3.0 (Akku) / 4.5 (S) / 8.6 • The owner shall be responsible for any damage which results from improper use. The manufacturer accepts no liability. • No tools should be used that have not been authorized by the manufacturer of this machine.
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Our products are "products" in the sense of the REACh regulation. In accordance with Article 33 of the REACh regulation, suppliers of products must inform their customers if the supplied product contains a substance specified in the REACh SVHC candidate list exceeding 0.1 percent by mass of the object.
• Use only the dimensions and materials listed in these instructions. Other materials may only be used after consulting with Orbitalum Tools customer service. • Use only genuine tools, spare parts, operating materials and accessories from Orbitalum Tools. • Repair and maintenance work on the electrical equipment may only be carried out by a qualified electrician.
Page 10
RPG 3.0 (Akku) / 4.5 (S) / 8.6 • Do not carry the machine by its cable and do not use the cable to pull the power plug out of the socket outlet (except in case of an emergency). Protect the cable against heat, oil and sharp edges (chips).
Page 11
RPG 3.0 (Akku) / 4.5 (S) / 8.6 DANGER If the power cable is damaged, exposed parts can be energized with lethal voltage! Fatal electric shock. ► Do not allow the power cable of the motor to be near the machine, especially the cutting tool (MFW).
Page 12
RPG 3.0 (Akku) / 4.5 (S) / 8.6 DANGER Grounded body! Fatal electric shock. ► Avoid contact with grounded surfaces such as tubes, heating, cook- ers or refrigerators. DANGER Danger of fire from charging the battery with a wrong charger! Severe injury or death.
Page 13
RPG 3.0 (Akku) / 4.5 (S) / 8.6 WARNING Parts thrown off/tool breakage and rotating pipe! Various injuries and damage to property. ► No damaged or deformed cutting tools (MFW) should be used. ► Firmly clamp the tube to be processed into the clamping unit.
RPG 3.0 (Akku) / 4.5 (S) / 8.6 WARNING Inadvertent actuation of the ON/OFF switch! Various injuries and damage to property. ► At the end of each working cycle, before transportation, changing tools, cleaning and performing any maintenance, adjustment or re- pair work, switch off the machine, wait until the machine/tool stops running and pull the mains plug or remove the battery.
Page 15
RPG 3.0 (Akku) / 4.5 (S) / 8.6 IMAGE POSITION ON MACHINE MEANING CODE Motor Warning: 790 086 199 (only with US Ver- Pull power plug before tool sion120 V) change or maintenance. Wear protective clothing. Keep hands away from mov- ing parts.
RPG 3.0 (Akku) / 4.5 (S) / 8.6 3.5.2 Tool holder (WH) for beveling and squaring 1 tool holder (WH) (code 790 038 320) is included with standard supply. Fits multifunctional tool. Incl. Torx fastening screw. Beveling with the RPG 4.5 S is not recommended.
The Tube Squaring Machine RPG 3.0 (battery), RPG 4.5 (S) or RPG 8.6 have the following features: • Pipe end preparation for standard compliant weld seam • Squaring and beveling with the RPG 3.0 (battery), RPG 4.5 and RPG 8.6. Beveling mode with the RPG 4.5 S is not recommended •...
RPG 3.0 (Akku) / 4.5 (S) / 8.6 • Advance: - Total: 15 mm - Per revolution: 3 mm • Scale ring with zero position • A cover hood or protection in combination with a chip container allows for clean operation...
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Technical specifications MACHINE MODEL RPG 3.0 RPG 3.0 (BATTERY): Dimensions [mm] 460 x 245 x 185 316 x 242 x 185 (including drive) [inch] 18.1 x 9.6 x 7.3 12.4 x 9.5 x 7.3...
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Storage and transport CAUTION Improper machine storage! Various injuries and damage to property. ► Store the machine in its original case and in dry conditions. DANGER Fatal electric shock! ► Before transportation or changing the workplace, switch off the ma- chine, wait until the machine/tool stops running and pull the mains plug.
Page 33
Transport in a packed state on a pallet and with a corresponding forklift truck (e.g. lift truck). Electric variant (RPG 3.0): Set the switch (1) in the Battery variant (RPG 3.0): (1) Set the switch in the center position to block the On/Off switch...
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Set-up and mounting NOTICE Because setup, assembly and operation with the tube squaring machine variants are mostly identical, the diagrams in this chapter show work steps only with examples of the RPG 4.5 and RPG 4.5 S machines.
Page 35
RPG 3.0 (Akku) / 4.5 (S) / 8.6 WARNING Fingers jammed between the clamping unit, clamping shells and tube! Irreversible crushing. ► Do not place fingers between the clamping unit, clamping shells and tube. ► At the end of each working cycle, before transportation, changing...
4. Remove the hexagon key (2) from working area. NOTICE To make the setting procedure easier for the RPG 3.0 machine, there are 3 visual markings for 1", 2", and 3" pipes. For the RPG 4.5 (S) machine, 4 visual markings (for 1", 2", 3", and 4" pipes) are fixed on the tool mounting plate (see figure below).
2. Unscrew the clamping screw. 3. Compress the clamping shell slightly and insert it into the hous- ing. 4. The Orbitalum logo (1) on the clamping shell must correspond with the clamping screw (2) (see figure). 5. Tighten the clamping screw (3).
RPG 3.0 (Akku) / 4.5 (S) / 8.6 8.3.2 Inserting the upper clamping shell 1. Place the upper clamping shell at the stop pin (1). 2. Swivel the clamping shell around the stop pin in the direction of the arrow until the mushroom han- dle locks into place.
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Clamping pipe WARNING Parts thrown off/tool breakage and rotating pipe! Various injuries and damage to property. ► No damaged or deformed cutting tools (MFW) should be used. ► Firmly clamp the tube to be processed into the clamping unit.
Page 40
RPG 3.0 (Akku) / 4.5 (S) / 8.6 8.4.2 RPG 4.5 and RPG 8.6 1. Open the clamping shells by shifting the clamping lever. 2. Insert the pipe with distance to the tool and support the pipe, if required. 3. Clamp the pipe by means of the clamping lever.
Page 41
RPG 3.0 (Akku) / 4.5 (S) / 8.6 8.4.4 Adjustment options with the clamping lever and adjusting bolt for offsetting tube tolerances (RPG 4.5 and RPG 8.6) The RPG provides the option of offsetting tube tolerances (deviations from nominal size) by means of an adjusting bolt (adjusting wheel) on the clamping lever.
Page 42
RPG 3.0 (Akku) / 4.5 (S) / 8.6 8.4.4.1 Shifting the adjusting bolt 1. Loosen the clamping lever and, if necessary, remove the tube. 2. Loosen the hexagon socket screw of the adjusting bolt using the Allan key. 3. Turn the adjusting bolt in the + or – direction.
Page 43
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Operation DANGER Starting up of the machine due to inadvertent actuation of the ON/ OFF button! Fatal electric shock. Various injuries and damage to property. ► At the end of each working cycle, before transportation, changing...
Page 44
RPG 3.0 (Akku) / 4.5 (S) / 8.6 WARNING Parts thrown off/tool breakage and rotating pipe! Various injuries and damage to property. ► No damaged or deformed cutting tools (MFW) should be used. ► Firmly clamp the tube to be processed into the clamping unit.
Page 45
RPG 3.0 (Akku) / 4.5 (S) / 8.6 WARNING Body parts can get caught between the cutting tool and the pipe! Severe injury. Do not put body parts between the cutting tool and the pipe. WARNING Flying hot and sharp chips, pipe surfaces, cutting edges and tools! Danger of injury to eyes and hands.
Page 46
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Shutdown (including in case of emergency) WARNING EMERGENCY STOP function not available by unplugging the power plug! Various injuries and damage to property. ► Do not use angled power plugs. ► Do not use click-in socket outlets and click-in power plugs (blue CEE power plugs) for power connection, otherwise the EMER- GENCY STOP does not function.
Page 47
RPG 8.6 168.3 RPG 8.6 219.1 * Operate the RPG 3.0 battery variants only in 1st gear. NOTICE The higher the cutting speed, the higher the attrition of the multi- functional tool. ► Set adjusting wheel for the speed selection (1) at the level desired (see table above)
Page 48
During machining, do not exceed a machining thickness of 0.2 mm. In the event of exceeding, the overload protection (adapter on RPG 4.5 (S)/RPG 8.6 Code 790 038 126. On RPG 3.0 (battery) adapter code 790 031 305) can be secured.
Page 49
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Switching off machine 1. Release the ON/OFF switch (1). ð The machine stops. 2. Disconnect the mains plug from power source/remove the battery from battery drive 3. Release the tube from the machine (see chapter Clamping pipe [} 39]).
Page 50
RPG 3.0 (Akku) / 4.5 (S) / 8.6 Maintenance, service and troubleshooting NOTICE Some of the tasks named are heavily dependent on use and ambi- ent conditions. The stated cycles are minimum values. In individ- ual cases, different maintenance cycles are possible. To ensure machine safety, have the maintenance performed annually by au- thorized service points with VDE testing.
Page 51
RPG 3.0 (Akku) / 4.5 (S) / 8.6 10.2 What to do if...? – General troubleshooting MALFUNCTION POSSIBLE CAUSE REMEDY Tool (MFW) hooks in during Feed too large. Dismantle the tool holder and take the pipe out machining. of the machine.
Page 53
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ERSATZTEILLISTE / SPARE PARTS LIST ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 54
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 55
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 56
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 57
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 58
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 59
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 60
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 61
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 62
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 63
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 64
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 65
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 66
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 67
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 68
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 69
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 70
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 71
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 72
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 73
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 74
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 75
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 76
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 77
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 78
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 79
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 80
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 81
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 82
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 83
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 84
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 85
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 86
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 87
RPG 3.0 (Akku) / 4.5 (S) / 8.6 SPARE PARTS ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 88
SPARE PARTS RPG 3.0 (Akku) / 4.5 (S) / 8.6 ORBITALUM TOOLS GmbH , D-78224 Singen www.orbitalum.com...
Page 89
(including optionally available accessories from Orbitalum): / Machine et type (y compris accessoires RPG 3.0 Orbitalum disponibles en option): / Macchina e tipo (inclusi gli articoli accessori acquistabili opzionalmente RPG 3.0 Akku da Orbitalum): / Máquina y tipo (incluidos los artículos de accesorios de Orbitalum disponibles RPG 4.5...
Page 90
Orbitalum Tools GmbH Josef-Schüttler-Straße 17 78224 Singen, Deutschland Tel. +49 (0) 77 31 792-0 Rohrplanmaschinen: Maschine und Typ (inklusive optional erhältlichen Zubehörartikeln von Orbitalum): / RPG 3.0 Machinery and type (including optionally available accessories from Orbitalum): RPG 3.0 Akku RPG 4.5 RPG 4.5 S...
Page 92
Orbitalum Tools GmbH provides global customers one source for the finest in pipe & tube cutting, beveling and orbital welding products. worldwide | sales + service NORTH AMERICA EUROPE ASIA Gulf Coast GERMANY CHINA Sales, Service & Rental Center E.H. Wachs E.H.