Trumpf TruTool TKF 1500 3A1, Operator'S Manual

Page 1: ... manual TruTool TKF 1500 3A1 3B1 Beveler TRUMPF Werkzeugmaschinen GmbH Co KG Technische Redaktion Johann Maus Straße 2 D 71254 Ditzingen Fon 49 7156 303 0 Internet http www trumpf com E Mail docu th de trumpf com ...

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Page 3: ...3 5 Adjusting height of the cutting tool 15 3 6 Select gear 16 3 7 Accessories included 17 Securing the chip box 17 Handle base 18 Tube shaped handle 18 Roller holder 19 3 8 Options 20 Roller holder for pipe and tube processing 20 Special tool for pipe and tube processing 21 Conversion kits for large material thick nesses 23 Suspension bracket 25 Workstation 26 4 Operation 28 4 1 Working with TruT...

Page 4: ...6 Accessories and consumables 34 6 1 Ordering consumables 35 7 Appendix Declaration of conformity guar antee replacement parts lists 36 2 Table of contents E1026en03 ...

Page 5: ...le Contact with a live conductor can cause metallic machine parts to become live and can lead to an electric shock Risk of injury from hot and sharp chips Chips exit the chip ejector at high speed Ø Use the chip box Risk of injury from falling machinery The entire weight of the machine must be taken up after machining the workpiece Ø Use the suspension bracket with balancer Ø Use the suspension ca...

Page 6: ...Risk of injury to hands Ø Do not reach into the processing line with your hands Ø Use both hands to hold the machine 4 Safety E1026en03 WARNING ...

Page 7: ... the following appli cations Preparation of all K V X and Y shaped welding grooves usual for gas and electrical fusion welding with various con tinuously adjustable angles of bevel and continuously adjust able lengths of bevels Forming of uniform oxide free bright metallic welding bevel edges in steel and aluminum Machining of chromium steel and similar high tensile materi als recommendation machi...

Page 8: ...e materials 2 2 Technical data Other countries USA Values Voltage 230 V 220 V China 120 V 110 V 120 V Frequency 50 60 Hz 50 60 Hz Max length of bevel ls continuously adjustable Mild steel and alumi num up to 400 N mm 15 mm 0 59 in Mild steel up to 600 N mm 9 mm 0 354 in Mild steel up to 800 N mm 6 mm 0 236 in Working Speed 2 m min 6 55 ft min Nominal power con sumption 2600 W 2000 W 2000 W Rated c...

Page 9: ...d 1 25 m min 1nd gear 2 m min 2nd gear 4 1 ft min 1st gear 6 55 ft min 2nd gear Nominal power con sumption 2600 W 2000 W 2000 W Rated current 16 A Stroke rate with nomi nal load 230 min 1st gear 370 min 2nd gear 170 min 1st gear 340 min 2nd gear 170 min 1st gear 340 min 2nd gear Weight with guide han dle 19 5 kg 43 3 lbs Material thicknesses Min 6 mm 0 236 in Max 40 mm 1 57 in Special 40 80 mm 80 ...

Page 10: ...amfer length in Inch Dimensions e g material thickness chamfer length no Idle speed Revolution speed without load min Revolutions strokes per minute Revolution speed stroke rate per minute Tab 3 2 4 Noise and vibration information Noise emission value may be exceeded Ø Wear hearing protection The vibration emission value can be exceeded Ø Select the right tools and exchange them in time in the eve...

Page 11: ...he machine is switched off or run ning but not actually in use can considerably reduce the vibration load during the entire working period Designation of measured value Unit Value according to EN 60745 Vibration emission value ah vector sum of three directions m s2 12 1 Uncertainty K for vibration emis sion value m s2 2 5 A class acoustic pressure level LPA typically dB A 87 A class acoustic power...

Page 12: ...6 7 6 6 6 5 6 4 6 3 6 2 6 b 10 6 9 6 8 6 7 6 6 6 5 6 4 6 3 6 2 6 hs ß 37 5 15 5 13 8 12 2 10 5 8 9 7 3 5 6 4 2 4 ls 9 4 8 4 7 4 6 4 5 4 4 4 3 4 2 4 1 4 b 12 3 11 9 6 8 3 7 5 8 4 4 3 1 1 9 hs ß 30 15 13 11 9 7 5 3 1 ls 7 5 6 5 5 5 4 5 3 5 2 5 1 5 0 5 b 13 11 2 9 5 7 8 6 4 3 2 6 0 8 hs ß 20 15 12 2 9 2 6 2 3 3 Is 5 1 4 2 3 1 2 1 1 1 b 14 11 4 8 6 5 8 3 1 hs ß Angle of bevel W Scale value which must ...

Page 13: ...angle of bevel ß 2 Consult the table to find the desired length of bevel ram length ls and the associated scale value W see Tab 5 pg 10 3 Rotate the crank sliding block 65 until the scale value W on the crank sliding block lines up with the reference point B 4 Tighten the hex screw 60 E1026en03 Setting work 11 ...

Page 14: ... head screw Fig 84793 Notes With stripper 1 the angle of bevel ß is continuously adjustable between 20 and 45 With stripper 55 order number 0032119 the angle of bevel ß is adjustable between 20 and 55 Stripper 1 must be exchanged for this 1 Undo the screws 9 on both sides 2 Set the desired angle in accordance with the scale 3 Retighten the screws 9 12 Setting work E1026en03 ...

Page 15: ...with the clamping screw 4 3 4 Selecting cutting tool Cutting tool Default High tensile Aluminum High tensile 5575 Heavy duty cut ting tool Order number 0088503 0089335 0005014 0005575 0110399 Usage General mild steel of up to 500 N mm2 Higher tensile mild steel of up to 650 N mm2 chromium steel Aluminum alloys High tensile materials of up to 800 N mm2 chromium steel High tensile materials A direct...

Page 16: ... cut ting tool Regrinding dia gram Regrinding reserve 10 mm 10 mm 10 mm 10 mm 2 mm Cutting tools for TruTool TKF 1500 beveler Tab 7 Note Optimum utilzation of the high performance cutting tool is ensured only with the machine in the 2 gear version 14 Setting work E1026en03 ...

Page 17: ...y 1 mm min 0 max 3 mm out of the slid ing sleeve 6 1 Rotate the eccentric shaft 1 until the cutting tool 3 has achieved its highest point UDP upper dead point 2 Undo the clamping screw 2 3 Rotate the carrier 5 by 360 as often as needed until the cutting tools protrudes 0 3 mm out of the sliding sleeve 6 4 One rotation 360 corresponds to a height adjustment of 1 75 mm 5 Retighten the clamping screw...

Page 18: ... the gear switch only when the motor is running down or at rest Damage to property due to too high a stroke rate Damage to the motor due to an overload can be a consequence Ø Observe the specifications in the technical data 1 On Off switch 2 Release switch Fig 84872 1 Put the machine into a stable position 2 Switch on the machine briefly Press the release switch 2 forward and hold it Press the On ...

Page 19: ... machining are collected in the chip box 1 Screw 2 Locking bar 3 Chip box Fig 54642 1 Push the chip box 3 onto the clamping plate 2 Loosen screw 1 3 Turn the locking bar 2 downward 4 Retighten the screw 1 The chip box is secured against dropping out E1026en03 Setting work 17 ...

Page 20: ...rews M10x30 2 Handle base Fig 42381 Ø Tighten screws 1 Tube shaped handle 1 Tube shaped handle 2 Screws M10x20 Fig 41795 Note Do not use washers Ø Tighten the tube shaped handle with a screw 2 18 Setting work E1026en03 ...

Page 21: ...r for the left hand side can be ordered separately 1 When the roller holder is to be installed without a handle base the supplied screws washers and nuts will also be required Note Do not use washers 2 If the roller holder is also to be installed it must be clamped between handle base and tool E1026en03 Setting work 19 Roller holder without handle base Roller holder with handle base ...

Page 22: ...sing The roller holder below can be used to bevel tubes with an out side diameter of up to 200 mm The minimum tube inside diam eter must be 100 mm For roller holder for tubes with an outside diameter of up to 200 mm Fig 54643 20 Setting work E1026en03 ...

Page 23: ... fasten them to the machine using the screw 4 4 Set the material thickness on a level sheet using the spindle 5 Position the machine on the tube 6 Use the adjusting screw 1 to align both rollers to the radius of the tube Special tool for pipe and tube processing The special tool below order number 0027798 can be used for tube processing for beveling tubes with an inside diameter of 30 120 mm The w...

Page 24: ...6 on the special tool 3 but do not unscrew it completely 5 Undo the screw 8 on the lever 6 Remove the pressure die 5 from the special tool 7 Unscrew both screws from the special tool 3 and remove the stripper 4 8 Then retract the special tool into the supporting body 1 9 Tighten the screws 2 on the supporting body 10 Reinstall the stripper 4 from the special tool 2 with two screws 11 Retract the p...

Page 25: ...ective cap screws Spacers with longer cap screws are used for greater material thicknesses These screws are subject to great stress Ø When changing spacers check the cap screws 49 for wear and replace with new screws if necessary For maximum material thicknesses use a spacer and a longer cap screw Spacer and cap screw Material thick ness range M16x90 12 9 DIN 912 order number 0023203 40 80mm M16x1...

Page 26: ...th spindle 3 Attach the corresponding spacer with spindle 4 Tighten the cap screw with a moment of 250 Nm Tip In order for the machine to run better insert the roller holders for tube processing 24 Setting work E1026en03 Converting the machine for material thicknesses 40 mm ...

Page 27: ...Suspension bracket 1 Clamping screw Suspension bracket Fig 54644 Ø In order to install the suspension bracket on the handle base screw in the clamping screw 1 in the recess E1026en03 Setting work 25 ...

Page 28: ...veler can be fastened is used for machining small workpieces The workstation can be mounted on a base plate or on a pedes tal The pedestal must be fastened into the floor using a mounting hole Workstation with pedestal Fig 54645 26 Setting work E1026en03 ...

Page 29: ...1 Threaded hole Fig 84873 Ø Fasten the machine to the work station using the screw in the threaded hole 1 E1026en03 Setting work 27 Mounting the machine at a workstation ...

Page 30: ...d it Press the On Off switch 1 The motor is running Notes Do not move the machine towards the workpiece until full speed has been reached In order to improve the cutting result and increase the service life of the cutting tool coat the cutting track with oil before machining the workpiece 4 Processing the material Place machine on the sheet and at first maintain a few centimetres clearance between...

Page 31: ...along the sheet in such away that the machine axis is roughly parallel to the sheet edge Press the machine against the sheet edge while doing so 5 Press the On Off switch 1 E1026en03 Operation 29 Switching off the machine ...

Page 32: ...nd gear head After 300 operating hours arrange for a trained specialist to relubricate or to replace the lubricating grease Lubricating grease G1 0139440 Lower blank holder Clean as needed Cutting tool Regrind as required Change as needed Sliding sleeve Change as needed play between bushing and cutting tool 0 3 mm Ventilation slots Clean as needed Supporting body After 60 m cutting lubricate the s...

Page 33: ...isk of fatal injury due to electric shock Ø Remove the plug from the plug socket before undertaking any maintenance work on the machine Damage to property due to improper handling Collisions could result from setting the machine incorrectly Ø Rotate the eccentric shaft one full turn in a clockwise direc tion using the Allen key provided If no more collisions occur remove the Allen key and put the ...

Page 34: ...bottom 4 Screw out the cutting tool 2 5 Grease the square part of the cutting tool and the bore hole of the carrier slightly with S1 lubricating grease order num ber 0121486 6 Check the penetration depth of the punch with the setting gauge order number 1411767 5 3 Change the sliding sleeve If the clearance between liner and cutting tool is 0 3 mm then the liner must be changed 32 Maintenance E1026...

Page 35: ...Rotate supporting body 20 by 45 3 Pull the carrier out towards the top 4 Screw out the cutting tool 2 5 Undo the cap screw 23 pull the sliding sleeve 22 up and out of the supporting body 20 6 Slide the new sliding sleeve 22 into the supporting body 20 from above Observe the orientation 7 Tighten cap screw 23 8 Reinstall the supporting body E1026en03 Maintenance 33 ...

Page 36: ...iding sleeve 1884873 x Punching and nibbling oil for steel 500 ml 0103387 x Punching and nibbling oil for aluminum 1000 ml 0125874 Lubricating grease S1 tube 25g 0121486 x Lubricating grease S1 can 1 kg 0342887 Lubricating grease G1 can 900 g 0139440 Stripper 0023242 Consumables Tab 10 TruTool TKF 1500 3A1 3B1 Order number Scope of deliv ery Box for small parts 0353966 x Operator s manual TKF 1500...

Page 37: ...ab 11 6 1 Ordering consumables Note The following data must be specified in order to ensure that parts are delivered correctly and without delay 1 Specify the order number 2 Enter further order data Voltage data Quantity Machine type 3 Specify the complete shipping information Correct address Desired delivery type e g air mail courier express mail ordinary freight parcel post Note For TRUMPF servi...

Page 38: ...7 Appendix Declaration of conformity guarantee replacement parts lists 36 Appendix Declaration of conformity guarantee replacement parts lists E1026en03 ...