Trumpf TKA 300-0 User manual

Operator's manual
english
TKA 300-0

2 Safety E479EN_07.DOC
Overview of contents
1. Safety ..................................................................................3
1.1 General safety rules.............................................................3
1.2 Specific safety rules.............................................................4
2. Description .........................................................................5
2.1 Correct use ..........................................................................6
2.2 Technical data .....................................................................7
3. Tool assembly....................................................................9
3.1 Setting chamfer height.........................................................9
3.2 Select triple multi-edge cutter as tool ................................11
3.3 Use radius tool and multi-edge cutters as a tool ...............12
4. Operating instructions ....................................................13
4.1 Working with chamfering and deburring tool .....................14
5. Maintenance .....................................................................16
5.1 Change tool .......................................................................18
5.2 Change multi-edge cutter ..................................................19
5.3 Change impeller.................................................................20
5.4 Replace carbon brushes....................................................20
6. Original accessories and expendable parts .................21
Guarantee
Replacement parts list
Addresses

E479EN_07.DOC Safety 3
1. Safety
1.1 General safety rules
¾Read the Operator's Manual and the general safety rules
(Material number 1239438, red document) in their entirety
before starting up the machine. Follow precisely the directions
contained therein.
¾Read the Operator's Manual and the safety instructions
(Material number 125699, red document) in their entirety
before starting up the machine. Follow precisely the directions
contained therein.
¾The safety regulations according to DIN VDE, CEE, AFNOR
and other regulations which are valid in individual countries
should be adhered to.
Danger
Lethal danger due to electric shock!
¾Before carrying out any maintenance work on the appliance,
pull the plug out of the socket.
¾Before each time the appliance is used, check the plug, the
cable and the appliance for damage.
¾Keep the appliance dry and do not operate in damp rooms.
¾When using the electric tool outside, connect the fault
current (FI) protective switch with a maximum breaking
current of 30 mA.
Caution
Danger of injury due to incorrect handling!
¾When working with the machine, wear safety glasses, hearing
protection, protective gloves and work shoes.
¾Only insert the plug when the appliance is switched off. After
use, pull out the mains plug.
Caution
Damage to property can result from incorrect handling.
The device may be damaged or destroyed.
¾Do not carry the appliance by its cable.
¾Always guide the cable away from the back of the appliance
and to not pull the cable over sharp edges.
¾Arrange for startups and checks on manual electric tools to
be carried out by a trained engineer. Only used the original
accessories provided by TRUMPF.
USA/CAN
Rest of the world

4 Safety E479EN_07.DOC
1.2 Specific safety rules
Warning
Risk of injury to the hands!
¾Do not place your hand into the processing line.
¾Use both hands to hold the machine.
Caution
Damage to property can result from incorrect handling.
The device may be damaged or destroyed.
¾Do not carry the appliance by its cable.
¾Always guide the cable away from the back of the appliance
and to not pull the cable over sharp edges.
¾Arrange for startups and checks on manual electric tools to
be carried out by a trained engineer. Only used the original
accessories provided by TRUMPF.
Warning
Risk of injury from high-temperature chips!
High-temperature chips are expelled from the chip ejector at
high speed.
¾Use the swarf box.
Warning
Danger of injury possible due to improper handling!
¾When working with the machine, always ensure that it has a
secure base.
¾Never touch the tool while the machine is running.
¾Always guide the machine away from the body while working.
¾Do not work holding the machine above your head.

E479EN_07.DOC Description 5
2. Description
9 8 7
2
3
4
5
6
1
10
1 Speed controller
2 Motor
3 On/off switch
4 Spindle lock
5 Gear head
6 Handle
7 Support plate
8 Graduated collar
9 Clamping lever
10 Integrated 45° multi-edge cutter
mount
Chamfering and deburring tool in overview Fig. 30590, 30822

6 Description E479EN_07.DOC
2.1 Correct use
Caution
Can cause injury or damage to health!
¾For processing and materials, only use machines which are
named in "Correct use".
¾Do not machine materials which contain asbestos.
The TRUMPF TKA 300-0 chamfering and deburring tool is an
electrically driven portable machine:
•For machining workpieces in steel, chrome steel, aluminum,
aluminum alloys, brass and plastic (PA6).
•For commercial use in industry and trade.
•When adding visible edges in plant, tool and machine
construction.
•For rounding off e.g. T-beams in construction and structural
steel engineering.
•For removing burrs following cutting processes (e.g. guillotine
shearing).
•For use in shipbuilding, to remove sharp corners and edges,
owing to the risk of flaking of paint (corrosion protection).
•When machining steel furniture.

E479EN_07.DOC Description 7
2.2 Technical data
Other countries USA
Values Values Values Values
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Working speed 4-6 m/min 4-6 m/min 4-6 m/min 13-20 ft/min
Nominal power
consumption
850 W 670 W 670 W 670 W
Stroke rate with
idle run
8600/min 8700/min 8000/min 8700/min
Weight with lead
handle with
cable
2.9 kg 2.9 kg 2.9 kg 6.4 lbs
Min. sheet
thickness
1.5 mm 1.5 mm 1.5 mm 0.06 in
Smallest radius
with inner
cutouts
11 mm 11 mm 11 mm 0.44 in
Edge radius 3 mm 3 mm 3 mm 0.12 in
Protective
insulation
Class II Class II Class II Class II
Technical data
Noise and vibration Measured values as stated in EN 50 144
While idling When working
A-weighted sound level typically 83 dB (A) typically 92 dB (A)
A-weighted sound level typically 97 dB (A) typically 106 dB (A)
Hand-arm vibration typically less than or
equal to 1.8 m/s²
typically less than or
equal to 11.5 m/s²
Measured values for noise and vibration
Note
The measured values specified above may be exceeded while
working.
Tab. 1
Tab. 2

8 Description E479EN_07.DOC
1
2
3
1 Chamfer height
2 Chamfer length
3 Chamfer angle
Chamfer height [mm]
30° 45° 60°
Chamfer
length [mm]
Material and
tensile
strength
230 V 110/
120 V
230 V 110/
120 V
230 V 110/
120 V
230 V 110/
120 V
•Steel 400
N/mm²
•Steel 600
N/mm²
•Steel 800
N/mm²
•Aluminium
250
N/mm²
2.6
1.3
0.9
5.2
2.1/
0.082
1/
0.039
0.6/
0.023
4.3/
0.169
2.1
1.1
0.7
4.2
1.7/
0.66
0.7/
0.027
0.5/
0.019
3.4/
0.133
1.5
0.8
0.5
3
1.2/
0.047
0.6/
0.023
0.4/
0.015
2.5/
0.098
3
1.5
1
6
2.4/
0.094
1.1/
0.047
0.7/
0.027
5.0 /
0.196
Chamfer height
Fig. 36835
Tab. 3

E479EN_07.DOC Tool assembly 9
3. Tool assembly
Caution
Support plate and dial ring become hot!
Danger of burns
¾When configuring the chamfer height wear protective gloves.
3.1 Setting chamfer height
1 2 3
1 Clamping lever
2 Dial ring
3 Support plate
Setting chamfer height
The chamfer height is set with the aid of the support plate and can
be read off the numeric scale on the dial ring.
1. Loosen clamping lever (1).
2. Rotate support plate (3) until desired chamfer height can be
read at the dial ring (2). Chamfer height is calculated as
follows:
(Value on dial scale) + (value on dial ring) = chamfer height.
Example: 1.5 + 0.7 = 2.2
3. Retighten the clamping lever (1).
Chamfer height is set.
Fig. 30592

10 Tool assembly E479EN_07.DOC
The unit is adjusted in zero position on assembly. Zero position
means chamfer height zero. The dial ring can be readjusted.
2
1
1 Dial scale 2 Dial ring
Zero position
Dial ring
Fig. 31290

E479EN_07.DOC Tool assembly 11
3.2 Select triple multi-edge cutter as tool
3
2
1
1 45° Multi-edge cutter mount
2 Triple multi-edge cutter
3 Impeller
Integrated 45° multi-edge cutter mount
The triple multi-edge cutters, which are actually tools for
chamfering and deburring:
•For machining steel, aluminum and aluminum alloys as well as
plastic material.
•Suitable for processing bevels with 45°.
For each material there are the appropriate multi-edge cutters:
Tensile strength of workpiece Multi-edge cutter
Steel up to 400 N/mm² St
Steel up to 600 N/mm² Cr
Steel up to 800 N/mm² Cr
Aluminum/aluminum alloy
up to 250 N/mm²
Alu
Plastic material (PA6) Alu
Integrated 45° multi-edge
cutter mount
Fig. 32902
Tab. 4

12 Tool assembly E479EN_07.DOC
3.3 Use radius tool and multi-edge cutters
as a tool
When deburring or chamfering with radius the multi-edge cutter
mount R is inserted completely. The integrated multi-edge cutter
mount consists of the multi-edge cutter mount R, the multi-edge
cutters and the impeller R.
The multi-edge cutters, the actual tools as radius tools, are:
•useable for processing steel, aluminum and aluminum alloys
as well as plastic material.
•suitable for processing bevels with radius R2 or R3.
There is an appropriate multi-edge cutter for each material:
Tensile strength of
the workpiece
Radius Multi-edge
cutter
Chamfer height
[mm]
Steel up to 400 N/mm² R2 St R2 1.1
Steel up to 400 N/mm² R3 St R3 1.7
Steel up to 600 N/mm² R2 Cr R2 1.1
Steel up to 800 N/mm² R2 Cr R2 1.1
Aluminum/aluminum
alloy²
R2 Cr R2 1.1
Steel up to 600 N/mm² R2 Cr R2 1.1
Plastic material (PA6) R2 Cr R2 1.1
Multi-edge cutter and setting dim.
Note
The values for chamfer height are guidance values which may
differ from the stated values.
Note
Before processing steel and aluminum or aluminum alloys it is
recommended to oil the cutting edges with cutting oil to achieve
edges that can be better processed and a higher tool service life.
Multi-edge cutter and
Einstellmaß
Tab. 5

E479EN_07.DOC Operating instructions 13
4. Operating instructions
Caution
Damage to property due to an oversupply of power!
Damage to the motor
¾Check the power supply. The power supply must correspond
to the information on the machine type plate.
Caution
Damage to property due to blunt tools!
Overloading of the appliance.
¾Check tools regularly for wear. Sharp multi-edge cutters
ensure high quality cutting and protect the device. Rotate or
replace multi-edge cutters in good time.
Caution
Danger of injury due to incorrect handling!
¾When working with the machine, always ensure that it has a
secure base.
¾Never touch the tool while the machine is running.
¾Always guide the machine away from the body when
operating.
¾Do not work above your head with the appliance.
The appliance may switch off prematurely when affected by
electromagnetic faults. The appliance will continue to operate when
the faults have been cleared.
When the motor temperature is too high the motor switches off.
¾Let the unit run idle until it has cooled down.
After cooling the unit can be operated again as normal.
Electromagnetic faults
Overload protection motor

14 Operating instructions E479EN_07.DOC
4.1 Working with chamfering and
deburring tool
2
1
3
1 Speed controller
2 Motor
3 On/off switch
1. Set the speed controller (1) (230 V) to the highest level
(= level G).
2. Push the On/off switch (3) on the motor (2) and press the
switch down till it catches.
Motor runs.
2. Set the speed controller (1) (230 V) to the highest level
(= level G).
1. Only move the machine towards the workpiece when full speed
has been reached.
2. Processing material.
When deburring or chamfering the device must always be
moved from left to right (up-milling).
Switch on chamfering and
deburring tool
Fig. 30594
Working with chamfering and
deburring tool

E479EN_07.DOC Operating instructions 15
Work is performed with two-hand operation for all machine
positions.
Two-hand operation
When operating the machine ensure that the machine is held with
both hands in such a way that both hands are kept away from the
processing point.
1. Remove machine from material.
2. On/off switch (see Fig. 30594, p. 14, 3) first press down on
motor then push switch back.
The motor is stopped.
Two-hand operation
Fig. 31628
Switch off chamfering and
deburring tool

16 Maintenance E479EN_07.DOC
5. Maintenance
Danger
Lethal danger due to electric shock!
¾When carrying out a tool change, and above all, when
carrying out maintenance work on the appliance, pull the plug
out of the socket.
Caution
Tool and multi-edge cutter mount become hot!
Danger of burns
¾For tool change wear protective gloves.
Caution
Damage to property due to blunt tools!
Overloading of the appliance.
¾Check tools regularly for wear. Sharp multi-edge cutters
ensure high quality cutting and protect the device. Rotate or
replace multi-edge cutters in good time.
Warning
Risk of injury due to incorrect repairs!
The appliance will not function properly.
¾Repairs should only be carried out by a trained engineer.

E479EN_07.DOC Maintenance 17
1
2
3
1 Gear head 2 Tapping gear housing and
tapping support plate
3 Ventilation slit
Maintenance positions on the TKA 300-0
Maintenance point Procedure and interval Empfohlene Schmiermittel Recommended
lubricants
Gearbox and
gear head (1)
After 100 operating hours, arrange
for a trained engineer
to relubricate or to replace the
lubricating grease.
"G1" lubricating grease 0139440
Integral tapping gear
housing and integral
tapping support plate (2)
Clean and grease if necessary "G3" lubricating grease 0353969
Ventilation slit (3) Clean as required. - -
Multi-edge cutter Turn or insert a new one if
necessary.
- -
Impeller Change if necessary. - -
Maintenance positions and maintenance intervals
Fig. 30823
Tab. 6

18 Maintenance E479EN_07.DOC
5.1 Change tool
1
2
3
1 Face wrench
2 Support plate
3 Bores on the multi-edge cutter
mount
Tool changes
1. Insert face wrench in the corresponding bores (3) on the multi-
edge cutter mount.
2. Press spindle lock and at the same time turn the face wrench
(1) counter-clockwise.
3. Take out the integrated multi-edge cutter mount.
Dismantle multi-edge cutter
mount
Fig. 30596

E479EN_07.DOC Maintenance 19
5.2 Change multi-edge cutter
1
2
2
1
1 Fixing screw 2 Triple multi-edge cutter
1. Loosen fixing screw (1) and take out multi-edge cutter (2).
2. Turn multi-edge cutter or insert a new one.
3. Refasten multi-edge cutter with fixing screws.
Fig. 30598

20 Maintenance E479EN_07.DOC
5.3 Change impeller
The impeller must be changed if worn, or else the chamfer
surfaces will be unevenly machined.
1
2
3
1 Multi-edge cutter mount
2 Impeller
3 Hexagonal nut
1. Loosen hexagonal nut (3) with single end spanner.
2. Pull impeller (2) away and exchange it.
3. Refasten the new impeller with hexagonal nut.
5.4 Replace carbon brushes
The motor remains at a standstill when the carbon brush is worn
out.
¾Have carbon brushes checked and replaced by an expert
when required.
Note
Only use original replacement parts and take note of the infor-
mation on the rating plate.
Fig. 31289