Trumpf TKA 500-0 User manual

Operator´smanual
english
TKA500-
0

2 Safety E500EN_05.DOC
Overviewofcontents
1. Safety..............................................................................3
1.1 Generalsafetyrules.........................................................3
1.2 Specificsafetyrules.........................................................4
2. Description.....................................................................5
2.1 Correct use......................................................................6
2.2 Technicaldata..................................................................7
3. Tool assembly................................................................9
3.1 Setting chamferheight.....................................................9
3.2 Selecttriplemulti-edge cutterastool...............................10
3.3 Useradiustooland multi-edge cuttersasatool...............11
4. Operatinginstructions..................................................13
4.1 Working withchamfering 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 Replacecarbon brushes..................................................20
6. Original accessories and expendableparts.................21
Guarantee
Replacementpartslist
Addresses

E500EN_05.DOC Safety 3
1.Safety
1.1Generalsafetyrules
ØRead the Operator's Manualand the generalsafetyrules
(Materialnumber1239438,red document)intheirentirety
beforestarting up the machine.Followpreciselythe directions
contained therein.
ØRead the Operator'sManualand the safetyinstructions
(Materialnumber125699,red document)intheirentirety
beforestarting up the machine.Followpreciselythe directions
contained therein.
ØThe safetyregulationsaccording toDINVDE,CEE,AFNOR
and otherregulationswhicharevalidinindividualcountries
shouldbe adhered to.
Danger
Lethaldanger duetoelectricshock!
ØBeforecarrying outanymaintenancework onthe appliance,
pullthe plug out of thesocket.
ØBeforeeachtimethe applianceisused,check theplug,the
cableand the appliancefordamage.
ØKeep the appliancedry and do notoperateindamprooms.
ØWhen using the electrictool outside,connectthe fault
current (FI)protectiveswitchwithamaximumbreaking
current of30mA.
Warning
Danger ofinjury duetoincorrecthandling!
ØWhen working withthe machine, wearsafetyglasses, hearing
protection,protectiveglovesand work shoes.
ØOnlyinsertthe plug whenthe applianceisswitched off. After
use, pull outthe mainsplug.
Caution
Damagetopropertycanresultfromincorrecthandling.
Thedevice may bedamagedordestroyed.
ØDo not carrythe appliancebyitscable.
ØAlwaysguide the cableawayfromthe back ofthe appliance
and tonot pullthe cableoversharpedges.
ØArrange forstartupsand checkson manual electrictoolsto
be carried outbyatrained engineer.Onlyused the original
accessoriesprovided byTRUMPF.
USA/CAN
Restoftheworld

4 Safety E500EN_05.DOC
1.2Specificsafetyrules
Warning
Risk ofinjurytothehands!
ØDo not placeyourhand intothe processing line.
ØUsebothhandstoholdthemachine.
Caution
Damagetopropertycanresultfromincorrecthandling.
Thedevice may bedamagedordestroyed.
ØDo not carrythe appliancebyitscable.
ØAlwaysguide the cableawayfromthe back ofthe appliance
and tonot pullthe cableoversharpedges.
ØArrange forstartupsand checkson manual electrictoolsto
be carried outbyatrained engineer.Onlyused the original
accessoriesprovided byTRUMPF.
Warning
Risk ofinjuryfromhigh-temperature chips!
High-temperature chipsare expelledfromthechipejectorat
high speed.
ØUsethe swarfbox.
Warning
Danger ofinjury possibleduetoimproper handling!
ØWhen working withthe machine,alwaysensurethatithasa
securebase.
ØNevertouchthe tool whilethe machine isrunning.
ØAlwaysguide the machineawayfromthe bodywhileworking.
ØDo not work holding the machine aboveyourhead.

E500EN_05.DOC Description 5
2.Description
9 8 7
2
3
4
5
6
1
10
1Speed controller
2Motor
3On/off switch
4Spindlelock
5Gear head
6Handle
7Support plate
8Graduated collar
9Clampinglever
10Triplemulti-edgecutter mount
Chamferinganddeburring toolinoverview Fig.33402

6 Description E500EN_05.DOC
2.1Correctuse
Warning
Can cause injury ordamagetohealth!
ØForprocessing and materials,onlyusemachineswhichare
named in"Correct use".
ØDo notmachine materialswhichcontainasbestos.
The TRUMPFTKA500-0chamfering and deburringtool isan
electricallydriven portablemachine:
·Formachining workpiecesinsteel,chromesteel,aluminum,
aluminumalloys, brass and plastic(PA6).
·Forcommercialuseinindustry and trade.
·When adding visibleedgesinplant, tooland machine
construction.
·Forrounding offe.g.T-beamsinconstruction and structural
steelengineering.
·Forremoving burrsfollowing cutting processes(e.g.guillotine
shearing).
·Foruseinshipbuilding,toremovesharpcornersandedges,
owing tothe riskofflaking of paint(corrosion protection).
·Whenmachining steel furniture.

E500EN_05.DOC Description 7
2.2Technicaldata
Othercountries USA
Values Values Values Values
Voltage 230V 120V 110V 120V
Frequency 50/60Hz 50/60Hz 50/60Hz 50/60Hz
Working speed 3-4m/min 3-4m/min 3-4m/min 10-13ft/min
Nominalpower
consumption
1400W 1400W 1200W 1140W
Stroke ratewith
idlerun
8390/min 7300/min 7300/min 7300/min
Weight withlead
handlewith
cable
3.5kg 3.5kg 3.5kg 7.8lbs
Min. sheet
thickness
1.5mm
R2:3.5mm
R3:4.5mm
1.5mm
R2:3.5mm
R3:4.5mm
1.5mm
R2:3.5mm
R3:4.5mm
0.059in
Smallest radius
withinner
cutouts
12 mm 12 mm 12 mm 0.472in
Edgeradius 3mm 3mm 3mm 0.12in
Protective
insulation
Class II Class II Class II Class II
Technicaldata
Noise and vibration Measured valuesasstatedinEN50 144
Whileidling Whenworking
A-weightedsoundlevel typically85dB(A) typically93dB(A)
A-weightedsoundlevel typically98dB(A) typically106dB(A)
Hand-armvibration typicallyless than or
equalto2.5m/s²
typicallyless than or
equalto5.8m/s²
Measured valuesfor noiseandvibration
Note
The measured valuesspecified abovemaybe exceeded while
working.
Tab. 1
Tab. 2

8 Description E500EN_05.DOC
1
2
3
1Chamfer height
2Chamfer length
3Chamferangle
Materialand
tensile
strength
Chamferheight[mm]
30° 45° 60°
Chamfer
length[mm]
230V 110/
120V
230V 110/
120V
230V 110/
120V
230V 110/
120V
·Steel 400
N/mm²
·Steel 600
N/mm²
·Steel 800
N/mm²
·Aluminium
250
N/mm²
4.3
2.2
1.3
6.1
3.5/
0.138
1.9/
0.079
1.1/
0.047
6.1/
0.311
3.5
1.8
1.1
4.9
2.8/
0.110
1.6/
0.059
0.9/
0.051
4.9/
0.335
2.5
1.3
0.8
5
2.0/
0.078
1.1/
0.047
0.7/
0.027
4.3/
0.169
5.0
2.5
1.5
7.0
4.0/
0.157
2.2/
0.087
1.3/
0.051
7.0/
0.335
Chamfer height
Fig.36835
Tab. 3

E500EN_05.DOC Toolassembly 9
3.Toolassembly
Caution
Supportplateanddial ringbecomehot!
Danger ofburns
ØWhenconfiguring the chamferheightwearprotectivegloves.
3.1Settingchamferheight
1
2
3
1Clampinglever
2Dial ring
3Support plate
Setting chamferheight
The chamferheightissetwiththe aidof the supportplateand can
be read off the numericscaleon the dialring.
1.Loosenclampinglever(1).
2.Rotatesupportplate(3)until desired chamferheightcan be
read atthe dialring (2).Chamferheightiscalculated as
follows:
(Value on dialscale)+(value on dialring)=chamferheight.
Example:1.5+0.7=2.2
3.Retighten the clamping lever(1).
Chamferheightisset.
Fig.33408

10 Toolassembly E500EN_05.DOC
The unitisadjusted inzeroposition on assembly.Zeroposition
meanschamferheight zero.The dialring canbe readjusted.
2
1
1Dial scale 2Dial ring
Zeroposition
Todeburr andchamferthe integrated 45°multi-edge cuttermount
isused.The integrated multi-edge cuttermount consistsof the 45°
multi-edge cuttermount, the triplemulti-edge cutterand the
impeller.
3.2Selecttriplemulti-edgecutteras tool
The triplemulti-edge cutters,whichareactuallytoolsfor
chamfering and deburring:
·Formachining steel,aluminumand aluminumalloysaswell as
plasticmaterial.
·Suitableforprocessing bevelswith45°.
Foreachmaterialtherearetheappropriatemulti-edge cutters:
Tensilestrengthof workpiece Multi-edgecutter
Steel upto400 N/mm²0–2.2x45°
2.2–3.5x45°
St
Cr
Steel upto600 N/mm² Cr
Steel upto800 N/mm² Cr
Aluminum/aluminumalloy
up to250N/mm² 250N/mm²
Alu
Plasticmaterial (PA6) Alu
Dial ring
Fig.33409
Tab. 4

E500EN_05.DOC Toolassembly 11
3.3Use radiustooland multi-edgecutters
as atool
3
2
1
1Triplemulti-edgecutter mount
2Triplemulti-edgecutter
3Impeller
Triplemulti-edgecutter mount
When deburring orchamfering withradiusthe multi-edge cutter
mountRisinserted completely.The integrated multi-edge cutter
mountconsistsofthe multi-edge cuttermountR,themulti-edge
cuttersand the impellerR.
The multi-edge cutters,the actualtoolsasradiustools,are:
·useableforprocessing steel,aluminumand aluminumalloys
aswell asplasticmaterial.
·suitableforprocessing bevelswithradiusR2 orR3.
Triplemulti-edgecutter
mount
Fig.33407

12 Toolassembly E500EN_05.DOC
Thereisan appropriatemulti-edge cutterforeachmaterial:
Tensilestrengthof
the workpiece
Radius Multi-edge
cutter
Chamferheight
[mm]
Steel upto400 N/mm² R2 St R2 1.1
Steel upto400 N/mm² R3 St R3 1.7
Steel upto600 N/mm² R2 Cr R2 1.1
Steel upto800 N/mm² R2 Cr R2 1.1
Aluminum/aluminum
alloy²
R2 Cr R2 1.1
Steel upto600 N/mm² R2 Cr R2 1.1
Plasticmaterial (PA6)R2 Cr R2 1.1
Multi-edgecutterandsettingdim.
Note
The valuesforchamferheightareguidancevalueswhichmay
differfromthe stated values.
Note
Beforeprocessing steeland aluminumoraluminumalloysitis
recommended tooil the cutting edgeswithcutting,toachieve
edgesthat can be betterprocessed and ahighertoolservicelife.
Multi-edgecutter and Setting
dimension
Tab. 5

E500EN_05.DOC Operating instructions 13
4.Operatinginstructions
Caution
Damagetopropertydueto anoversupplyofpower!
Damagetothemotor
ØCheck the powersupply.The powersupplymustcorrespond
tothe informationon the machine type plate.
Warning
Danger ofinjury duetoincorrecthandling!
ØWhen working withthe machine,alwaysensurethatithasa
securebase.
ØNevertouchthe tool whilethe machine isrunning.
ØAlwaysguide the machine awayfromthe bodywhen
operating.
ØDo not work aboveyourhead withthe appliance.
Caution
Damagetoproperty!
Wear and destruction ofthemulti-edgecutters andthemulti-
edgecutter mount,toolfailure.
ØAvoidcollisionswhen working.
The appliancemayswitchoff prematurelywhen affected by
electromagneticfaults. The appliancewillcontinue tooperatewhen
the faultshavebeen cleared.
Whenthe motortemperatureistoo high the motorswitchesoff.
The red indicatorlamp(LED)atthe motorwilllight up.
ØLet the unit runidleuntilithascooled down.
Aftercooling the unitcan be operated againasnormal.
Electromagneticfaults
Overloadprotectionmotor

14 Operating instructions E500EN_05.DOC
4.1Workingwithchamferingand
deburring tool
2
3
1
1Speed controller
2Motor
3On/off switch
1.Set the speed controller(1)tothe highest level(=level6).
2.Pushthe On/off switch(3)on the motor(2)and pressthe
switchdowntill it catches.
Motorruns.
1.Onlymovethe machine towardsthe workpiecewhen fullspeed
hasbeen reached.
2.Processing material.
When deburring orchamfering the devicemustalwaysbe
moved fromleft to right (up-milling).
Switchonchamferingand
deburring tool
Fig.33404
Workingwithchamferingand
deburring tool

E500EN_05.DOC Operating instructions 15
Work isperformed withtwo-hand operation forall machine
positions.
Two-handoperation
When operating the machine ensurethatthe machineisheldwith
bothhandsinsuchawaythatbothhandsarekeptawayfromthe
processing point.
1.Removemachine frommaterial.
2.On/off switchfirst press downon motorthen pushswitchback.
The motorisstopped.
Two-handoperation
Fig.31628
Switchoff chamfering and
deburring tool

16 Maintenance E500EN_05.DOC
5.Maintenance
Danger
Lethaldanger duetoelectricshock!
ØWhen carrying outatoolchange,and aboveall,when
carrying out maintenancework on theappliance, pull the plug
out ofthe socket.
Caution
Tool andmulti-edgecutter mountbecome hot!
Danger ofburns
ØFortoolchange wearprotectivegloves.
Caution
Damagetopropertyduetoblunttools!
Overloadingoftheappliance.
ØCheck toolsregularlyforwear.Sharpmulti-edge cutters
ensurehigh qualitycutting and protectthe device.Rotateor
replacemulti-edge cuttersingood time.
Warning
Risk ofinjurydueto incorrectrepairs!
Theappliance willnotfunctionproperly.
ØRepairsshouldonlybe carried out byatrained engineer.

E500EN_05.DOC Maintenance 17
2
3
1
1Gear head 2Tappinggear housing and
tappingsupport plate
3Ventilation slit
Maintenancepositionson theTKA 500-0
Maintenancepoint Procedureand interval Empfohlene Schmiermittel Recommended
lubricants
Gearboxand
gear head (1)
After 100operatinghours,arrange
foratrained engineer
torelubricateor toreplacethe
lubricating grease.
"G1" lubricatinggrease 0139440
Integraltappinggear
housingandintegral
tappingsupport plate(2)
Clean andgreaseifnecessary "G3" lubricatinggrease 0353969
Ventilation slit (3) Clean asrequired. - -
Multi-edgecutter Turnorinsert anewoneif
necessary.
- -
Impeller Changeif necessary. - -
Maintenancepositionsandmaintenanceintervals
Fig.33405
Tab. 6

18 Maintenance E500EN_05.DOC
5.1Changetool
4
3
2
1
1Facewrench
2Support plate
3Boresonthemulti-edgecutter
mount
4Socketwrench
Tool changes
1.Placesocketwrench(see Fig.33534, p. 18,4)on the milling
cutter.
2.Insertfacewrench(see Fig. 33534, p.18, 3)intothe
corresponding boreholesinthe socket wrench.
3.Press the spindlelock and simultaneouslyturnthe facewrench
(see Fig. 33534, p. 18,3)counter-clockwise.
4.Completelyremovethe multi-edge cuttermount.
Dismantlemulti-edgecutter
mount
Fig.33534

E500EN_05.DOC Maintenance 19
5.2Changemulti-edgecutter
1
2
2
1
2
1
1Fixingscrew 2Triplemulti-edgecutter
1.Loosenfixing screw(1)and takeoutmulti-edge cutter(2).
2.Turnmulti-edge cutterorinsert anewone.
3.Refasten multi-edge cutterwithfixing screws.
Fig.33406

20 Maintenance E500EN_05.DOC
5.3Changeimpeller
The impellermustbe changed ifworn,orelsethe chamfer
surfaceswillbe unevenlymachined.
1
2
3
1Multi-edgecutter mount
2Impeller
3Hexagonalnut
1.Loosenhexagonalnut(3)withsingleend spanner.
2.Pullimpeller(2)awayand exchange it.
3.Refasten the newimpellerwithhexagonalnut.
5.4Replacecarbonbrushes
The motorremainsatastandstillwhen the carbon brushisworn
out.
ØHavecarbon brusheschecked andreplaced byanexpert
whenrequired.
Note
Onlyuseoriginalreplacementpartsand takenoteofthe infor-
mation on the rating plate.
Fig.33410