Trumpf TKF 1100-0 User manual

Operator's manual
english
TKF 1100-0

2 Table of contents E543EN_03.DOC
Table of contents
1. Safety ..................................................................................3
2. Description .........................................................................5
2.1 Correct use ..........................................................................6
2.2 Technical data .....................................................................7
3. Tool assembly....................................................................8
3.1 Setting the sheet thickness..................................................8
3.2 Adjusting the ram length ......................................................9
3.3 Selecting angle of bevel.....................................................10
3.4 Adjusting height of the cutting tool.....................................12
3.5 Selecting cutting tool..........................................................13
3.6 Motor handle......................................................................15
4. Operation..........................................................................16
4.1 Working with the TKF 1100-0 ............................................17
4.2 Changing the cutting direction ...........................................18
5. Maintenance .....................................................................19
5.1 Regrind cutting tool............................................................20
Checking cutting tool guide wear..................................20
Inspecting and replacing the wearing plate ..................21
5.2 Replace cutting tool ...........................................................21
Disassembling cutting tool............................................22
Mounting the cutting tool ..............................................22
5.3 Replacing carbon brushes.................................................22
6. Original accessories and wearing parts........................23
Guarantee
Replacement parts list
Addresses

E543EN_03.DOC Safety 3
1. Safety
Read the operator's manual and the general safety rules (mate-
rial number 1239438, red document) completely before putting
the machine into service. Follow precisely the instructions con-
tained therein.
Read the operator's manual and the safety instructions (material
number 125699, red document) completely before putting the
machine into service. Follow precisely the instructions contained
therein.
Adhere to the safety regulations in accordance with DIN VDE,
CEE, AFNOR and to the specific regulations of the country of
operation.
Danger
Risk of fatal injury from electric shock!
Remove the plug from the plug socket before undertaking any
maintenance work on the machine.
Check the plug, cable and machine for damage each time
before using the machine.
Keep the machine dry and do not operate it in damp rooms.
Connect the earth leakage (EL) circuit breaker with a maxi-
mum release current of 30 mA when using the electric tool
outside.
Warning
Danger of injury due to improper handling!
Wear safety glasses, hearing protection, protective gloves
and work shoes when working at the machine.
Do not insert the plug unless the machine is switched off. Pull
the power plug after use.
Warning
Danger of injury to hands!
Do not reach into the processing line with your hands.
Use both hands to hold the machine.
USA/CAN
Other countries

4 Safety E543EN_03.DOC
Caution
Damage to property due to improper handling!
The machine will be damaged or destroyed.
Do not use the power cable to carry the machine.
Always lay the electrical cable away from the back of the
machine and do not pull it over sharp edges.
Have hand-held electrical tools serviced and checked by
qualified technicians. Only use original TRUMPF accessories.
Warning
Risk of injury from falling machinery
The entire weight of the machine must be taken up after
processing of the work workpiece.
Use suspension bracket with balancer.
Use suspension cable.
Caution
Damage to property possible due to improper handling!
Collisions could result from an erroneous setting of the ma-
chine.
Turn the eccentric shaft (2) one full clockwise rotation using the
Allen key provided. If no collisions can be detected, remove the
Allen key and put the machine into operation in accordance
with regulations (see Fig. 39412, p. 5).

E543EN_03.DOC Description 5
2. Description
2
3
4
5
6
7
8
14
9
1
10 11
1213
1 Bow-handle (can be installed in
2 positions)
2 Eccentric shaft
3 Roller holder
4 Spiral bevel gear
5 Stripper
6 Cutting tool guide
7 Rest plate
8 Pressure die
9 Mount
10 Locking mechanism for mount
11 Clamping lever for fastening the
handle
12 On/Off switch
13 Release inhibiter knob
14 Spindle wheel
TKF 1100-0
Fig. 39412

6 Description E543EN_03.DOC
2.1 Correct use
Warning
Danger of injury!
Only use the machine for the tasks and materials described in
"Intended use".
The TRUMPF TKF 1100-0 bevelling machine is an electric hand
tool used for the following applications:
•Preparation of all K-, V-, X- and Y-shaped welding grooves
used for gas and electrical fusion welding with various angles
of bevel and continuously adjustable lengths of bevel.
•Forming of uniform, oxide-free, bright metallic welding bevel
edges in steel and aluminium.
•Machining of chromium steel and similar high-tensile materials.
•Bevelling of straight and curved edges insofar as the minimum
radius with inner curves is at least 40 mm.
•Bevelling of edges on flat and crooked workpieces, particularly
in connection with tubes when the inside diameter is at least 80
mm in size.
•Bevelling of edges in both directions, whereby the bevelling
can begin and end at any give point on the sheet edge.
•Bevelling of edges on large, bulky workpieces, for which the
bevelling machine is guided as a hand-held device.
•Bevelling of edges in normal position (carrier underneath the
machine) and in "upside-down position" (carrier above the ma-
chine), which is particularly advantageous with the bevelling of
X- and K-welding grooves.

E543EN_03.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
Bevelling
lengths "ls"
continuously
adjustable
•Material
tensile
strength
400 N/mm²
•Material
tensile
strength
600 N/mm²
•Material
tensile
strength
800 N/mm²
Max. 11 mm
Max. 9 mm
Max. 6 mm
Max. 11 mm
Max. 9 mm
Max. 6 mm
Max. 11 mm
Max. 9 mm
Max. 6 mm
0.430 in
0.354 in
0.236 in
Working speed 2.0 m/min 2.0 m/min 2.0 m/min 6.5 ft/min
Nominal power
consumption
1600 W 1500 W 1500 W 1500 W
Stroke rate with
nominal load
340/min 340/min 320/min 340/min
Idle stroke rate 450/min 450/min 440/min 450/min
Weight 10 kg 10 kg 10 kg 25.7 lbs
Sheet thickness
Max. 25 mm
Min. 3 mm
Max. 25 mm
Min. 3 mm
Max. 25 mm
Min. 3 mm
0.984 in
0.12 in
Angle of bevel
"ß"
30°, 37.5°,
45°
30°, 37.5°,
45°
30°, 37.5°,
45°
30°, 37.5°,
45°
Smallest radius
with inner
cutouts
40 mm 40 mm 40 mm 1.57 in
Smallest tube
inside diameter
80 mm 80 mm 80 mm 3.15 in
Protective insu-
lation
Class II Class II Class II Class II
Technical data
Table 1

8 Tool assembly E543EN_03.DOC
Noise and vibration Measured values in accordance
with EN 60745
A-classified sound pressure level Typically 89 dB (A)
A-classified acoustic power level Typically 100 dB (A)
Hand-arm vibration Typically less than or equal to 2.5 m/s²
Measured values for noise and vibration
Note
The measured values specified above may be exceeded while
working.
3. Tool assembly
3.1 Setting the sheet thickness
7
14
7 Rest plate 14 Spindle wheel
1. Place machine on the sheet (work position).
2. Adjust the rest plate (7) to match the sheet thickness using the
spindle wheel (14). Allow for 0.5 to 1 mm of play when doing so.
Tab. 2
Fig. 39413

E543EN_03.DOC Tool assembly 9
3.2 Adjusting the ram length
4
15
9
4 Spiral bevel gear
9 Mount
15 Clamping screw
1. Loosen clamping screw (15).
2. Change the setting by turning the spiral bevel gear (4) until the
desired ram length (scale on stripper 5) lines up with the mark-
ing.
3. Afterwards, screw in the clamping screw (15) until it is tight.
Fig. 39414

10 Tool assembly E543EN_03.DOC
3.3 Selecting angle of bevel
s
s
h
l
h
ß
b
s
b = l sin ß
s.
h = l cos ß
s.
h = s - h
s
s
lsLength of bevel
ß Angle of bevel
s Sheet thickness
Fig. 40332

E543EN_03.DOC Tool assembly 11
Angle of
bevel
Length
of bevel
Height of
bevel
Width of
bevel
Length of
bevel ls
11 mm 9 mm 7.5 mm 6 mm 4.5 mm 3 mm
Angle of
bevel ß
30°
Height of
bevel hs 9.5 mm 7.8 mm 6.5 mm 5.2 mm 3.9 mm 2.6 mm
Width of
bevel b 5.5 mm 4.5 mm 3.8 mm 3 mm 2.3 mm 1.5 mm
Length of
bevel ls
11 mm 9 mm 7.5 mm 6 mm 4.5 mm 3 mm
Angle of
bevel ß
37.5°
Height of
bevel hs 8.7 mm 7.1 mm 6 mm 4.8 mm 3.6 mm 2.4 mm
Width of
bevel b 6.7 mm 5.5 mm 4.6 mm 3.7 mm 2.7 mm 1.8mm
Length of
bevel ls
11 mm 9 mm 7.5 mm 6 mm 4.5 mm 3 mm
Angle of
bevel ß
45°
Height of
bevel hs 7.8 mm 6.4 mm 5.3 mm 4.2 mm 3.2 mm 2.1 mm
Width of
bevel b 7.8 mm 6.4 mm 5.3 mm 4.2 mm 3.2 mm 2.1 mm
3 carriers are available with the angles 30° / 37.5° / 45° for the
bevelling machine.
The selection of the angle is determined by replacing the entire
carrier (see Fig. 39415, p. 12):
1. Release the lock (10).
2. Rotate the die carrier (9) by 45°.
3. Pull carrier (9) out from the bottom
4. Insert other carrier.
5. Tighten locking mechanism (10).
Table 3

12 Tool assembly E543EN_03.DOC
3.4 Adjusting height of the cutting tool
60
17
16
10
9
9 Mount
10 Locking mechanism
16 Cutting tool
17 Ram
1. Release the lock (10).
2. Remove carrier (9).
3. Turn cutting tool (16) so that it protrudes 60 mm from the ram
(17).
4. Insert carrier (9).
5. Retighten locking mechanism (10).
Fig. 39415

E543EN_03.DOC Tool assembly 13
3.5 Selecting cutting tool
KK
min. 95 mm
min. 95 mm
088503 089335
min. 95 mm
005014
110399
A
min. 103 mm
A
A
A
A
A
A
A
A machining direction K identification marking on the upper end face for distinguishing between
the standard cutting tool for mild steel and the cutting tool for high-tensile
sheets
Fig. 9666

14 Tool assembly E543EN_03.DOC
The following cutting tools are available for the machining of sheets
of different material types and tensile strength:
Cutting tool Material no.
Mild steel 088503
High-tensile sheets 089335
Aluminum 005014
Heavy-duty cutting tool 110399
Note
Optimum usage of the heavy-duty cutting tool is guaranteed only in
conjunction with a speed controller (option for the electrical version
of the bevelling machine).
Order no. of 230 V speed controller: 0362455.
Table 4

E543EN_03.DOC Tool assembly 15
3.6 Motor handle
Caution
Damage to property from dust being sucked into the ventila-
tion slot!
Turn the motor handle so that air suction point cannot suck in
any dust.
90°
1
2 3
1
1 Release knob
2 Release inhibiter knob
3 On/Off switch
Turn handle as needed for the individual application.
1. Press the release knob (1).
2. Turn the handle (+/- 90°).
3. Let go of the release knob (1).
4. Turn the handle carefully until it engages.
Fig. 38394

16 Operation E543EN_03.DOC
4. Operation
Caution
Damage to property due to high power supply voltage!
Motor damage.
Check the power supply voltage. The power supply voltage
must correspond to the information on the type plate of the
machine.
Warning
Danger of injury due to improper handling!
Make sure the machine is in a stable position when operating it.
Never touch the tool while the machine is running.
Always operate the machine away from your body.
Do not operate the machine above your head.
Caution
Damage to property possible due to improper handling!
Collisions could result from an erroneous setting of the ma-
chine.
Turn the eccentric shaft (2) one full clockwise rotation using
the Allen key provided. If no collisions can be detected, re-
move the Allen key and put the machine into operation in ac-
cordance with regulations (see Fig. 39412, p. 5).

E543EN_03.DOC Operation 17
4.1 Working with the TKF 1100-0
13 12
12 On/Off switch 13 Release inhibiter knob
1. Press the release inhibiter knob (13), keep holding it and press
the ON-OFF switch (12).
The motor will start to run.
2. Let go of the ON-OFF switch (12).
Note
Momentary operation is possible.
Press the release inhibiter knob (13). Keep holding it and press the
ON-OFF switch (12). Then let go of the release inhibiter knob.
Note
The cutting result is improved and the service life of the cutting tool
increased if the cutting track is coated with oil before machining the
workpiece.
Component Oil
Steel Punching and nibbling oil,
Order No. 103387
Aluminum Wisura oil, Order No. 125874
Recommendation for oil
Switching on and off
Fig. 39416
Switching on the TKF 1100-0
Continuous operation
Table 5

18 Operation E543EN_03.DOC
1. Do not move the machine towards the workpiece until full
speed has been reached.
2. Machine the material.
–Place machine on the sheet and at first maintain a few
centimetres clearance between the cutting tool and the
sheet edge.
–Carefully slide the machine as far as possible against the
sheet edge "piercing".
–Slide the machine along the sheet in such a way that the
machine axis is roughly parallel to the sheet edge.
–Press the machine against the sheet edge while doing so.
Press and release the On/Off switch (12).
4.2 Changing the cutting direction
Depending on the application, the tool can be mounted to permit a
different cutting direction
•Install tool after turning it either 90° to the right or 90° to the left.
1. Open locking mechanism (10).
2. Turn the carrier (9) in the desired direction.
3. Close locking mechanism (10).
Working with the TKF 1100-0
Switching off the TKF 1100-0

E543EN_03.DOC Maintenance 19
5. Maintenance
Caution
Damage to property due to blunt tools!
Machine overload.
Check the cutting edge of the cutting tool hourly for wear.
Sharp cutting tools provide good cutting performance and are
easier on the machine. Replace cutting tool promptly.
Warning
Danger of injury due to improper repairs!
Machine does not work properly.
Repair work may only be carried out by a qualified specialist.
2
S
S Grease nipple for regreasing the cutting tool guide with a grease gun
Fig. 39417

20 Maintenance E543EN_03.DOC
Maintenance point Procedure and interval Recommended lubricants Order no.
Lubricants
Cutting tool guide Every 50 cutting metres and with
tool changes
Lubricating grease "G1" 0139440
Gearbox and gear head Have them relubricated or the
lubricating grease replaced by a
qualified specialist every 300
operating hours.
"G1" lubricating grease 0139440
Wearing plate Turn as needed - -
Wearing plate Replace as necessary - -
Pressure die Clean as needed - -
Ventilation slots Clean as needed - -
Regrind cutting tool Regrind it as required - -
Replace cutting tool Replace as necessary - -
Maintenance points and maintenance intervals
5.1 Regrind cutting tool
The cutting tool for mild steel (Order No. 088503) and for high-
tensile sheets (Order No. 089335 has two cutting edges. It does
not need to be reground until both edges are blunt.
Regrind the cutting tool flat (90°) on the grinding face when
both edges are blunt.
Note
The minimum length must be observed. Shorter cutting tools are
not usable.
The cutting tools for aluminium and the heavy-duty cutting tools are
ground at an angle on the grinding face. Please observe the respec-
tive regrinding diagram. (see Fig. 9666, p. 13)
Checking cutting tool guide wear
Replace the cutting tool guide (6) if the play between the cut-
ting tool guide and the cutting tool has increased to more than
0.3 mm.
Table 6