Trumpf TruTool N 1000 User manual

Operator's manual
TruTool N 1000 (1B1)

Table of contents
1 Safety 3
1.1 General safety information 3
1.2 Specific safety information for nibbler 3
2 Description 5
2.1 Intended use 5
2.2 Technical data 6
2.3 Symbols 7
2.4 Noise and vibration information 7
3 Setting work 9
3.1 Selecting a die 9
3.2 Select punch 10
3.3 Select gear 11
3.4 Setting the penetration depth 12
4 Operation 14
4.1 Working with TruTool N 1000 15
4.2 Changing the cutting direction 15
4.3 Nibbling with templates 16
4.4 Producing interior cutouts 16
5 Maintenance 17
5.1 Replacing the tool 17
Changing the punch 18
Changing the die and punch guide 19
5.2 Regrinding the punch 19
5.3 Changing the wearing plate 21
5.4 Changing the power cable 22
5.5 Replacing carbon brushes 22
6 Accessories and consumables 23
6.1 Ordering consumables 23
7 Appendix: Declaration of conformity, guar-
antee, replacement parts lists
25
2Table of contents E232en_06

1. Safety
1.1 General safety information
■Read all the safety information and instructions including
those in the brochure also supplied.
■Failure to comply with the safety information and instructions
can cause electric shock, burns and/or serious injury.
■Retain all the safety information and instructions for future
use.
Electrical voltage! Risk of fatal injury due to electric shock!
ØRemove the plug from the plug socket before undertaking
any maintenance work on the machine.
ØCheck the plug, cable and machine for damage each time
before using the machine.
ØKeep the machine dry and do not operate it in damp rooms.
ØConnect the fault current (FI) circuit breaker with a maximum
breaking current of 30 mA when using the electric tool out-
side.
ØProtect the machine cable in areas where there are sparks.
ØOnly use original TRUMPF accessories.
Damage to the machine due to improper handling.
ØWear safety glasses, hearing protection, protective gloves
and working shoes when working.
ØConnect the plug only when the machine is switched off.
Pull the power plug after use.
ØDo not carry the machine by the cable.
ØHave maintenance carried out by specialists.
1.2 Specific safety information for nibbler
Electrical voltage! Risk of fatal injury due to electric shock!
ØAlways lay the power cable away from the back of the
device and do not pull it over sharp edges.
ØDo not perform any work that may cause the machine to
come into contact with hidden power lines or its own cable.
Contact with a live conductor can cause metallic machine
parts to become live and can lead to an electric shock.
E232en_06 Safety 3
DANGER
WARNING
DANGER

Risk of injury to hands.
ØDo not reach into the processing line with your hands.
ØUse both hands to hold the machine.
Risk of injury from hot and sharp chips!
Chips exit the chip ejector at high speed.
ØUse a chip bag.
Risk of injury from falling machinery
The entire weight of the machine must be taken up after
machining the workpiece.
ØUse the suspension bracket with balancer.
ØUse the suspension cable.
4Specific safety information for nibbler E232en_06
WARNING
WARNING
WARNING

2. Description
1 On switch
2Off switch
3 Release switch
4 Die
5 Punch guide
6 Wearing plate
7 Die carrier
9 Punch
14 Clamping screw (= fixing screw
for the die carrier)
16 Handle
22 Eccentric shaft
24 Cap screw (2 pieces) for fas-
tening the handle or suspension
bracket
40 Gear switch
46 Roller holder
A Suspension bracket (optional)
Nibbler TruTool N 1000 Fig. 54784
2.1 Intended use
The TRUMPF Nibbler TruTool N 1000 is an electrically operated
hand-held device for:
■Cutting of plate-shaped workpieces made of a punchable
material such as steel, aluminum, nonferrous heavy metal
and plastic.
■Cutting of tubes and machining of edged sheet profiles and/
or press brake bendings e.g. for tanks, crash barriers,
troughs etc.
■Nibbling of straight or curved exterior and interior cutouts.
■Nibbling along scribed lines or templates.
Note
The nibbling process produces cutting edges free of deforma-
tions.
E232en_06 Description 5

2.2 Technical data
TruTool N 1000 Other countries USA
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz 50 Hz 50/60 Hz
Permissible material thickness:
steel up to 400 N/mm2
10 mm
(1st gear)
8 mm
(2nd gear)
10 mm
(1st gear)
8 mm
(2nd gear)
10 mm
(1st gear)
8 mm
(2nd gear)
0.394 in
(1st gear)
0.315 in
(2nd gear)
Permissible material thickness:
steel up to 600 N/mm2
7 mm
(1st gear)
5 mm
(2nd gear)
7 mm
(1st gear)
5 mm
(2nd gear)
7 mm
(1st gear)
5 mm
(2nd gear)
0.276 in
(1st gear)
0.2 in
(2nd gear)
Permissible material thickness:
steel up to 800 N/mm2
5 mm
(1st gear)
4 mm
(2nd gear)
5 mm
(1st gear)
4 mm
(2nd gear)
5 mm
(1st gear)
4 mm
(2nd gear)
0.2 in
(1st gear)
0.157 in
(2nd gear)
Permissible material thickness:
aluminum up to 250 N/mm2
12 mm
(1st gear)
10 mm
(2nd gear)
12 mm
(1st gear)
10 mm
(2nd gear)
12 mm
(1st gear)
10 mm
(2nd gear)
0.472 in
(1st gear)
0.394 in
(2nd gear)
Working speed 1 m/min
(1st gear)
approx. 1.6 m/
min
(2nd gear)
1 m/min
(1st gear)
approx. 1.6 m/
min
(2nd gear)
1 m/min
(1st gear)
approx. 1.6 m/
min
(2nd gear)
3.3 ft/min
(1st gear)
5.2 ft/min
(2nd gear)
Nominal power consumption 2000 W 2000 W 2000 W -
Nominal current - - - 15 A
Idle stroke rate 360/min
(1st gear)
approx. 560/min
(2nd gear)
360/min
(1st gear)
approx. 560/min
(2nd gear)
360/min
(1st gear)
approx. 560/min
(2nd gear)
360/min
(1st gear)
approx. 560/min
(2nd gear)
Weight 14.7 kg 14.7 kg 14.7 kg 32.7 lbs
Sheet profiles (90°) at 10 mm
material thickness:
Inside bending radius
min. 12 mm min. 12 mm min. 12 mm 0.472 in
Start hole for die min. 75 mm min. 75 mm min. 75 mm 2.95 in
Cutting track width 12 mm 12 mm 12 mm 0.472 in
Smallest radius for curved cut-
outs
300 mm 300 mm 300 mm 11.8 in
Protective insulation
II / II / II / II /
Tab. 1
6Technical data E232en_06

2.3 Symbols
Note
The following symbols are important for reading and understand-
ing the instruction manual. The correct interpretation of the sym-
bols will help you operate the machine better and safer.
Symbol Name Meaning
Read operating manual Read the operator's manual and safety information in
their entirety before starting up the machine. Closely
follow the instructions given.
Safety class II Indicates a doubly insulated tool.
Alternating current Type or property of current
V Volt Voltage
A Ampere Current, current input
Hz Hertz Frequency (oscillations per second)
W Watt Power, power input
mm Millimeters Dimensions e.g.: material thickness, chamfer length
in Inch Dimensions e.g.: material thickness, chamfer length
noIdle speed Revolution speed without load
.../min Revolutions/strokes per minute Revolution speed, stroke rate per minute
Tab. 2
2.4 Noise and vibration information
Noise emission value may be exceeded.
ØWear hearing protection.
Vibration emission value may be exceeded.
ØSelect tools correctly and replace them promptly when they
show wear.
ØMaintenance may be carried out by trained specialist techni-
cians only.
ØEstablish additional safety precautions for the protection of
the operator against the effects of vibrations (e.g. keeping
hands warm, organizing the work sequences, machining with
normal feed power).
E232en_06 Symbols 7
WARNING
WARNING

Vigorous upward and downward movements (hammering)
due to unsuitable die.
Excessive tool wear and increasing loads on the machine.
ØUse dies with the greatest height possible (keep distance X,
shown in the drawing below, as small as possible).
Notes
■The specified vibration emission value was measured in
accordance with a standardized testing procedure and can
be used to compare one electric tool with another.
■The specified vibration emission value can also be applied
for a provisional estimate of the vibration load.
■Times during which either the machine is switched off or run-
ning but not actually in use can considerably reduce the
vibration load during the entire working period.
■Times during which the machine works independently and
self-propelled do not have to be calculated.
Designation of measured value Unit Value according to
EN 60745
Vibration emission value ah (vector
sum of three directions)
m/s212.8
Uncertainty K for vibration emission
value
m/s23.6
A-class acoustic pressure level LPA
typically
dB (A) 87
A-class acoustic power level LWA
typically
dB (A) 98
Uncertainty K for noise emission
value
dB 3
Tab. 3
8Noise and vibration information E232en_06
CAUTION

3. Setting work
3.1 Selecting a die
Vigorous upward and downward movements (hammering)
due to unsuitable die.
Excessive tool wear and increasing loads on the machine.
ØUse dies with the greatest height possible (keep distance X,
shown in the drawing below, as small as possible).
1 Die (see following table)
5Punch guide
9 Punch
W Workpiece
XDistance between sheet surface
and punch guide
Fig. 16802
Depending on the thickness, tensile strength and type of the
workpiece, one of the following types of die can be selected for
the machining process:
E232en_06 Setting work 9
CAUTION

Types of die and their respective order numbers Fig. 18270
Type of die
5
Type of die
7
Type of die
10
Type of die
P10
Material thickness in mm for a flat single rolled sheet
Aluminum 250 N/mm2-5 >5-7 >7-10 >10-12
Mild steel 400 N/mm2-5 >5-7 >7-10 -
Stainless steel 600 N/mm2-5 >5-7 - -
Stainless steel 800 N/mm2-5 - - -
Material thickness in mm when machining "profiles", e.g. workpieces with press brake bending up to 90°
--3 >3-5 >5-7 >7-10
Tab. 4
3.2 Select punch
There are 2 different punches available for machining sheets of
various tensile strength:
10 Select punch E232en_06

Components Standard punch Punch for high-ten-
sile steels
Area of application Suitable for machining
materials up to 400 N/
mm2 e. g. aluminum,
mild steel.
Suitable for machining
materials over 400 N/
mm2 e. g. stainless
steel.
Order number 112900 120344
Aluminum 250 N/mm2X -
Mild steel 400 N/mm2X -
Stainless steel 600 N/
mm2
- X
Stainless steel 800 N/
mm2
- X
Tab. 5
3.3 Select gear
Note
Depending on the material thickness, tensile strength and type of
workpiece, a different gear must be selected for machining.
Instead of in 2nd gear, 1st gear can always be worked with, but
never vice versa.
Damage to property due to turning the gear switch during
operation.
Damage to the gearbox can be a consequence.
ØUse 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.
ØObserve the specifications in the technical data (see "Tech-
nical data", pg. 6).
E232en_06 Select punch 11
CAUTION
CAUTION

1 On switch
2 Off switch
3 Release switch
4 Die
5 Punch guide
6 Wearing plate
7 Die carrier
9 Punch
14 Clamping screw (= fixing screw
for the die carrier)
16 Handle
22 Eccentric shaft
24 Cap screw (2 pieces) for fas-
tening the handle or suspension
bracket
40 Gear switch
46 Roller holder
A Suspension bracket (optional)
Nibbler TruTool N 1000 Fig. 54784
1. Put the machine into a stable position.
2. Switch on the machine briefly:
− Press the release switch (3).
− Press the On switch (1) and Off switch (2) at the same
time.
3. While the motor is running down, turn the gear switch (40) to
the desired position.
3.4 Setting the penetration depth
Notes
■A greater penetration depth causes less vibrations, but a
greater effort is required when pushing the machine forward
and the service life of the punch is reduced.
■The penetration depth of the punch into the die should be 1
to 3 mm.
12 Select punch E232en_06

7 Die carrier
9 Punch
14 Clamping screw
22 Eccentric shaft
Fig. 9763
1. Rotate the eccentric shaft (22) until the punch (9) has
reached its maximum penetration depth.
2. Open the locking mechanism.
Note
One rotation of 360° corresponds to a height adjustment of
1.75 mm.
3. Rotate the die carrier (7) by 360° as often as needed until
the punch penetration depth of 1-3 mm has been achieved.
4. Close the locking mechanism.
E232en_06 Select punch 13

4. Operation
Damage to the machine due to improper handling.
ØMake sure the machine is always in a stable position when
operating it.
ØNever touch the tool while the machine is running.
ØAlways operate the machine away from your body.
ØDo not operate the machine above your head.
Damage to property due to excessively high line voltage
Motor damage
ØCheck the line voltage. The power supply voltage must cor-
respond to the information on the nameplate of the machine.
ØWhen using an extension cord that is longer than 5 m, the
cord must have a line diameter of at least 2.5 mm².
Damage to property due to turning the gear switch during
operation.
Damage to the gearbox can be a consequence.
ØUse the gear switch only when the motor is running down or
at rest.
In order to improve the cutting result and increase the service
life of the punch, coat the cutting track with oil before machining
the workpiece.
Material Oil
Steel Punching and nibbling oil for steel (0.5 l, order
no. 0103387)
Aluminum Punching and nibbling oil for aluminum (1 l, order
no. 0125874)
Tab. 6
14 Operation E232en_06
WARNING
CAUTION
CAUTION

4.1 Working with TruTool N 1000
1 On switch
2Off switch
3 Release switch
Fig. 9306
1. Put the machine in position in front of the tool.
2. Either
ØTo switch the machine to continuous operation:
− Keep the release switch (3) pressed.
− Press the On switch (1).
The switch remains engaged. The motor is running.
or
ØTo switch the machine to instantaneous connection:
− Press the release switch (3).
− Press the On switch (1) and Off switch (2) at the same
time.
The motor is running.
3. Once the full speed has been reached: move the machine
toward the workpiece.
4. Process the desired cutting line.
5. If the cutting track ends in the sheet: retract the running
machine a few millimeters in the direction of the already free-
cut cutting track.
6. Press the off switch (2).
4.2 Changing the cutting direction
In situations where space is limited, the tool can be mounted in
such a way as to have a different cutting direction (see "Fig.
54784", pg. 5)
■For cutting profiles: mount the tool at an angle of 90° either
to the left or to the right.
■For nibbling to the rear: mount the tool at an angle of 180°.
1. Undo the clamping screw (14).
E232en_06 Operation 15
Positioning the machine
Switching on
Processing the material
Switching off

2. Rotate the die carrier (7) in the desired direction.
3. Retighten the clamping screw (14) by hand.
4. Check the penetration depth of the punch.
4.3 Nibbling with templates
The following requirements must be met when nibbling with tem-
plates:
■The template must be at least 5 mm thick.
■There must be a clearance of 15.5 mm between the contour
of the template and the contour to be nibbled out.
■The nibbler must be guided in such a way that the exterior
cutout of the punch guide (5) always remains up against the
template.
■Observe a minimum bending radius of 400 mm.
4.4 Producing interior cutouts
ØProduce start bore with at least a 65 mm diameter.
16 Nibbling with templates E232en_06

5. Maintenance
Electrical voltage! Risk of fatal injury due to electric shock.
ØRemove the plug from the plug socket before undertaking
any maintenance work on the machine.
Risk of injury due to incorrect repair work
Machine does not work properly.
ØMaintenance may be carried out by trained specialist techni-
cians only.
Damage to property caused by blunt tools!
Machine overload.
ØCheck the cutting edge of the cutting tool every hour for
wear or in the event of poor cutting behavior or poor work
result. Sharp cutting tool produces good cutting performance
and protects the machine.
ØChange the cutting tool in a timely manner.
Maintenance point Procedure and interval Recommended
lubricant
Lubricant
order number
Punch, die and wear parts Check every hour - -
Punch Regrind/replace as nee-
ded.
- -
Ventilation slots/grids Clean as needed - -
Die Change as needed - -
Wearing plate Change as needed - -
Punches and die holders For tool change Lubricating grease "S1" 0121486
Gearbox and gear head Every 300 operating
hours, have a trained spe-
cialist relubricate or
replace the lubricating
grease.
Lubricating grease "G1" 0139440
Maintenance positions and maintenance intervals Tab. 7
5.1 Replacing the tool
Note
When the punch or die is blunt, or the punch cannot be
reground, the tools must be replaced.
E232en_06 Maintenance 17
DANGER
WARNING
CAUTION

1 Die
4Screws for fastening the die
and punch guide
6 Wearing plate
7 Die holder
9 Punch
14 Clamping screw
F Tube of lubricating grease "S1"
Fig. 9764
Changing the punch
1. Loosen the clamping screw (14).
2. Rotate the die holder (7) by 45°.
3. Pull the die holder (7) downward and out.
4. Screw out the punch (9).
18 Replacing the tool E232en_06

Note
To grease, use lubricating grease "S1" (order num-
ber 121486).
5. Apply a thin film of grease on the square part of the punch
and die holder bore.
6. Screw in the punch and align to 45°.
7. Check the penetration depth of the punch with the setting
gauge (order number 1411767).
8. Close the locking mechanism.
Changing the die and punch guide
1. Unscrew and remove the screws (4).
2. Clean the support areas on the die carrier (7).
3. Clean the replacement parts if necessary.
Note
To grease, use lubricating grease "S1" (order num-
ber 121486).
4. Lubricate the guide surfaces of the punch guide.
Note
Use original screws only.
5. Tighten the screws (4) (torque 40 Nm).
5.2 Regrinding the punch
Notes
■Dies cannot be reground.
■Use only original spare parts from TRUMPF.
■The punch can be reground in total 5 to 10 mm, depending
on with which die it is used. Shorter punches must be
replaced (risk of collision).
Type of die Minimum length X Regrinding reserve
for punch
P10 92 mm 5 mm
10 89.5 mm 7.5 mm
7 87 mm 10 mm
E232en_06 Replacing the tool 19

Type of die Minimum length X Regrinding reserve
for punch
5 85 mm 12 mm
Tab. 8
X Minimum length
Fig. 9017
1. Regrind the grinding surface according to the sketch, paying
attention to good cooling.
2. Dress the cutting edge lightly with a fine oil stone.
20 Replacing the tool E232en_06