Trumpf TruTool N 500 User manual

Operator's manual
english
TruTool N 500 (1A2)

E615EN_03.DOC Contents 3
Contents
1. Safety ..................................................................................4
1.1 General safety information...................................................4
1.2 Specific safety information...................................................5
2. Description .........................................................................6
2.1 Correct use ..........................................................................7
2.2 Technical data .....................................................................8
3. Setting work .......................................................................9
3.1 Selecting the tool .................................................................9
4. Operation..........................................................................11
4.1 Working with the TruTool N 500 ........................................11
4.2 Changing the cutting direction ...........................................13
4.3 Nibbling with templates......................................................14
4.4 Making inner cutouts..........................................................14
5. Maintenance .....................................................................15
5.1 Replacing the tool ..............................................................16
Disassembling the punch .............................................17
Installing the punch.......................................................17
Changing the die and the punch guide.........................17
5.2 Regrinding the punch.........................................................18
5.3 Supplying with power and guaranteeing lubrication ..........19
5.4 Replacing fins ....................................................................20
5.5 Cleaning the strainer..........................................................20
6. Original accessories and wearing parts........................21
Guarantee
Spare parts list
Addresses

4 Safety E615EN_03.DOC
1. Safety
1.1 General safety information
¾Read the operating manual and the safety information (order
no. 0373678, red document) in their entirety before starting up
the machine. Closely follow the instructions given.
¾Adhere 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
¾When working with the machine do not touch any electrical
lines. The machine is not insulated.
Warning
Risk of injury due to improper handling.
¾Always remove the compressed air hose from the machine
prior to maintenance work.
¾Check the compressed air hose, connection coupling, and
machine for damage each time before using the machine.
¾Wear safety glasses, hearing protection, protective gloves
and work shoes when working at the machine.
¾Connect compressed air only when the machine is switched
off.
¾Always lay the compressed air hose away from the back of
the machine.
Other countries

E615EN_03.DOC Safety 5
1.2 Specific safety information
Warning
Risk of injury to hands
¾Do not reach into the processing line with your hand.
¾Use both hands to hold the machine.
Caution
Damage to property due to improper handling!
Machine will be damaged or destroyed.
¾Have servicing and inspections of hand-held compressed air
tools carried out by a qualified technician. Only use original
TRUMPF accessories.
Warning
Risk of injury from hot and sharp chips!
Hot and sharp chips are emitted from the chip dumping at
high speed.
¾The use of a chip bag is recommended.
Warning
Risk of injury from falling machinery!
The entire weight of the machine must be taken up after
processing of the work workpiece.
¾Use suspension eyelet with balancer.

6 Description E615EN_03.DOC
2. Description
1 Handle
2 Gear housing
3 Punch guide
4 Punch
5 Die
6 Die carrier
7 Lock (clamping for the die)
8 Lever
9 Quick-release coupling
10 Pushbutton (locking pin)
Nibbler TruTool N 500
Fig. 53777

E615EN_03.DOC Description 7
2.1 Correct use
Warning
Risk of injury
¾Only use the machine for work and materials described in
"Intended use".
The TRUMPF Nibbler TruTool N 500 is a hand tool powered by
compressed air used for the following applications:
•Slitting plate-shaped workpieces made of a punchable material
such as steel, aluminum, non-ferrous heavy metals, and
plastic.
•slitting of tubes and machining of edged sheet profiles and/or
press brake bendings, e.g. for tanks, crash barriers, troughs,
etc.
•Nibbling straight or curved exterior and interior cutouts.
•Nibbling along scribed lines or templates.
Note
The nibbling process produces cutting edges free of deformations.

8 Description E615EN_03.DOC
2.2 Technical data
Other countries USA
Value Value
Max. material thickness:
Steel 400 N/mm²
Steel 600 N/mm²
Steel 800 N/mm²
Aluminum 250 N/mm²
5.0 mm
3.2 mm
2.5 mm
7 mm
0.2 in
0.125 in
0.1 in
0.28 in
Working speed 1.4 m/min 4.6 ft/min
Nominal power consumption 1100 W 1100 W
Stroke rate at complete load 530/min 530/min
Weight 4.8 kg 10.58 lbs
Cutting track width 8 mm 0.31 in
Start hole diameter for die 41 mm 1.6 in
Sheet profile 90° bending radius
inside
8 mm 0.31 in
Smallest radius with curved cuts 90 mm 3.54 in
Max. operating pressure
(flow pressure)
6.2 bar 90 psi
Air consumption at 6 bar 0.8 m³/min 28.3 cubic ft/min
Connecting thread 1/4" 1/4"
Inside diameter of the compressed
air hose
10mm 0.4 in (3/8")
Technical data
Noise and vibration Measured values in accordance
with EN 50144
A-class sound pressure level Typically 86 dB (A)
A-class acoustic power level Typically 94 dB (A)
Hand-arm vibration Typically less than or equal to
3.7 m/s²
Measured noise and vibration values
Note
The measured values specified above may be exceeded while
working.
Table 1
Table 2

E615EN_03.DOC Setting work 9
3. Setting work
3.1 Selecting the tool
Tensile strength of the workpiece Acceptable material thickness
Mild steel up to 400 N/mm² 5 mm
Stainless steel up to 600 N/mm² 3.2 mm
Stainless steel up to 800 N/mm² 2.5 mm
Aluminum up to 250 N/mm² 7 mm
Certain material thicknesses can be machined, depending on the
workpiece type.
Material thickness [mm]
Single rolled
sheet
Sectional sheet Type of die Type of punch
1-2 1
Order no. 975468
Order no. 1453187
2-3.2 1-2
Order no. 975466
Order no. 1453187
3-5 2-3
Order no. 975464
Order no. 1451224
5-7 3-5
Order no. 975462
Order no. 1451224
Selecting type of die and punch
Table 3
Table 4

10 Setting work E615EN_03.DOC
X
3
4
W
5
3 Punch guide
4 Punch (2/3,5/P5)
5 The four types of dies (2,3,5,P5)
W Workpiece
x Clearance between sheet
surface and punch guide
Clearance between die and punch guide
Note
The distance between the sheet surface and the punch (x) must
remain as small as possible.
Does severe back-and-forth movement (hammering) occur
during the cutting process?
The reason is an unsuitable die. Excessive tool wear and
increasing loads on the machine are the result.
¾Use the die with the greatest feasible height.
Use the die with the greatest
feasible height
Fig. 52810

E615EN_03.DOC Operation 11
4. Operation
4.1 Working with the TruTool N 500
Warning
Risk of injury due to improper handling.
¾Make sure the machine is always in a stable position when
operating it.
¾Never touch the tool while the machine is running.
¾Always move the machine during work away from your body.
¾Do not operate the machine above your head.
1
2
1 Push button 2 Lever
1. Press the pushbutton (1).
2. Actuate the lever (2).
The motor continues to run for as long as the lever remains
pressed down.
3. Release the pushbutton (1).
Note
The cutting result is improved and the service life of the punch
increased if the cutting track is coated with oil before machining the
workpiece.
Material Oil
Steel Punching and nibbling oil (0.5 l, order no. 103387)
Aluminum Wisura oil (1 l, order no. 125874)
1. Do not move the machine towards the workpiece until full
speed has been reached.
2. Machine the material.
–Machine the desired cutting line
Switching on the
TruTool N 500
Fig. 10332
Table 5
Working with the
TruTool N 500

12 Operation E615EN_03.DOC
3. In the event that the cutting track ends in the sheet, pull the
still-running machine a few millimeters back towards where the
cutting track has already been cut open.
4. Switch off machine.
¾Release lever.
The lever springs back to the initial position and the compressed
air is interrupted.
Switching off the
TruTool N 500

E615EN_03.DOC Operation 13
4.2 Changing the cutting direction
In situations where space is limited, the tool and/or the cutting
direction can be turned by 90° to the right, to the left, or by 180°
(see Fig. 52772, p. 16).
1. Open locking mechanism (9).
2. Rotate die carrier (7) by 90° or 180° in the desired direction.
3. Close locking mechanism (9).
Cutting profiles Fig. 52794

14 Operation E615EN_03.DOC
4.3 Nibbling with templates
The following requirements must be met when nibbling with
templates:
•The template must be at least 3 mm thick.
•The contour of the template must have a clearance of 8.5 mm
to the contour to be nibbled out.
•Observe a minimum radius of 90 mm on the workpiece.
•The nibbler is to be guided in such a way that the punch guide
is always up against the template.
h1
a
h2
R1
R2
2
3
1
1 Punch guide
2 Workpiece
3 Template
a Clearance of the contour of the
template to the contour of the
workpiece to be nibbled out
h1 Thickness of the template
h2 Thickness of the workpiece
R1Minimum radius in the template
R2 Minimum radius in the workpiece
4.4 Making inner cutouts
¾Make a start hole at least 41 mm in diameter.
Fig. 52793

E615EN_03.DOC Maintenance 15
5. Maintenance
Warning
Risk of injury due to uncontrolled machine movements.
¾Remove the compressed air hose when changing tools and
before performing any maintenance work on the machine.
Caution
Damage to property caused by blunt tools!
Machine overload.
¾Check the cutting edge of the cutting tool hourly for wear. A
sharp punch provides good cutting performance and is easier
on the machine. Regrind or replace the punch promptly.
Warning
Risk of injury due to repair work not being carried out
properly!
Machine does not work properly.
¾Repair work may only be carried out by a qualified technician.
Maintenance point Procedure and interval Recommended
lubricant
Lubricant
order no.
Punch Regrind as needed (see section 5.2, p. 18). - -
Punch Change as needed (see section 5.1, p. 16). - -
Ventilation slots Clean as needed - -
Die Replace as necessary. - -
Punch and die carrier Lubricate upon tool change Lubricating
grease "G1"
0344969
Gearbox and gear head After 300 operating hours, arrange for a qualified
technician to relubricate or to replace the lub-
ricating grease.
Lubricating
grease "G1"
0139440
Filter, oil mist lubrication
device
Maintain daily in accordance with the manu-
facturer's specifications (see "Supplying with
power and guaranteeing lubrication", p. 19).
- -
Strainer Clean every 10 operating hours and when there
has been a decline in performance (see
"Cleaning the strainer", p. 20).
- -
Maintenance points and maintenance intervals
Table 6

16 Maintenance E615EN_03.DOC
5.1 Replacing the tool
d
b
a
c
7
2
3
4
5
6
8
1
F
1 Gear housing
2 Punch guide
3 Screws for fastening the punch
guide
4 Screws for fastening the die
5 Die
6 Die carrier
7 Punch
8 Locking mechanism
F Lubricating grease "G1"
(40 g, order no. 0344969)
¾If the punch or die becomes blunt, resharpen the punch or
change the tool.
Fig. 52772

E615EN_03.DOC Maintenance 17
Disassembling the punch
1. Open locking mechanism (8).
2. Rotate the die carrier (6) by 45°.
3. Pull die carrier (6) out towards the bottom.
4. Turn punch (7) until it can be pulled out.
Installing the punch
1. Lightly lubricate the square part of the punch (7) and bore hole
on the die carrier (6) with lubricating grease "G1"
(order no. 0344969).
2. Rotate the punch (7) to the 45° position.
3. Connect the die carrier (6).
4. Make the locking mechanism (8) engage.
Changing the die and the punch guide
1. To replace the die and the punch guide, unscrew the fixing
screws (3 and 4).
2. Clean the support areas on the die carrier (6).
3. Take care to ensure that the replacement parts are clean.
4. Lubricate the guide surfaces of the punch guide with lubricating
grease "G1" (order no. 0344969).
5. Screw the fastening screws tightly when mounting the die and
the punch guide (torque 9 Nm). Use original screws only.

18 Maintenance E615EN_03.DOC
5.2 Regrinding the punch
3°
1 x 45°
8°
1 x 45°
X min.
A
B
3°
A Punch (Standard)
X min. minimum length of the punch
B Recommendation for the
polished section of a standard
punch for aluminum machining.
The punch can be reground, depending on the die with which it is
utilized
Note
Dies can not be resharpened.
1. Regrind the grinding surface, making sure that it is well-cooled
during the process.
2. Lightly apply fine-grained oil stone to the cutting edge.
3. Observe the minimum length (X min.) while grinding.
4. Replace shorter punches.
Punch Die Regrinding reserve of
the punch
Minimum length (X
min.) of the punch
5/P5 P5 0.5 mm 58.8 mm
5/P5 5 2.8 mm 56.5 mm
2/312, 3 - -
1This type of punch cannot be reground.
Fig. 52773
Table 7

E615EN_03.DOC Maintenance 19
5.3 Supplying with power and
guaranteeing lubrication
Caution
Damage to property due to improper handling!
Failure of the compressed air motor.
¾Do not exceed the maximum operating pressure.
¾Regularly lubricate the compressed air motor. Install an oil
mist lubrication device into the compressed air line.
Prerequisites
•The pressure regulating valve and the connecting threads are
laid out correctly (see "Technical data", Table 1, p. 8).
1 Connecting thread 1/4"
2 Oil mist lubrication device
3 Pressure regulating valve
4 Filter and water separator
5 Inside diameter of the
compressed air hose min.
10 mm or 3/8"
Compressed air supply
1. Install the filter and water separator (4).
2. Drain/check the water separator daily.
Note
To ensure a supply of compressed air the tube cross-sections in
the entire line system must be twice to three times the size of the
inside diameter of the compressed air hose.
Supplying compressed air
Fig. 52385

20 Maintenance E615EN_03.DOC
¾Hold a piece of paper in front of the exhaust air vent in the
motor housing when the machine is running.
The oil supply is sufficient when oil spots appear.
When there is no oil mist lubrication device available:
¾Fill the air inlet bore hole with 0.5-1 ccm of oil every two hours.
Recommended lubricant
•BP Energol RD 80 (-15° to +10°C/+5° to +50°F).
•BP Energol RD-E80 (+10° to +30°C/+50° to +86°F).
•Shell Tellus Oil 15 (-15° to +10°C/+5° to +50°F).
•Torculla 33 (+10° to +30°C/+50° to +86°F).
Note
Secure the compressed air hose against undesired movements
using a compressed air safety device.
5.4 Replacing fins
Worn fins decrease machine performance.
¾Have the fin set checked and replaced as needed by a quali-
fied technician.
Note
Only use original replacement parts and observe the information
on the rating plate.
5.5 Cleaning the strainer
Dirty strainers decrease machine performance. Clean the strainer,
which is screwed into the connection piece (328), every 10
operating hours. (For an illustration of the positions 328 (=
"connection") and 329 (= "nipple"), see the replacement parts list.)
1. Unscrew the strainer and blow it out with compressed air.
2. Screw the strainer back in.
Checking the oil supply