Trumpf TruTool S 450 User manual

Operator's manual
english
TruTool S 450 (1A1)

2 Safety E465EN_04.DOC
Table of contents
1. Safety ..................................................................................3
2. Description .........................................................................5
2.1 Correct use ..........................................................................6
2.2 Technical data TruTool S 450 .............................................7
3. Tool assembly....................................................................8
3.1 Changing the stroke rate .....................................................8
3.2 Configuring workstation (optional) .......................................9
3.3 Selecting the blade ............................................................11
3.4 Setting the cutting clearance .............................................13
Cutting clearance..........................................................14
3.5 Setting the height of the moving cutter blade ....................15
4. Operation..........................................................................17
Working with the TruTool S 450 ...................................18
5. Maintenance .....................................................................19
5.1 Replacing carbon brushes.................................................21
5.2 Changing the blade............................................................21
Turning the moving cutter blade over or
replacing it ....................................................................21
Turning the fixed cutter blade over or replacing
it ....................................................................................21
6. Wearing parts...................................................................22
7. Original accessories........................................................23
8. Options .............................................................................23
Warranty
Replacement parts list
Addresses

E465EN_04.DOC Safety 3
1. Safety
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!
¾Remove the plug from the plug socket before undertaking any
maintenance work on the machine.
¾Check the plug, the cable and the machine for damage each
time before the appliance is used.
¾Keep the machine 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.
Warning
Danger of injury possible due to improper handling!
¾When working with the machine, wear safety glasses, hearing
protection, protective gloves and work shoes.
¾Do not plug in the plug unless the machine has been
switched off. Pull out the mains plug after use.
Warning
Risk of injury to the hands!
¾Do not place your hand into the processing line.
¾Use both hands to hold the machine.
USA/CAN
Rest of the world

4 Safety E465EN_04.DOC
Caution
Damage to property possible due to improper handling!
The machine will be damaged or destroyed.
¾Do not use the power cord to carry the machine.
¾Always guide the electric cord away from the back of the
machine and do not pull it across sharp edges.
¾Arrange for start-ups and checks on manual electric tools to
be carried out by a trained specialist. Only used the original
accessories provided by TRUMPF.
Warning
Risk of injury from chip!
¾Use chip deflector.

E465EN_04.DOC Description 5
2. Description
9
14
10
12
13
11
8
5
6
7
4
2 13
1 Fixed blade carrier
2 Adjusting screw
3 Fixing screw for fixed cutter
blade
4 Fixed cutter blade
5 Fixing screw for moving cutter
blade
6 Thread for fastening the traction
eyelet (optional)
7 Moving cutter blade
8 Ram
9 Axis
10 On/Off switch
11 Handle
12 Speed controller
13 Red indicator light (LED) "Motor
overload"
14 Chip deflector (hand protection)
Fig. 28483

6 Description E465EN_04.DOC
2.1 Correct use
Warning
Risk of injury!
¾For processing and materials, only use machines which are
named in "Correct use".
The TRUMPF portable shears TruTool S 450 are an electric hand
tool used for the following applications:
•Chip-free slitting and edge-planing of plate-shaped workpieces
made of steel, aluminium, non-ferrous heavy metals and
plastic.
•Production of straight or curved exterior and interior cutouts.
•Slitting along scribed lines.
•Slitting of coils.

E465EN_04.DOC Description 7
2.2 Technical data TruTool S 450
Rest of the world 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
•Steel
400 N/mm²
•Steel
600 N/mm²
•Steel
800 N/mm²
•Aluminium
250 N/mm²
4.5 mm
(Coil 4.0
mm)
3.5 mm
(Coil 3.0
mm)
2.5 mm
(Coil 2.0
mm)
5.0 mm
4.5 mm
(Coil 4.0
mm)
3.5 mm
(Coil 3.0
mm)
2.5 mm
(Coil 2.0
mm)
5.0 mm
4.5 mm
(Coil 4.0
mm)
3.5 mm
(Coil 3.0
mm)
2.5 mm
(Coil 2.0
mm)
5.0 mm
0.179 mm
(Coil 0.157
in)
0.138 in
(Coil 0.12 in)
0.1 in
(Coil 0.079
in)
0.2 in
Working speed 4-6 m/min 4-6 m/min 4-6 m/min 13-20 ft/min
Nominal power
consumption
1400 W 1200 W 1140 W 1200 W
Stroke rate with
idle run
1640/min 1480/min 1480/min 1480/min
Weight 6.2 kg 6.2 kg 6.2 kg 13.8 lbs
Start hole
diameter
75 in 75 in 75 in 2.95 in
Smallest radius 35 mm
(right)
25 mm (left)
35 mm
(right)
25 mm (left)
35 mm
(right)
25 mm (left)
1.38 in
(right)
0.984 in (left)
Protective
insulation
Class II Class II Class II Class II
Technical data
Noise and vibration Measured values in accordance
with EN 50144
A-weighted sound level Typically 86 dB (A)
A-weighted acoustic power level Typically 94 dB (A)
Hand-arm vibration Typically less than or equal to
2.7 m/s²
Measured values for noise and vibration
Note
The measured values specified above may be exceeded while
working.
Table 1
Table 2

8 Tool assembly E465EN_04.DOC
3. Tool assembly
3.1 Changing the stroke rate
1
1 Setting wheel for speed
controller on motor
Speed controller
¾Rotate the setting wheel for the speed controller counter-
clockwise.
Reducing the number of strokes improves the quality of the work
•for precise machining along scribed lines.
•for machining radiuses.
•for machining steel with a tensile strength > 400 N/mm²
(improved service life).
Fig. 27948
Reducing the stroke rate

E465EN_04.DOC Tool assembly 9
3.2 Configuring workstation (optional)
Danger
Possible lethal danger due to electric shock!
¾Remove the plug from the plug socket before undertaking any
maintenance work on the machine.
¾Check the plug, the cable and the machine for damage each
time before the appliance is used.
¾Keep the machine 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
Damage to property can result from improper operation!
¾Do not slide the workpiece into the machine until the machine
has been switched on and it has reached its full revolutions
per minute.
42
43 (2x) 41
A
S
44 (6x)
43
41 Casing
42 Front casing
43 Screw for fastening the machine
in the workstation
44 2x3 Screws for connecting the
casing
A Recess for the
On/Off switch
S Pedestal for the workstation
Work station
Fig. 17461

10 Tool assembly E465EN_04.DOC
Example: machining a workpiece
The workstation (Order No. 979371) in which the machine can be
fastened is used for machining small workpieces.
This workstation can be bolted down solidly through mounting
holes
¾to a table (workbench)
or
¾to a pedestal (Order No. 003677) with four screws.
1. Unscrew bow-handle and chip deflector.
2. Place machine in the casing (41).
3. Use the screws (43 and 44) to secure the machine and the
forward casing tightly in the casing.
Fig. 17464

E465EN_04.DOC Tool assembly 11
3.3 Selecting the blade
Caution
Damage to property can result from improper blade
selection!
The quality of the cut will be severely impaired and the
individual tools will be overloaded.
¾Use suitable tools only.
The blade is notable for the following points:
•Moving cutter blade (upper blade) and fixed cutter blade (lower
blade) are identical in shape and can be used interchangeably
(above or below).
•All blades have two cutting edges.
•They are non-regrindable "2-way multi-edge, throw-away
cutters".
Note
2 different blade types can be selected for the machining process,
depending on the thickness or the tensile strength of the workpiece
(see Table 3, Pg. 12).

12 Tool assembly E465EN_04.DOC
K
K
R
R
SCr
K Sharp cutting edge on the
standard blade
S Standard blade
Cr Chromium steel blade
R Radius 0.2 mm at the cutting
edge of the chromium steel
blade
Blade with type identification
Note
Standard blades with a tensile strength of ≤400 N/mm² have no
special identification marking. Chromium steel blades are marked
with "Cr".
Blade type Sheet thickness
ranges
[mm]
Type of material
and
Tensile strength
Material No.
Standard 1.0-5.0 Aluminium
250 N/mm²
140451
Standard 1.5-4.5
(Coil
1.0-4.0
Mild steel
400 N/mm²
140451
Standard 1.0-1.5 Stainless steel
600 N/mm²
140451
Cr 1.5-3.5
(Coil 1.0-3.0)
Stainless steel
600 N/mm²
140452
Cr 1.0-2.5
(Coil
1.0-2.0)
Stainless steel
800 N/mm²
140452
Fig. 14843
Table 3

E465EN_04.DOC Tool assembly 13
3.4 Setting the cutting clearance
5s
1s
3
5
t
2
1
t
a Blade clearance = cutting
clearance
1s Fixing screw for the moving
cutter blade
1t Fixing screw for the fixed cutter
blade
2 Adjusting screw
3 Fixed blade carrier
5s Moving cutter blade
5t Fixed cutter blade
1. Push the On/Off switch several times until the moving cutter
blade (5s) has reached the lower dead point.
2. Pull the machine plug out of the plug socket.
3. Screw on the fixed cutter blade (5t) loosely with the fixing
screw (1t).
4. Using the adjusting screw (2), set the fixed cutter blade (5t) to
the desired cutting clearance.
5. Check the cutting clearance with a feeler gauge.
6. Tighten the fixing screw (1t).
7. Tighten the adjusting screw (2) slightly.
Fig. 14844

14 Tool assembly E465EN_04.DOC
Cutting clearance
The cutting clearance must be 0.2 x
Examples:
Sheet thickness s [mm] Blade clearance = cutting
clearance "a" [mm]
1.0 0.2
2.0 0.4
3.0 0.6
4.0 0.8
4.5 0.9
Table 4

E465EN_04.DOC Tool assembly 15
3.5 Setting the height of the moving cutter
blade
In order to ensure the realisation of optimum cutting behaviour for
both the slitting of metal sheets and the cutting of curved lines, the
clearance between the moving cutter blade and the fixed cutter
blade (penetration depth into the sheet) must be adjusted in
accordance with both the projected cutting task and the sheet
thickness.
6
3
5s
5t
X
27
38
2
1
12
1 Direction of rotation 1: Setting
value x becomes smaller
2 Direction of rotation 2: Setting
value x becomes larger
3 Fixed blade carrier
5s Moving cutter blade (upper
blade)
5t Fixed cutter blade (lower blade)
6 Ram
27 Turning handle with scale for
height adjustment of the moving
cutter blade (example for sheet
thickness of 4.5 mm)
38 Fixed point on the scale
x Setting value (height clearance
between upper and lower
blades) 1
Height adjustment of the moving cutter blade
1* The ram is located at the upper dead point
Fig. 17460

16 Tool assembly E465EN_04.DOC
1. Push the turning handle when the machine is either at a
standstill or running and rotate it.
2. The turning handle locks into place when it is released.
Note
Marker points have been placed on the turning handle (27) which
are to be positioned in accordance with sheet thickness and the
particular application to be carried out.
Altering the clearance between the two blades allows optimisation
of cutting behaviour to match particular applications.
(+) intermediate stage in direction of rotation 2
(-) intermediate stage in direction of rotation 1
Adjusting the turning handleSheet thickness
[mm] Cutting curves Cutting straight
lines
Cutting coils
4.5 4(+) 4(+) -
4.0 4(+) 4 1
3.5 4 3(+) 1
3.0 3(+) 3 1
2.5 3 2(+) 1
2.0 2(+) 2 1
1.5 2 1(+) 1
1.0 1(+) 1 1
Changing the height
clearance between moving
cutter blade and fixed
cutter blade
Table 5

E465EN_04.DOC Operation 17
4. Operation
Caution
Damage to property possible due to too-high network
voltage!
Damage to the motor.
¾Check the power supply. The power supply must correspond
to the information on the machine type plate.
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.
The appliance may switch off prematurely when affected by
electromagnetic disruptions. The appliance will resume operation
once the faults have been cleared.
If the motor temperature is too high, the motor will switch off. The
red indicator light (LED) with the motor lights up.
¾Allow the machine to run in idle until it has cooled down.
The machine can be operated again normally after it has cooled
down.
Electromagnetic faults
Motor overload protection

18 Operation E465EN_04.DOC
Working with the TruTool S 450
¾Move the On/Off switch to the front.
1
80°-90°
1 On/Off switch
1. Do not move the machine towards the workpiece until full
speed has been reached.
2. Machine/process the material.
–Move the device forward at an angle of 80 to 90° to the
sheet surface (Illustration).
Cutting radiuses
•Do not tilt the machine.
•Proceed with a low feed rate.
Cutting on the edge
•Cut in upside-down position.
•The fixed blade carrier faces upwards.
¾Move the On/Off switch to the front.
Switching on the
TruTool S 450
Working with the
TruTool S 450
Fig. 28475
Switching off the
TruTool S 450

E465EN_04.DOC Maintenance 19
5. Maintenance
Danger
Possible lethal danger due to electric shock!
¾Pull the plug out of the socket when carrying out tool changes
and before all maintenance work on the machine.
Caution
Damage to property possible due to blunt tools!
Overloading of the machine.
¾Check the cutting edge of the cutting tool hourly for wear.
Sharp cutting tools provide good cutting performance and are
easier on the machine. Replace blades promptly.
Warning
Risk of possible injury due to improper repairs!
The machine does not function properly.
¾Repairs should be carried out only by a trained specialist.

20 Maintenance E465EN_04.DOC
12
6
15
G1
3
3 Fixed blade carrier
6 Ram
12 Housing
15 Lubricating heads
G1 Lubricating grease TRUMPF
Material No.139440
Grease nipple, ram guide
Maintenance point Procedure and time interval Recommended lubricants Order No.
Lubrication
agents
Ram guide Lubricate every 20 hours of
operation
Lubricating grease "G1" 139440
Gearbox and
gear head (2)
After 300 operating hours, arrange
for a trained specialist to lubricate
or to replace the lubricating
grease
Lubricating grease "G1" 139440
Fixed cutter blade Turn over as needed - -
Fixed cutter blade Replace as needed - -
Moving cutter blade Turn over as needed - -
Moving cutter blade Replace as needed - -
Ventilation slots Clean as needed - -
Maintenance positions and maintenance intervals
Fig. 28476
Table 6