Trumpf TruTool TKF 1100 User manual

Operator's manual
TruTool TKF 1100 (1A1)
TruTool TKF 1101 (1A1)

Table of contents
1 Safety 3
1.1 General safety information 3
1.2 Specific safety information for beveler 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 Adjusting the ram length 9
3.2 Adjusting the angle of bevel 10
3.3 Setting the cutting tool height 11
3.4 Setting material thickness 12
3.5 Selecting cutting tool 12
4 Operation 14
4.1 Switching the TruTool TKF 1100/ Tru-
Tool TKF 1101 on and off
15
4.2 Working with the TruTool TKF 1100/ Tru-
Tool TKF 1101
16
4.3 Changing the cutting direction 16
5 Maintenance 17
5.1 Regrinding cutting tool 17
5.2 Changing the cutting tool 18
5.3 Lubricating the cutting tool guide 20
5.4 Checking the cutting tool guide 20
5.5 Checking and replacing the wearing plate 20
5.6 Changing the power cable 21
5.7 Replacing carbon brushes 21
6 Accessories and consumables 22
6.1 Ordering consumables 22
7 Appendix: Declaration of conformity, guar-
antee, replacement parts lists
24
2Table of contents E543EN_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.
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
beveler
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.
E543EN_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 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.
Damage to property due to improper handling.
Collisions could result from setting the machine incorrectly.
ØRotate the eccentric shaft one full turn in a clockwise direc-
tion using the Allen key provided. If no more collisions
occur, remove the Allen key and put the machine into oper-
ation in accordance with regulations.
4Specific safety information for beveler E543EN_06
WARNING
WARNING
CAUTION

2. Description
1 Bow-handle (installable in 2
positions)
2 Eccentric shaft
3 Roller holder
4 Spiral bevel gear
5 Stripper
6 Cutting tool guide
7Rest plate
8 Pressure die
9 Carrier
10 Locking mechanism for carrier
11 Clamping lever for fastening the
handle
12 On/Off switch
13 Release-lock knob
14 Spindle wheel
TruTool TKF 1100 (1A1)/ TruTool TKF 1101 (1A1) Fig. 39412
2.1 Intended use
The TRUMPF TruTool TKF 1100 (1A1)/ TruTool TKF 1101 (1A1)
beveler is an electrically powered hand-held device for the fol-
lowing applications:
■Preparation of all K-, V-, X-and Y-shaped welding grooves
usual for gas and electrical fusion welding with various con-
tinuously adjustable angles of bevel and continuously adjust-
able lengths of bevels.
■Bevelling of straight and curved edges, provided the mini-
mum radius of the inner curve is 40 mm.
■Bevelling of edges on level and crooked workpieces, in par-
ticular tubes with an inside diameter of at least 80 mm.
■Bevelling of edges in both directions, with the bevelling proc-
ess being able to be started and finished at any point of the
sheet edge.
■Bevelling of edges in normal position (carrier below the
machine) and in "upside-down position" (carrier above the
E543EN_06 Description 5

machine), which is of advantage in particular when bevelling
X and K welding joints.
■Beveling of edges on large, bulky workpieces by using the
beveler as a hand-held device.
■Forming of uniform, oxide-free, bright metallic welding bevel
edges in steel and aluminum.
■For TruTool TKF 1100: machining of chromium steel and
similar high-tensile materials.
2.2 Technical data
Other countries USA
Values
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz
Max. length of bevel "ls" continuously adjustable:
Mild steel with 400 N/
mm²
11 mm 0.59 in
Mild steel with 600 N/
mm²
9 mm 0.354 in
Mild steel with 800 N/
mm²
6mm 0.236 in
Working speed 2.0 m/min
2.5 m/min
4.1 ft/min
6.55 ft/min
Nominal power con-
sumption
1600 W 1340 W 1500 W 1340 W
Stroke rate with nominal
load
340/min
440/min
340/min
440/min
320/min
410/min
340/min
440/min
Idle stroke rate 450/min
650/min
450/min
650/min
440/min
630/min
450/min
650/min
Weight 10 kg 25.7 lbs
Material thicknesses:
Min. 3mm 0.12 in
Max. 25mm 0.984 in
Angle of bevel "ß" con-
tinuously adjustable
30°, 37.5°, 45° 30°, 37.5°,
45°
Smallest radius with
inner cutouts
40mm 1.57 in
Smallest tube inside
diameter
80mm 3.15 in
Safety class
II / II /
Tab. 1
6Technical data E543EN_06
TruTool TKF 1100 (1A1) /
TruTool TKF 1101 (1A1)

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).
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.
E543EN_06 Symbols 7
WARNING
WARNING

■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/s28.2
Uncertainty K for vibration emission value m/s22
A-class acoustic pressure level LPA typi-
cally
dB (A) 89
A-class acoustic power level LWA typically dB (A) 100
Uncertainty K for noise emission value dB 3
Tab. 3
8Noise and vibration information E543EN_06

3. Setting work
3.1 Adjusting the ram length
4 Spiral bevel gear
9 Carrier
15 Clamping screw
Fig. 39414
1. Undo the clamping screw (15).
2. Turn the spiral bevel gear (4) until the desired ram length
(scale on stripper 5) corresponds to the marking.
3. Retighten the clamping screw (15).
E543EN_06 Setting work 9

3.2 Adjusting the angle of bevel
s Material thickness
β Angle of bevel
ls Length of bevel
hs Height of bevel
bWidth of bevel
h Residual height
Length of bevel and angle of bevel Fig. 9664
Angle
of
bevel
Length of bevel
ls [mm]
Height of bevel
hs [mm]
Width of bevel b
[mm]
ß 30° 11 9.5 5.5
9 7.8 4.5
7.5 6.5 3.8
6 5.2 3
4.5 3.9 2.3
3 2.6 1.5
ß 37.5° 11 8.7 6.7
9 7.1 5.5
7.5 6 4.6
6 4.8 3.7
4.5 3.6 2.7
3 2.4 1.8
ß 45° 11 7.8 7.8
9 6.4 6.4
7.5 5.3 5.3
6 4.2 4.2
4.5 3.2 3.2
3 2.1 2.1
Tab. 4
Three carriers with angles of 30°/37.5°/45° are available for the
beveler.
The angle is selected by replacing the entire carrier (see
Fig. 39415, p. 13):
1. Undo the locking mechanism (10).
2. Turn the carrier (9) 45°.
3. Pull out the carrier (9) downwards.
10 Setting work E543EN_06

4. Insert a different carrier.
5. Tighten the locking mechanism (10).
3.3 Setting the cutting tool height
9 Carrier
10 Locking mechanism
16 Cutting tool
17 Bevel
Fig. 39415
1. Undo the locking mechanism (10).
2. Remove the carrier (9).
3. Turn the cutting tool (16) until it protrudes 60 mm from the
ram (17).
4. Insert the carrier (9).
5. Retighten the locking mechanism (10).
E543EN_06 Setting work 11

3.4 Setting material thickness
7 Rest plate 14 Spindle wheel
Fig. 39413
1. Position the machine on the sheet (working position).
2. Tighten the rest plate (8) against the lower sheet edge by
turning the spindle (7). Leave play of 0.5 to 1 mm.
3.5 Selecting cutting tool
Cutting tool Standard High-tensile Aluminum High-tensile
5575
Heavy-duty cut-
ting tool
Order number 0088503 0089335 0005014 0005575 0110399
Application General mild
steel of up to
500 N/mm²
Higher-tensile
mild steel of up
to 650 N/mm²,
chromium steel
Aluminum alloys High-tensile
materials of up
to 800 N/mm²,
chromium steel
High-tensile
materials
12 Selecting cutting tool E543EN_06

Cutting tool Standard High-tensile Aluminum High-tensile
5575
Heavy-duty cut-
ting tool
A = direction of processing
E = distinguishing feature
Regrinding dia-
gram
Regrinding
reserve
10mm 10 mm 10 mm 10 mm 10mm
Tab. 5
E543EN_06 Selecting cutting tool 13

4. Operation
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.
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 improper handling.
Collisions could result from setting the machine incorrectly.
ØRotate the eccentric shaft one full turn in a clockwise direc-
tion using the Allen key provided. If no more collisions
occur, remove the Allen key and put the machine into oper-
ation in accordance with regulations.
During operation, at an interval of approx. 20 m, the grease nip-
ple on the supporting body should be lubricated with one or two
squirts of grease. Doing so prolongs the service life of the cut-
ting tool.
In order to improve the cutting result and increase the service
life of the cutting tool, coat the cutting track with oil before
machining the workpiece.
14 Operation E543EN_06
DANGER
WARNING
CAUTION
CAUTION
Monitoring during operation
Lubricating oil

Material Oil
Steel Punching and nibbling oil for steel (0.5 l, order number
0103387)
Aluminum Punching and nibbling oil for aluminum (1 l, order no.
0125874)
Tab. 6
4.1 Switching the TruTool TKF 1100/
TruTool TKF 1101 on and off
Condition
■All setting work has been carried out.
12 On/Off switch 13 Release-lock knob
Fig. 39416
1. Insert the mains plug.
Note
In order to fix the switch in On position, first release the
switch and then the release button.
2. Press the release button (13) and the On/Off switch (12) on
the motor.
3. Press the On/off switch (12) on the motor and release it
again.
Note
The machine is equipped with a restart inhibit. After a power
cut, the machine must be switched off prior to work.
E543EN_06 Operation 15
Switching on the machine
Switching off the machine

4. Pull out the mains plug.
4.2 Working with the TruTool TKF 1100/
TruTool TKF 1101
Notes
■Do not move the machine towards the workpiece until full
speed has been reached.
■In order to improve the cutting result and increase the
service life of the cutting tool, coat the cutting track with
oil before machining the workpiece.
1. Processing material: position the machine on the sheet and,
at first, keep a distance of a few centimeters between the
cutting tool and sheet edge.
2. Push the machine carefully as far as possible against the
sheet edge i. e. "piercing".
3. Push the machine along the sheet in such a manner that the
machine axis is about parallel to the sheet edge, while press-
ing the machine against the sheet edge.
4.3 Changing the cutting direction
The tool or cutting direction can be turned 90° clockwise or
counter-clockwise in the event of confined space conditions.
1. Open the locking mechanism.
2. Turn the carrier 90° in the desired direction.
3. Close the locking mechanism again.
16 Operation E543EN_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 for wear every
hour. Sharp cutting tools provide good cutting performance
and are easier on the machine. Replace the cutting tool
promptly.
Maintenance point Interval Procedure Recommended lubri-
cants
Cutting tool Regrind/replace as needed.
Lubricate upon tool change.
- -
Cutting tool guide Lubricate every 50 m.
Lubricate upon tool change.
Re-lubricate with a grease
gun.
Lubricating grease
"G1"
Wear plate Turn if necessary.
Change as needed.
- -
Pressure die Clean as needed. - -
Ventilation slots Clean as needed.
Motor Approx. every 300 operating
hours.
Change the carbon brushes. -
Gearbox and gear
head
After 300 operating hours,
arrange for a trained specialist
to relubricate or to replace the
lubricating grease.
- Lubricating grease
"G1"
Maintenance positions and intervals Tab. 7
5.1 Regrinding cutting tool
The aluminum cutting tools and heavy-duty cutting tools are
ground at an angle on the grinding face. Observe the corre-
sponding regrinding diagram (see "Tab. 4", pg. 10).
E543EN_06 Maintenance 17
DANGER
WARNING
CAUTION

The cutting tool for mild steel and high-tensile sheets has two
cutting edges. It only has to be reground if both edges are blunt.
Notes
■Maintain the minimum length of the cutting tools (see "Tab.
4", pg. 10).
■Do not use shorter cutting tools.
■Dress the cutting edge with an oil stone after regrinding.
ØIf both cutting edges are blunt, regrind the cutting tool level
(90°) on the grinding face.
5.2 Changing the cutting tool
Note
The cutting tool can be reground.
It can be reground if necessary.
18 Maintenance E543EN_06

9 Carrier
10 Locking mechanism
16 Cutting tool
18 Wearing plate
F"G1" lubricating grease
Fig. 39418
1. Undo the locking mechanism (10).
2. Turn the carrier (9) 45°.
3. Pull out the carrier (9) downwards.
4. Screw out the cutting tool (16).
5. Check the wearing plate (18).
6. Grease the square part of the new cutting tool and the bore
hole of the carrier slightly with "G1" lubricating grease (order
number 0139440).
7.
8. Align the cutting tool, observing the bevel grind while doing
so.
E543EN_06 Maintenance 19

5.3 Lubricating the cutting tool guide
S Grease nipple
Fig. 39417
ØLubricate the grease nipple (S) on the cutting tool guide with
a grease gun.
5.4 Checking the cutting tool guide
ØReplace the cutting tool guide (6) if the play between the cut-
ting tool guide and cutting tool exceeds 0.3 mm (see "Fig.
39412", pg. 5).
5.5 Checking and replacing the wearing
plate
1. Remove the carrier (9) (see "Fig. 39415", pg. 11).
2. Check the wearing plate (18) for scratch marks.
20 Maintenance E543EN_06
Checking the wearing plate