Trumpf TruTool TKF 1500 3A1 User manual

Operator's manual
TruTool TKF 1500 (3A1), (3B1)
Beveler
TRUMPF Werkzeugmaschinen GmbH + Co. KG, Technische Redaktion
Johann-Maus-Straße 2, D-71254 Ditzingen
Fon: [phone] - 0
Internet: http://www.trumpf.com
E-Mail: [email protected]

Table of contents
1 Safety 3
1.1 General safety information 3
1.2 Specific safety information for bevelers 3
2 Description 5
2.1 Intended use 5
2.2 Technical data 6
2.3 Icons 8
2.4 Noise and vibration information 8
3 Setting work 10
3.1 Adjusting the ram length 10
3.2 Adjusting the angle of bevel 12
3.3 Setting material thickness 13
3.4 Selecting cutting tool 13
3.5 Adjusting height of the cutting tool 15
3.6 Select gear 16
3.7 Accessories included 17
Securing the chip box 17
Handle base 18
Tube-shaped handle 18
Roller holder 19
3.8 Options 20
Roller holder for pipe and tube processing 20
Special tool for pipe and tube processing 21
Conversion kits for large material thick-
nesses
23
Suspension bracket 25
Workstation 26
4 Operation 28
4.1 Working with TruTool TKF 1500 (3A1), (3B1) 28
5 Maintenance 30
5.1 Regrinding cutting tool 30
5.2 Changing the cutting tool 31
5.3 Change the sliding sleeve 32
E1026en03 Table of contents 1

6 Accessories and consumables 34
6.1 Ordering consumables 35
7 Appendix: Declaration of conformity, guar-
antee, replacement parts lists
36
2Table of contents E1026en03

1. Safety
1.1 General safety information
Read all the safety information and instructions.
ØFailure to comply with the safety information and instruc-
tions can cause electric shock, burns and/or serious injury.
ØRetain all the safety information and instructions for future
use.
1.2 Specific safety information for
bevelers
Electrical voltage! Risk of fatal injury due to electric shock!
ØAlways keep the power cable behind 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.
Risk of injury from hot and sharp chips!
Chips exit the chip ejector at high speed.
ØUse the chip box.
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.
E1026en03 Safety 3
WARNING
DANGER
WARNING
WARNING
CAUTION

Risk of injury to hands.
ØDo not reach into the processing line with your hands.
ØUse both hands to hold the machine.
4Safety E1026en03
WARNING

2. Description
1 Eccentric shaft
2 Clamping screw (fixing screw
for the supporting body)
3 Supporting body
4 Supporting roller
5 Stripper
6 Cutting tool
7 Rest plate
8 Spindle (for setting material
thickness)
9 Cap screw
10 Crank sliding block
11 Side plate, right
12 Side plate, left
13 On/Off switch
TruTool TKF 1500 beveler (3A1), (3B1) Fig. 84792
2.1 Intended use
The TRUMPF TruTool TKF 1500 beveler (3A1), (3B1) is an elec-
trical powered hand-held device designed for the following appli-
cations:
■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.
■Forming of uniform, oxide-free, bright metallic welding bevel
edges in steel and aluminum.
■Machining of chromium steel and similar high-tensile materi-
als (recommendation: machine in 2-gear version).
■Bevelling of straight and curved edges, provided the mini-
mum radius of the inner curve is 55 mm.
■Bevelling of edges on level and crooked workpieces, in par-
ticular tubes with an inside diameter of at least 100 mm.
E1026en03 Description 5

■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 on large, bulky workpieces, for which the
bevelling machine is guided as a hand-held device.
■Bevelling of edges in normal position (carrier below the
machine) and in "upside-down position" (carrier above the
machine), which is of advantage in particular when bevelling
X and K welding joints.
The TRUMPF TruTool TKF 1500 beveler (3B1) also offers 2-
gear changing for modifying the working speed when machining
high-tensile materials.
2.2 Technical data
Other countries USA
Values
Voltage 230 V
220 V
(China)
120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz
Max. length of bevel "ls" continuously adjustable:
Mild steel and alumi-
num up to 400 N/mm²
15 mm 0.59 in
Mild steel up to
600 N/mm²
9 mm 0.354 in
Mild steel up to 800
N/mm²
6 mm 0.236 in
Working Speed 2 m/min 6.55 ft/min
Nominal power con-
sumption
2600 W 2000 W 2000 W -
Rated current: - 16 A
Stroke rate with nomi-
nal load
370/min 340/min 340/min 340/min
Weight 16.5 kg 36.7 lbs
Material thicknesses:
Min. 6 mm 0.236 in
Max. 40 mm 1.57 in
Special 40-80 mm
80-120 mm
120-160 mm
1.57-3.14 in
3.14-4.71 in
4.71-6.28 in
Angle of bevel "ß" con-
tinuously adjustable
20°-45° 20°-45°
With special stripper 20°-55° 20°-55°
6Description E1026en03
TruTool TKF 1500 (3A1)

Other countries USA
Values
Smallest radius with
inner cutouts
55 mm 2.17 in
Safety classSafety class
II / II /
Tab. 1
Other countries USA
Values
Voltage 230 V
220 V
(China)
120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz
Max. length of bevel "ls" continuously adjustable:
Mild steel and alumi-
num up to 400 N/mm²
15 mm (1st + 2nd gear) 0.59 in
Mild steel up to
600 N/mm²
11 mm (1st gear)
9 mm (2nd gear)
0.433 in
0.354 in
Mild steel up to 800
N/mm²
9 mm (1st gear)
6 mm (2nd gear)
0.354 in
0.236 in
Working Speed 1.25 m/min
(1nd gear)
2 m/min
(2nd gear)
4.1 ft/min
(1st gear)
6.55 ft/min
(2nd gear)
Nominal power con-
sumption
2600 W 2000 W 2000 W -
Rated current: - 16 A
Stroke rate with nomi-
nal load
230/
min
(1st
gear)
370/
min
(2nd
gear)
170/min
(1st gear)
340/min
(2nd gear)
170/min
(1st gear)
340/min
(2nd gear)
Weight with guide han-
dle
19.5 kg 43.3 lbs
Material thicknesses:
Min. 6 mm 0.236 in
Max. 40 mm 1.57 in
Special 40-80 mm
80-120 mm
120-160 mm
1.57-3.14 in
3.14-4.71 in
4.71-6.28 in
Angle of bevel "ß" con-
tinuously adjustable
20°-45° 20°-45°
With special stripper 20°-55° 20°-55°
Smallest radius with
inner cutouts
55 mm 2.17 in
Safety class
II / II /
Tab. 2
E1026en03 Description 7
TruTool TKF 1500 (3A1)
TruTool TKF 1500 (3B1)

2.3 Icons
Note
The following symbols are important for reading and understand-
ing the operator's manual. The correct interpretation of the sym-
bols will help you operate the machine better and safer.
Icon Name Description
Read operator's 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. 3
2.4 Noise and vibration information
Noise emission value may be exceeded.
ØWear hearing protection.
The vibration emission value can be exceeded!
ØSelect the right tools and exchange them in time in the
event of wear.
ØHave maintenance carried out by trained specialized techni-
cians.
ØDefine additional safety measures for protecting the opera-
tor from the effect of vibrations (e. g. keep hands warm,
organization of working procedures, machining at normal
feed force).
ØDepending on the operating conditions and state of the elec-
tric tool, the actual load might be higher or lower than the
specified measured value.
8Description E1026en03
WARNING
WARNING

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.
Designation of measured value Unit Value according to
EN 60745
Vibration emission value ah (vector
sum of three directions)
m/s212.1
Uncertainty K for vibration emis-
sion value
m/s22.5
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 1.5
Tab. 4
E1026en03 Description 9

3. Setting work
3.1 Adjusting the ram length
s Material thickness
β Angle of bevel
ls Length of bevel
hs Height of bevel
b Width of bevel
h Residual height
Length of bevel and angle of bevel Fig. 9664
W 8 7 6 5 4 3 2 1 0 mm
ß 55° 14.5 13.3 12.1 10.8 9.7 8.4 7.2 6.0 4.8 ls
11.9 10.9 9.9 8.9 7.9 6.9 5.9 4.9 3.9 b
8.3 7.7 7.0 6.2 5.6 4.8 4.2 3.5 2.8 hs
ß 45° 15 13.6 12.12 10.8 9.4 8 6.5 5.1 3.7 ls
10.6 9.6 8.6 7.6 6.6 5.6 4.6 3.6 2.6 b
10.6 9.6 8.6 7.6 6.6 5.6 4.6 3.6 2.6 hs
ß 37.5° 15.5 13.8 12.2 10.5 8.9 7.3 5.6 4 2.4 ls
9.4 8.4 7.4 6.4 5.4 4.4 3.4 2.4 1.4 b
12.3 11 9.6 8.3 7 5.8 4.4 3.1 1.9 hs
ß 30° - 15 13 11 97531ls
- 7.5 6.5 5.5 4.5 3.5 2.5 1.5 0.5 b
- 13 11.2 9.5 7.8 6 4.3 2.6 0.8 hs
ß 20° - - 15 12.2 9.2 6.2 3.3 - - Is
- - 5.1 4.2 3.1 2.1 1.1 - - b
- - 14 11.4 8.6 5.8 3.1 - - hs
ß Angle of bevel
W Scale value which must be adjusted on the crank sliding block
Tab. 5
For angles of bevel > 45°, machine using special stripper.
Example for working with the table:
β desired 30°
ls13 mm
W (from the table) 6
Tab. 6
10 Setting work E1026en03

60 Hexagon head screw
65 Crank sliding block
B Reference point
Fig. 10063
1. Undo the hex. screw (60).
Note
Observe angle of bevel ß.
2. Consult the table to find the desired length of bevel/ram
length ls and the associated scale value W (see "Tab. 5",
pg. 10).
3. Rotate the crank sliding block (65) until the scale value W
on the crank sliding block lines up with the reference point B.
4. Tighten the hex. screw (60).
E1026en03 Setting work 11

3.2 Adjusting the angle of bevel
1 Stripper
3 Rest plate
4 Clamping screw
5 Spindle for setting the material
thickness
6 Cap screw
7 Clamping plate
8 Supporting arm
9 Hexagon head screw
Fig. 84793
Notes
■With stripper (1), the angle of bevel "ß" is continuously
adjustable between 20° and 45°.
■With stripper 55° (order number 0032119), the angle of
bevel "ß" is adjustable between 20° and 55°. Stripper (1)
must be exchanged for this.
1. Undo the screws (9) (on both sides).
2. Set the desired angle in accordance with the scale.
3. Retighten the screws (9).
12 Setting work E1026en03

3.3 Setting material thickness
1. Position the machine on the sheet (working position).
2. Undo the clamping screw (4).
3. Adjust the rest plate (3) to match the material thickness
using the spindle (5). Allow for 0.5 to 1 mm of play when
doing so.
4. Lock the spindle (5) into place with the clamping screw (4).
3.4 Selecting cutting tool
Cutting tool Default High-tensile Aluminum High-tensile
5575
Heavy-duty cut-
ting tool
Order number 0088503 0089335 0005014 0005575 0110399
Usage 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
A = direction of processing
E = distinguishing feature
E1026en03 Setting work 13

Cutting tool Default High-tensile Aluminum High-tensile
5575
Heavy-duty cut-
ting tool
Regrinding dia-
gram
Regrinding
reserve
10 mm 10 mm 10 mm 10 mm 2 mm
Cutting tools for TruTool TKF 1500 beveler Tab. 7
Note
Optimum utilzation of the high-performance cutting tool is
ensured only with the machine in the 2-gear version.
14 Setting work E1026en03

3.5 Adjusting height of the cutting tool
1 Eccentric shaft
2 Clamping screw
3 Cutting tool
4 Pressure die
5 Carrier
6 Sliding sleeve
Fig. 84871
Adjust the height of the cutting tool in such a way that it pro-
trudes approximately 1 mm (min. 0, max. 3 mm) out of the slid-
ing sleeve (6).
1. Rotate the eccentric shaft (1) until the cutting tool (3) has
achieved its highest point (UDP = upper dead point).
2. Undo the clamping screw (2).
3. Rotate the carrier (5) by 360° as often as needed until the
cutting tools protrudes 0-3 mm out of the sliding sleeve (6).
4. One rotation (360°) corresponds to a height adjustment of
1.75 mm.
5. Retighten the clamping screw (2).
E1026en03 Setting work 15

3.6 Select gear
Note
Depending on the material thickness, strength and type of work-
piece, 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 .
1 On/Off switch 2 Release switch
Fig. 84872
1. Put the machine into a stable position.
2. Switch on the machine briefly:
− Press the release switch (2) forward and hold it.
− Press the On/Off switch (1).
3. While the motor is running down, turn the gear switch to the
desired position.
16 Setting work E1026en03
CAUTION
CAUTION

3.7 Accessories included
Securing the chip box
Chips that fall away during machining are collected in the chip
box.
1 Screw
2 Locking bar
3 Chip box
Fig. 54642
1. Push the chip box (3) onto the clamping plate.
2. Loosen screw (1).
3. Turn the locking bar (2) downward.
4. Retighten the screw (1).
The chip box is secured against dropping out.
E1026en03 Setting work 17

Handle base
1 Screws (M10x30) 2 Handle base
Fig. 42381
ØTighten screws (1).
Tube-shaped handle
1 Tube-shaped handle 2 Screws (M10x20)
Fig. 41795
Note
Do not use washers.
ØTighten the tube-shaped handle with a screw (2).
18 Setting work E1026en03