Trumpf TruTool TKF 1500 User manual

Operator's manual
TruTool TKF 1500 (1A1), (1B1)

Table of contents
1 Safety 4
1.1 General safety information 4
1.2 Specific safety information for beveler 4
2 Description 6
2.1 Intended use 6
2.2 Technical data 7
2.3 Symbols 9
2.4 Noise and vibration information 9
3 Setting work 11
3.1 Adjusting the ram length 11
3.2 Adjusting the angle of bevel 13
3.3 Setting material thickness 14
3.4 Selecting cutting tool 14
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 (1A1), (1B1) 28
5 Maintenance 30
5.1 Regrinding cutting tool 30
5.2 Changing the cutting tool 31
5.3 Change the sliding sleeve 32
2Table of contents E681en_02

6 Accessories and consumables 34
6.1 Ordering consumables 35
7 Appendix: Declaration of conformity, guar-
antee, replacement parts lists
36
E681en_02 Table of contents 3

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 maxi-
mum breaking current of 30 mA when using the electric tool
outside.
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
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.
4Safety E681en_02
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 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.
E681en_02 Specific safety information for beveler 5
WARNING
WARNING
WARNING
CAUTION

2. Description
1 Cutting tool
7 Clamping screw (fixing screw
for the supporting body)
15 Eccentric shaft
20 Supporting body
24 Stripper
25 Supporting roller
37 Spindle (for setting material
thickness)
43 Rest plate
49 Cap screw
56 Side plate, right
59 Side plate, left
65 Crank sliding block
226 On/Off switch
TruTool TKF 1500 beveler (1A1), (1B1) Fig. 13201
2.1 Intended use
The TRUMPF TruTool TKF 1500 beveler (1A1), (1B1) 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).
6Description E681en_02

■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.
■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 (1B1) 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 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
15 mm 0.59 in
Mild steel
with 600 N/mm²
9 mm 0.354 in
Mild steel
with 800 N/mm²
6 mm 0.236 in
Working speed 2 m/min 6.55 ft/min
Nominal power con-
sumption
2000 W -
Nominal current - 15 A
Stroke rate with nominal
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°
Smallest radius with
inner cutouts
55 mm 2.17 in
E681en_02 Technical data 7
TruTool TKF 1500 (1A1)

Other countries USA
Values
Safety classSafety class
II / II /
Tab. 1
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
15 mm (1st + 2nd gear) 0.59 in
Mild steel
with 600 N/mm²
11 mm (1st gear)
9 mm (2nd gear)
0.433 in
0.354 in
Mild steel
with 800 N/mm²
9 mm (1st gear)
6 mm (2nd gear)
0.354 in
0.236 in
Working speed 1.25 m/min
(1st gear)
2 m/min
(2nd gear)
4.1 ft/min
(1st gear)
6.55 ft/min
(2nd gear)
Nominal power con-
sumption
2000 W -
Nominal current - 15 A
Stroke rate with nominal
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
8Technical data E681en_02
TruTool TKF 1500 (1A1)
TruTool TKF 1500 (1B1)

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. 3
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.
E681en_02 Symbols 9
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.
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 emission
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
10 Noise and vibration information E681en_02

3. Setting work
3.1 Adjusting the ram length
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
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
E681en_02 Setting work 11

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.
11).
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).
12 Setting work E681en_02

3.2 Adjusting the angle of bevel
23 Clamping screw
24 Stripper
36 Supporting arm
37 Spindle for setting the material
thickness
43 Rest plate
49 Cap screw
50 Clamping plate
61 Hexagon head screw
Fig. 38120
Notes
■With stripper (24), 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
(24) must be exchanged for this.
1. Undo the screws (61) (on both sides).
2. Set the desired angle in accordance with the scale.
3. Retighten the screws (61).
E681en_02 Setting work 13

3.3 Setting material thickness
1. Position the machine on the sheet (working position) (see
"Fig. 38120", pg. 13).
2. Undo the clamping screw (23).
3. Adjust the rest plate (43) to match the material thickness
using the spindle (37). Allow for 0.5 to 1 mm of play when
doing so.
4. Lock the spindle (37) into place with the clamping screw
(23).
3.4 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
A = direction of processing
E = distinguishing feature
Regrinding dia-
gram
14 Selecting cutting tool E681en_02

Cutting tool Standard High-tensile Aluminum High-tensile
5575
Heavy-duty cut-
ting tool
Regrinding
reserve
10mm 10 mm 10 mm 10 mm 2 mm
Cutting tool for TruTool TKF 1500 beveler (1A1), (1B1) Tab. 7
Note
Optimum utilzation of the high-performance cutting tool is
ensured only with the machine in the 2-gear version.
3.5 Adjusting height of the cutting tool
1 Cutting tool
7 Clamping screw
15 Eccentric shaft
20 Carrier
22 Sliding sleeve
28 Pressure die
Fig. 13094
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 (22).
1. Rotate the eccentric shaft (15) until the cutting tool (1) has
achieved its highest point (UDP = upper dead point).
2. Undo the clamping screw (7).
E681en_02 Selecting cutting tool 15

3. Rotate the carrier (20) by 360° as often as needed until the
cutting tools protrudes 0-3 mm out of the sliding sleeve (22).
4. One rotation (360°) corresponds to a height adjustment of
1.75 mm.
5. Retighten the clamping screw (7).
3.6 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 .
1 On switch
2 Off switch
3 Release switch
Fig. 9659
1. Put the machine into a stable position.
2. Switch on the machine briefly:
16 Selecting cutting tool E681en_02
CAUTION
CAUTION

− 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 to the
desired position.
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.
E681en_02 Accessories included 17

Handle base
1 Screws (M10x25) 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 Accessories included E681en_02

Roller holder
1 Screws 2 Roller holder
Roller holder on the right-hand side Fig. 41794
The roller holder on the right-hand side is delivered with the
machine as standard. A roller holder for the left-hand side can
be ordered separately.
1. When the roller holder is to be installed without a handle
base, the supplied screws, washers, and nuts will also be
required.
Note
Do not use washers.
2. If the roller holder is also to be installed, it must be clamped
between handle base and tool.
E681en_02 Accessories included 19
Roller holder without handle
base
Roller holder with handle
base

3.8 Options
Roller holder for pipe and tube processing
The roller holder below can be used to bevel tubes with an out-
side diameter of up to 200 mm. The minimum tube inside diam-
eter must be 100 mm.
For roller holder for tubes with an outside diameter of up to
200 mm
Fig. 54643
20 Options E681en_02