Trumpf TruTool S 160 (1A2) is a hand tool powered with compressed air used for the following applications: • Cutting plate-shaped workpieces made of steel, aluminum, plastic, etc. • Cutting straight or curved exterior and inner cutouts. • Cutting along scribed lines. This versatile tool features: • Variable cutting clearance for optimum cutting results on various material thicknesses. • Replaceable blades with four cutting edges for extended tool life. • Exhaust hose for reduced noise emissions and improved operator comfort. • Compact and lightweight design for easy handling and maneuverability.
Trumpf TruTool S 160 (1A2) is a hand tool powered with compressed air used for the following applications: • Cutting plate-shaped workpieces made of steel, aluminum, plastic, etc. • Cutting straight or curved exterior and inner cutouts. • Cutting along scribed lines. This versatile tool features: • Variable cutting clearance for optimum cutting results on various material thicknesses. • Replaceable blades with four cutting edges for extended tool life. • Exhaust hose for reduced noise emissions and improved operator comfort. • Compact and lightweight design for easy handling and maneuverability.
Operator's manual
English
TruTool S 160 (1A2)
E601EN_01.DOC Contents 3
Contents
1. Safety ..................................................................................4
1.1 General safety information...................................................4
1.2 Specific safety information...................................................4
2. Description .........................................................................5
2.1 Intended use ........................................................................6
2.2 Technical data of the TruTool S 160 ...................................7
3. Setting work .......................................................................8
3.1 Installing the exhaust hose ..................................................8
3.2 Selecting the blade ..............................................................9
3.3 Setting the cutting clearance .............................................10
4. Operation..........................................................................11
4.1 Operating the TruTool S 160 .............................................11
5. Maintenance .....................................................................13
5.1 Changing the blade............................................................14
5.2 Supplying with power and guaranteeing lubrication ..........15
5.3 Replacing fins ....................................................................16
5.4 Cleaning the strainer..........................................................17
5.5 Changing mufflers..............................................................17
6. Original accessories and wearing parts........................18
7. Disposal............................................................................18
Guarantee
Spare parts list
Addresses
4 Safety E601EN_01.DOC
1. Safety
1.1 General safety information
¾ Before starting-up the machine, read the operator's manual
and the safety information (order no. 0373678, red document)
in its entirety and carefully follow the instructions given.
¾ Comply with the safety regulations in accordance with
DIN VDE, CEE, AFNOR as well as any other regulations that
apply in the individual countries.
Danger
Risk of fatal injury from electric shock!
¾ When working with the machine do not touch any electrical
lines. The machine is not insulated.
Warning
Risk of injury due to improper handling!
¾ Always remove the compressed air hose from the machine
prior to maintenance work.
¾ Check the compressed air hose, connection coupling, and
machine for damage each time before using the machine.
¾ Wear safety glasses, hearing protection, protective gloves
and work shoes when working at the machine.
¾ Connect compressed air only when the machine is switched
off.
¾ Always lay the compressed air hose away from the back of
the machine.
1.2 Specific safety information
Warning
Risk of injury due to improper handling!
¾ Make sure the machine is always in a stable position when
operating it.
¾ Never touch the tool while the machine is running.
¾ Always move the machine away from your body and do not
pull it over sharp edges.
E601EN_01.DOC Description 5
Caution
Damage to property due to improper handling!
Machine will be damaged or destroyed.
¾ Have servicing and inspections of hand-held compressed air
tools carried out by a qualified technician. Only use original
TRUMPF accessories.
2. Description
9
347
12
11
14 15 16
1821 20
9 Ram
11 Upper blade and
lower blade
12 Fixing screw
14 Fixing screw
15 Adjusting screw
16 Fixed blade carrier
18 Chip deflector (hand protection)
20 Lever
21 Safety lever
347 Sleeve
Portable shears TruTool S 160
Fig. 52527
6 Description E601EN_01.DOC
2.1 Intended use
Warning
Risk of injury
¾ Only use the machine for the tasks and materials described in
"Intended use".
The TRUMPF portable shears TruTool S 160 are a hand tool
powered with compressed air used for the following applications:
• Cutting plate-shaped workpieces made of steel, aluminum,
plastic, etc.
• Cutting straight or curved exterior and inner cutouts.
• Cutting along scribed lines.
E601EN_01.DOC Description 7
2.2 Technical data of the TruTool S 160
Other countries USA
Value Value
Max. material thickness:
• Steel 400 N/mm²
• Steel 600 N/mm²
• Steel 800 N/mm²
• Aluminum 250 N/mm²
1.6 mm
1.2 mm
1.0 mm
2.0 mm
0.063 in
0.048 in
0.039 in
0.079 in
Working speed 8-12 m/min 26-39 ft/min
Nominal power consumption 600 W 600 W
Idle stroke rate 5500/min 5500/min
Stroke rate with nominal load 5000/min 5000/min
Weight 1.6 kg 3.5 lbs
Smallest radius with curved cuts 15 mm 0.6 in
Starting hole diameter 27 mm 1.06 in
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
10 mm 0.4 in (3/8")
Technical data
Vibration Specifications in accordance with
EN 12096
Measured values in accordance
with EN ISO 8662-10
Vibration value at the handle a 6.41 m/s²
Uncertainty K 1.5 m/s²
Measured values were measured while cutting sheet steel
400 N/mm² with max. material thickness.
Noise emissions Designations in accordance with
EN ISO 4871
Measured values in accordance
with EN ISO 15744
A-rated sound level LWA 94 dB
A-rated acoustic power level at the
work place LPA
83 dB
The noise emission values given are the sum of the measured
values and the corresponding uncertainties. They represent an
upper value limit which can emerge during measurements.
Table 1
Table 2
Table 3
8 Setting work E601EN_01.DOC
3. Setting work
3.1 Installing the exhaust hose
The exhaust hose reduces noise emissions and guides the
exhaust air away from the operator.
1 Adapter
2 Teflon tape
3 Sleeve
4 Compressed air hose
5 Hose clip
6 Exhaust hose
7 Spring ring
Exhaust hose
1. Put the exhaust hose (6) and the hose clip (5) over the
compressed air hose (4).
2. Undo the spring ring (7) and screw the adapter (1) onto the
motor.
3. Wind Teflon tape (2) around the sleeve (3).
4. Firmly screw in the sleeve (3) in the motor.
5. Push the compressed air hose (4) on to the sleeve (3).
6. Position the hose clip (5) and tighten.
7. Push the exhaust hose (6) on to the adapter (1).
8. Secure the exhaust hose (6) using the spring ring (7).
Fig. 52422
E601EN_01.DOC Setting work 9
3.2 Selecting the blade
Caution
Damage to property due to the wrong blade selection!
The cutting quality will be severely impaired and the
individual tools overloaded.
¾ Use only appropriate tools.
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 four cutting edges.
• They are non-regrindable "4-way multi-edge, throw-away
cutters".
Notes
• Two different blade types can be selected for the machining
process, depending on the material thickness or the tensile
strength of the workpiece.
• Standard blades with a tensile strength of ≤400 N/mm² have no
special identification marking. Chromium steel blades are
marked with "Cr".
• For these reasons, it is highly recommended that only such
tools be used as those which correspond to the specifications
contained in this table.
Blade type Material thickness
ranges [mm]
Type of material
and tensile
strength
Order no.
Standard 0.3-2.0 Aluminum
250 N/mm²
126471
Standard 0.3-1.6 Mild steel
400 N/mm²
126471
Cr 0.3-1.2 Stainless steel
600 N/mm²
919760
Cr 0.3-1.0 Stainless steel
800 N/mm²
919760
Table 4
10 Setting work E601EN_01.DOC
3.3 Setting the cutting clearance
Warning
Risk of injury due to uncontrolled machine movements.
¾ Remove the compressed air hose when changing tools and
before performing any maintenance work on the machine.
The blade clearance "a" is factory-set to a material thickness of
1.0 mm when the machine is first delivered.
Set the following values to obtain optimum cutting results:
Material thickness "s" [mm] Blade clearance = cutting clearance "a"
[mm]
0.3-0.6 0.1
0.8-1.2 0.2
1.3-1.6 0.3
1. Push the On/Off switch several times until the moving cutter
blade has reached the lower dead point.
2. Loosen the lower blade.
3. Set the blade to the required clearance using the adjusting
screw.
4. Retighten the blade.
5. Tighten the adjusting screw slightly.
6. Check clearance with the setting gauge.
Table 5
E601EN_01.DOC Operation 11
4. Operation
Warning
Risk of injury due to improper handling!
¾ Make sure the machine is always in a stable position when
operating it.
¾ Never touch the tool while the machine is running.
¾ Always move the machine away from your body and do not
pull it over sharp edges.
4.1 Operating the TruTool S 160
1. Turn the safety lever (21).
2. Press the lever (20) against the motor housing.
1. Do not move the machine towards the workpiece until full
speed has been reached.
2. Machine the material.
– Move the device forward at an angle of 80 to 90° to the
sheet surface.
Requirements for cutting radiuses
• Do not tilt the machine.
• Proceed with a low feed rate.
Requirements for cutting at the edge
Cut upside down, i.e. the fixed blade carrier points upward.
Switching on the
TruTool S 160
Operating the TruTool S 160
Fig. 24014
12 Operation E601EN_01.DOC
¾ Release the lever.
The lever springs back to initial position, the compressed air is
interrupted.
Note
Do not subject the machine to heavy loads to such an extent that it
stops.
Switching off the
TruTool S 160
E601EN_01.DOC Maintenance 13
5. Maintenance
Warning
Risk of injury due to uncontrolled machine movements.
¾ Remove the compressed air hose when changing tools and
before performing any maintenance work on the machine.
Warning
Risk of injury due to repair work not being carried out
properly!
Machine does not work properly.
¾ Repair work may only be carried out by a qualified technician.
Caution
Damage to property caused by blunt tools!
Machine overload.
¾ Check the cutting edge of the blade hourly for wear. Sharp
blades ensure good cutting quality and protect the machine.
Replace the blades in due time.
Maintenance point Procedure and interval Recommended lubricant Lubricant
order no.
Ram guide Every 300 operating hours Lubricating grease "S1" 0121486
Gearbox and gear head After 300 operating hours, arrange
for a qualified technician to relu-
bricate or to replace the lubricating
grease.
Lubricating grease "G1" 139440
Fixed cutter blade Turn as required - -
Fixed cutter blade Replace as necessary - -
Moving cutter blade Turn as required - -
Moving cutter blade Replace as necessary - -
Tools Check tools hourly for wear
Filter, oil mist lubrication
device
Maintain daily in accordance with
the manufacturer's specifi-
cations(see "Supplying with power
and guaranteeing lubrication",
p. 15)
- -
Strainer Clean every 10 operating hours
and when there has been a
decline in performance (see
"Cleaning the strainer", p. 17).
- -
Maintenance overview
Table 6
14 Maintenance E601EN_01.DOC
5.1 Changing the blade
Warning
Risk of injury due to uncontrolled machine movements.
¾ Remove the compressed air hose when changing tools and
before performing any maintenance work on the machine.
Upper and lower blades are identical. They each have 4 cutting
edges and can be used interchangeably.
In the event of insufficient cutting performance, rotate each of the
blades by 90° respectively or replace them.
a Blade clearance
12 Ram
13 Fixing screw
17 Upper blade and lower blade
18 Adjusting screw
1. Loosen the screw on the respective blade.
2. Rotate blade by 90°
3. Tighten the screw.
Note
Take care to ensure that the adjusting screw (18) is up against the
lower blade.
Fig. 24015
E601EN_01.DOC Maintenance 15
5.2 Supplying with power and
guaranteeing lubrication
Caution
Damage to property due to improper handling!
Failure of the compressed air motor.
¾ Do not exceed the maximum operating pressure.
¾ Regularly lubricate the compressed air motor. Install an oil
mist lubrication device into the compressed air line.
Condition
• The pressure regulating valve and the connecting threads are
laid out correctly (see "Technical data", section 2.2, p. 7).
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
16 Maintenance E601EN_01.DOC
¾ Hold 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:
¾ Fill 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.
5.3 Replacing fins
Worn fins decrease machine performance.
¾ Have the fin set checked and replaced as needed by a
qualified technician.
Note
Only use original replacement parts and observe the information
on the rating plate.
Checking the oil supply
E601EN_01.DOC Maintenance 17
5.4 Cleaning the strainer
Dirty strainers decrease machine performance.
1
1
2
3
1 Muffler
2 Housing ring
3 Air inlet with strainer
Air inlet
1. Remove the air inlet with strainer.
2. Clean the strainer or replace the complete air inlet.
3. Reinstall the air inlet.
5.5 Changing mufflers
Change the mufflers as needed (see Fig. 52402, p. 17).
1. Remove the air inlet (3).
2. Pull off the housing ring (2).
3. Replace the mufflers (1).
4. Reinstall the housing ring and the air inlet.
Fig. 52402
18 Original accessories and wearing parts E601EN_01.DOC
6. Original accessories and wearing parts
Supplied original
accessories
Wearing parts Options Order no.
2 Standard blade for the machining of
mild steel
+ + 126471
2 Chromium steel blades for the
machining of high-tensile sheets
+ + 919760
Set of tools (upper and lower multi-
edge cutters, mounted) Allen key
DIN 911-2
+ + 002946
Allen key DIN 911 + 094840
Case + 1408552
Sleeve + 0376078
Fin set (x 4) + 1440002
Operator's manual + 1440912
Safety information (red document) + 0373678
Lubricating grease "G1"
(900 g/1.98 lbs)
+ 0139440
Lubricating grease "S1"
(25 g/0.055 lbs)
+ 0121486
Note
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 four cutting edges. They are
non-regrindable "4-way multi-edge, throw-away cutters".
To ensure the correct and fast delivery of original parts and
wearing parts:
1. Specify the order number.
2. Enter further order information:
– Voltage data.
– Quantity
– Machine type.
3. Provide complete shipping information:
– Correct address.
– Desired delivery type (e.g. air mail, courier, express mail,
ordinary freight, parcel post).
4. Send the order to the TRUMPF representative office. For
TRUMPF service addresses, see the address list at the end of
the document.
7. Disposal
To dispose of the machine, completely disassemble it, degrease it
and send it, according to the different types of material, for
recycling.
Table 7
Ordering wearing parts
-
1
-
2
-
3
-
4
-
5
-
6
-
7
-
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
Trumpf TruTool S 160 (1A2) is a hand tool powered with compressed air used for the following applications: • Cutting plate-shaped workpieces made of steel, aluminum, plastic, etc. • Cutting straight or curved exterior and inner cutouts. • Cutting along scribed lines. This versatile tool features: • Variable cutting clearance for optimum cutting results on various material thicknesses. • Replaceable blades with four cutting edges for extended tool life. • Exhaust hose for reduced noise emissions and improved operator comfort. • Compact and lightweight design for easy handling and maneuverability.
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