Trumpf TruTool S 160 (1A2) User manual

Brand: Trumpf

Model: TruTool S 160 (1A2)

Type: User manual

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

347

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 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

Trumpf TruTool S 160 (1A2) User manual

Trumpf TruTool S 160 (1A2) User manual

Trumpf TruTool S 160 (1A2) User manual

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