Operator's manual
english
TKF 1500 - 0 PLUS
2 Safety E262EN_06.DOC
Table of contents
1. Safety ..................................................................................3
1.1 General safety rules.............................................................3
1.2 Specific safety rules.............................................................4
2. Description .........................................................................5
2.1 Designated use....................................................................6
2.2 Technical data .....................................................................7
3. Tool assembly....................................................................9
3.1 Adjusting the ram length ......................................................9
3.2 Adjusting the angle of bevel ..............................................12
3.3 Setting the sheet thickness................................................13
3.4 Selecting the cutting tool....................................................15
3.5 Adjusting height of the cutting tool.....................................16
3.6 Configuration of the various additional equipment ............18
4. Operation..........................................................................21
Working with the TKF 1500-0 PLUS ............................22
5. Maintenance .....................................................................24
5.1 Regrind cutting tool............................................................25
5.2 Replace cutting tool ...........................................................26
Disassembling cutting tool............................................27
Mounting the cutting tool ..............................................27
5.3 Replacing carbon brushes.................................................27
6. Wearing parts...................................................................28
7. Original accessories........................................................29
8. Options .............................................................................30
Warranty
Replacement parts list
Addresses
E262EN_06.DOC Safety 3
1. Safety
1.1 General safety rules
Read the Operator's Manual and the general safety rules
(Material number 1239438, red document) in their entirety
before starting up the machine. Follow precisely the directions
contained therein.
Read the Operator's Manual and the safety instructions
(Material number 125699, red document) in their entirety
before starting up the machine. Follow precisely the directions
contained therein.
The safety regulations according to DIN VDE, CEE, AFNOR
and other regulations which are valid in individual countries
should be adhered to.
Danger
Lethal danger due to electric shock!
Remove the plug from the plug socket before undertaking any
maintenance work on the machine.
Check the plug, the cable and the machine for damage each
time before the appliance is used.
Keep the machine dry and do not operate in damp rooms.
When using the electric tool outside, connect the fault current
(FI) protective switch with a maximum breaking current of
30 mA.
Warning
Danger of injury possible due to improper handling!
When working with the machine, wear safety glasses, hearing
protection, protective gloves and work shoes.
Do not plug in the plug unless the machine has been
switched off. Pull out the mains plug after use.
Warning
Risk of injury to the hands!
Do not place your hand into the processing line.
Use both hands to hold the machine.
USA/CAN
Rest of the world
4 Safety E262EN_06.DOC
Caution
Damage to property possible due to improper handling!
The machine will be damaged or destroyed.
Do not use the power cord to carry the machine.
Always guide the electric cord away from the back of the
machine and do not pull it across sharp edges.
Arrange for start-ups and checks on manual electric tools to
be carried out by a trained specialist. Only used the original
accessories provided by TRUMPF.
Warning
Risk of injury from high-temperature chips!
High-temperature chips are expelled from the chip ejector at
high speed.
Use a swarf box.
Warning
Risk of injury from falling machinery!
The entire weight of the machine must be taken up after
processing of the work workpiece.
Use suspension bracket with balancer.
Use suspension cable.
Warning
Damage to property possible due to improper handling!
Collisions could result from an erroneous setting of the
machine.
Turn the screw (15) one full clockwise rotation using the allen
key provided. If no collisions can be detected, remove the
allen key and put the machine into operation in accordance
with regulations (see Fig. 13201, Pg. 5)
1.2 Specific safety rules
Ensure the tool is connected to a circuit protected with a time delay
fuse (15 A min.).
E262EN_06.DOC Description 5
2. Description
15
7
37 49 65
20
25
24
1
43
59
56
226
1 Cutting tool
7 Clamping screw (fastening
screw for the die carrier)
15 Eccentric shaft
20 Supporting body
24 Stripper
25 Supporting roller
37 Spindle (for the sheet thickness
setting)
43 Rest plate
49 Cap screw
56 Side plate, right
59 Side plate, left
65 Crank sliding block
226 On/Off switch
Bevelling machine TKF 1500-0 PLUS
Fig. 13201
6 Description E262EN_06.DOC
2.1 Designated use
Warning
Risk of injury!
For processing and materials, only use machines which are
named in "Correct use".
The TRUMPF bevelling machine TKF 1500-0 PLUS is an electric
hand tool used for the following applications:
• Preparation of all of the K-, V-, X- and Y-shaped welding
grooves usual for gas and electrical fusion welding with various
continuously-adjustable angles of bevel and continuously-
adjustable lengths of bevels.
• Forming of uniform, oxide-free, bright metallic welding bevel
edges in steel and aluminium.
• Machining of chromium steel and similar high-tensile materials
(recommendation: machine in 2-gear version).
• Bevelling of straight and curved edges insofar as the minimum
radius with inner curves is at least 55 mm.
• Bevelling of edges on flat and crooked workpieces, particularly
in connection with tubes when the inside diameter is at least
100 mm in size.
• Bevelling of edges in both directions, whereby the bevelling
can begin and end at any give point on 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 underneath the
machine) and in "upside-down position" (carrier above the
machine), which is particularly advantageous with the bevelling
of X- and K-welding grooves.
E262EN_06.DOC Description 7
2.2 Technical data
Rest of the world USA
Values Values Values Values
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Bevelling
lengths "ls"
continuously
adjustable
• Material
tensile
strength
400 N/mm²
• Material
tensile
strength
600 N/mm²
• Material
tensile
strength
800 N/mm²
max. 15 mm
(1st gear)
15 mm
(2nd gear)
max. 11 mm
(1st gear)
9 mm
(2nd gear).
max. 9 mm
(1st gear)
6 mm
(2nd gear)
max. 15 mm
(1st gear)
15 mm
(2nd gear)
max. 11 mm
(1st gear)
9 mm
(2nd gear)
max. 9 mm
(1st gear)
6 mm
(2nd gear)
max. 15 mm
(1st gear)
15 mm
(2nd gear)
max. 11 mm
(1st gear)
9 mm
(2nd gear)
max. 9 mm
(1st gear)
6 mm
(2nd gear)
0.59 in
0.59 in
0.43 in
0.354 in
0.354 in
0.236 in
Working speed 1.25 m/min
(1st gear)
2 m/min
(2nd gear)
1.25 m/min
(1st gear)
2 m/min
(2nd gear)
1.25 m/min
(1st gear)
2 m/min
(2nd gear)
4.01 ft/min
(1st gear)
6.55 ft/min
(2nd gear)
Nominal power
consumption
2000 W 2000 W 2000 W -
Nominal current - - - 15 A
Stroke rate with
idle run
560/min
(1st gear)
360/min
(2nd gear)
510/min
(1st gear)
340/min
(2nd gear)
500/min
(1st gear)
330/min
(2nd gear)
510/min
(1st gear)
340/min
(2nd gear)
Weight with
guide handle
19.5 kg
19.5 kg
19.5 kg
43.3 lbs
Maximum sheet
thickness
Standard
Special
equipment
40 mm
40-80 mm
80-120 mm
120-160 mm
40 mm
40-80 mm
80-120 mm
120-160 mm
40 mm
40-80 mm
80-120 mm
120-160 mm
1.57 in
1.57-3.14 in
3.14-4.71 in
4.71-6.28 in
8 Description E262EN_06.DOC
Rest of the world USA
Values Values Values Values
Angle of bevel
"ß" continu-
ously adjustable
Angle of bevel
"ß" with special
stripper
20°-45°
20°-55°
20°-45°
20°-55°
20°-45°
20°-55°
20°-45°
20°-55°
Smallest radius
with inner
cutouts
55 mm 55 mm 55 mm 2.17 in
Protective
insulation
Class II Class II Class II Class II
Technical data
Noise and vibration Measured values in accordance
with EN 50144
A-weighted sound level Typically 89 dB (A)
A-weighted acoustic power level Typically 97 dB (A)
Hand-arm vibration Typically less than or equal to
3.1 m/s²
Measured values for noise and vibration
Table 1
Table 2
E262EN_06.DOC Tool assembly 9
3. Tool assembly
3.1 Adjusting the ram length
60 Hexagon-head screw
65 Crank sliding block
B Reference point
Ram length
1. Loosen hexagon-head screw (60).
2. Consult the table to find the desired length of bevel (ram
length) "ls" and the associated scale value "W".
Note
Observe angle of bevel "ß".
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 hexagon-head screw (60).
Fig. 10063
10 Tool assembly E262EN_06.DOC
s Sheet thickness
ß 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
E262EN_06.DOC Tool assembly 11
ls Length of bevel
β Angle of bevel
W Scale value, which is to be
adjusted on the crank sliding
block (65)
• ß desired 30°
• l
s desired 13 mm
• W (from the Table) 6
Fig. 9746
Example
12 Tool assembly E262EN_06.DOC
3.2 Adjusting the angle of bevel
49
37
23
43
61
24
28
36
50
23 Clamping screw
24 Stripper
36 Supporting arm
37 Spindle for the sheet thickness
setting
43 Rest plate
49 Cap screw
50 Clamping plate
61 Hexagon-head screw
Note
The angle of bevel "ß" is continuously adjustable between 20° and
45° with the use of the standard stripper (24).
1. Loosen the screws (61) (on both sides).
2. Set the desired angle in accordance with the scale.
3. Retighten the screws (61).
Fig. 38120
E262EN_06.DOC Tool assembly 13
Note
Angles of bevel between 20° and 55° can be achieved with the
help of a special stripper (Order No. 032119). In such cases, the
stripper (24) is to be replaced prior to setting the desired angle of
bevel "ß".
3.3 Setting the sheet thickness
1. Place machine on the sheet (work position).
2. Loosen clamping screw (23).
3. Adjust the rest plate (43) to match the sheet 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).
Converting the machine for processing sheet thicknesses
> 40 mm
For maximum sheet thicknesses use a spacer and a longer
screw (49).
Spacer and cap screw Sheet thickness range
M16x90-12.9 DIN 912 (Order No.
023203)
40-80 mm
M16x130-12.9 DIN 912 (Order No.
023204)
80-120 mm
M16x170-12.9 DIN 912 (Order No.
027799)
120-160 mm
Caution
Damage possible to property as a result of defective cap
screws!
Longer cap screws are utilised with spacers for greater sheet
thicknesses. These screws are subject to great stress.
When replacing spacers, inspect the cap screws and replace
them with new original screws when they show signs of wear.
5. Remove swarf box.
6. Loosen cap screw (49) and unscrew it.
7. Remove supporting arm (36) with spindle (37) and clamping
plate (50).
8. Put the respective spacer into place at the bottom side of the
pressure die (28) with the smooth end between the side plates.
9. Place supporting arm (36) on the centring pin of the spacer.
Put on the clamping plate (50), screw in the associated cap
screw.
Table 3
14 Tool assembly E262EN_06.DOC
10. Align the individual parts before tightening. The play between
the rest plate (43), the spindle (37) and the pressure die (28)
should be approximately 0.1 mm.
11. Tighten the cap screw (49) with a moment of 250 Nm.
E262EN_06.DOC Tool assembly 15
3.4 Selecting the cutting tool
KK
min. 95 mm
min. 95 mm
088503 089335
min. 95 mm
005014
110399
A
min. 103 mm
A
A
A
A
A
A
A
A machining direction K identification marking on the
upper end face for distinguishing
between the standard cutting tool
for mild steel and the cutting tool
for high-tensile sheets
Regrinding diagrams for the cutting tools for the bevelling machine TKF 1500
Fig. 9666
16 Tool assembly E262EN_06.DOC
The following cutting tools are available for the machining of sheets
of different material types and tensile strength:
Cutting tool Order number
Mild steel (standard cutting tool) 088503
High-tensile sheets 089335
Aluminium alloys 005014
High-performance cutting tool 110399
Note
Optimum utilisation of the high-performance cutting tool is ensured
only in connection with the machine in the 2-gear version.
3.5 Adjusting height of the cutting tool
15
7
1
28
20 22
0-3 mm
1 Cutting tool
7 Clamping screw
15 Eccentric shaft
20 Carrier
22 Sliding sleeve
28 Pressure die
Table 4
Fig. 13094
E262EN_06.DOC Tool assembly 17
Adjust the height of the cutting tool in such a way that it protrudes
approximately 1 mm (min. 0, max. 3 mm) out of the sliding
sleeve (22).
1. Rotate the eccentric shaft (15) until the cutting tool (1) has
achieved its highest point (UDP = upper dead point).
2. Loosen clamping screw (7).
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 m.
5. Retighten clamping screw (7).
18 Tool assembly E262EN_06.DOC
3.6 Configuration of the various additional
equipment
1
42
3
1 Suspension bracket
2 Supporting roller
3 Handle base
4 Tube-shaped handle
2
1
1 Tube-shaped handle 2 Fixing screw
Tighten the tube-shaped handle with a bolt.
Do not use washers.
Overview of additional
equipment
Fig. 41796
Assembly of tube-shaped
handle
Fig. 41795
E262EN_06.DOC Tool assembly 19
1 2
1 Screw joints 2 Roller holder
If the roller holder is installed without a handle base, it is then
necessary to use the bolts, washers and nuts delivered.
Assembly of the roller holder
Fig. 41794
20 Tool assembly E262EN_06.DOC
1
3
2
1 Screw joints
2 Clamping screw for suspension
bracket
3 Handle base
The handle base is mounted using two bolts. If the roller holder
is also to be mounted, it must be clamped between handle
base and tool. Do not use washers.
If the suspension bracket is mounted on the handle base, the
clamping screw (2) must penetrate into the recess intended for
this purpose.
Assembly of the handle
base/to suspension bracket
Fig. 42381
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