Operator's manual
english
TruTool TKF 104 (1A2)
2 Contents E254EN_03.DOC
Contents
1. Safety ..................................................................................3
1.1 General safety information...................................................3
1.2 Specific safety information...................................................3
2. Description .........................................................................5
2.1 Intended use ........................................................................6
2.2 Technical data .....................................................................7
3. Setting work .......................................................................8
3.1 Adjusting the angle of bevel ................................................8
3.2 Setting material thickness..................................................10
3.3 Adjusting the ram length ....................................................11
3.4 Selecting cutting tool..........................................................12
3.5 Adjusting the height of the cutting tool...............................13
4. Operation..........................................................................14
4.1 Working with the TruTool TKF 104....................................14
5. Maintenance .....................................................................15
5.1 Replace cutting tool ...........................................................17
5.2 Regrinding cutting tools .....................................................18
5.3 Checking/replacing the wearing plate................................18
5.4 Supplying with power and guaranteeing lubrication ..........19
5.5 Replacing fins ....................................................................21
5.6 Cleaning filter.....................................................................21
6. Original accessories and nonrepairable items.............22
Guarantee
Replacement parts list
Addresses
E254EN_03.DOC Safety 3
1. Safety
1.1 General safety information
¾ Before putting the machine into service, read the operator's
manual and the safety information (Order. No. 0373678) 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 to hands.
¾ Do not reach into the processing line with your hands.
¾ Use both hands to hold the machine.
Warning
Risk of injury from hot and sharp chips!
Hot and sharp chips are emitted from the chip dumping at
high speed.
¾ Make sure the chips are emitted downwards.
¾ Use the chip bag.
4 Safety E254EN_03.DOC
Warning
Risk of injury from falling machinery.
The entire weight of the machine must be taken up after
processing of the work workpiece.
¾ Use suspension bracket with balancer.
¾ Use suspension cable.
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 operate the machine away from your body.
¾ Do not operate the machine above your head.
Warning
Risk of injury from falling machinery.
The entire weight of the machine must be taken up after
processing of the work workpiece.
¾ User suspension bracket (optional) with balancer or safety
rope.
Caution
Damage to property due to improper handling.
The 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.
E254EN_03.DOC Description 5
2. Description
38
21
36
58
45
50
37
9
52
358
345
9 Cutting tool
21 Eccentric shaft
36 Clamping screw for the die carrier
37 Cap screw (2 pieces ) for fastening
the handle
38 Handle (can be mounted in
2 different positions)
45 Rest plate
50 Pressure die
52 Carrier
46 Roller guide
345 Lever
358 Quick-release coupling
Beveler TruTool TKF 104
Fig. 11422
6 Description E254EN_03.DOC
2.1 Intended use
Warning
Risk of injury
¾ Only use the machine for work and materials as described
under "Intended use".
The TRUMPF Beveler TruTool TKF 104 is a hand tool powered by
compressed air used for the following applications:
• Preparation of all K-, V-, X- and Y-shaped welding grooves
used for gas and electrical fusion welding with three different
angles of bevel and correspondingly adjustable lengths of
bevel.
• 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 with rpm control).
• Bevelling of straight and curved edges insofar as the minimum
radius with inner curves is at least 50 mm.
• Bevelling of edges on flat and crooked workpieces, particularly
in connection with tubes when the inside diameter is at least
80 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 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.
E254EN_03.DOC Description 7
2.2 Technical data
Other countries USA
Value Value
Max. length of bevel ls:
• Steel 400 N/mm².
• Steel 600 N/mm².
• Steel 800 N/mm².
• Aluminum 250 N/mm².
11.0 mm
8.5 mm
6.0 mm
12.0 mm
0.433 in
0.354 in
0.236 in
0.472 in
Working speed 2.5 m/min 8.214 ft/min
Smallest inner radius 50 mm 2 in
Max. material thickness s 25 mm 0.984 in
Min. material thickness s 3 mm 0.120 in
Angle of bevel ß 30°/37.5°/45° 30°/37.5°/45°
Nominal power consumption 2900 W 2900 W
Stroke rate at complete load 400/min 400/min
Weight with handle 13.3 kg 29.3 lbs
Max. operating pressure
(flow pressure)
6 bar 87 psi
Air consumption at 6 bar 3.1 m³/min 110 cubic ft/min
Inside diameter of the
compressed air hose
18 mm 0.7 in (3/4")
Vibration Measured values in accordance
with EN 50144
Hand-arm vibration ≤2.5 m/s²
Measured values were measured while cutting sheet steel
400 N/mm² with max. material thickness.
Noise emissions Measured values in accordance
with EN 50144
A-rated sound level LWA 86 dB
A-rated acoustic power level at the
work place LPA
94 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 E254EN_03.DOC
3. Setting work
3.1 Adjusting the angle of bevel
Three carriers are available with the angles 30°/37.5°/45° for the
beveler.
The selection of the angle is determined by replacing the entire
carrier.
3
6
F
9
F
52
43
9 Cutting tool
36 Clamping screw
43 Wearing plate
52 Carrier
F Lubricating grease "S1"
(Order No. 121486)
1. Loosen clamping screw (36).
2. Rotate carrier (52) by 45°.
3. Pull the carrier out towards the bottom.
4. Utilise other carrier.
5. Tighten clamping screw (36).
Fig. 10981
Adjusting the angle of bevel
E254EN_03.DOC Setting work 9
ls
b
hs
ls
b
hs
ls
b
hs
10,8
7,6
7,6
9,4
6,6
6,6
8
5,6
5,6
6,5
4,6
4,6
5,1
3,6
3,6
3,7
2,6
2,6
10,5
6,4
8,3
8,9
5,4
7
7,3
4,4
5,8
5,6
3,4
4,4
4
2,4
3,1
2,4
1,4
1,9
11
5,5
9,5
9
4,5
7,8
7
3,5
6
5
4,3
3
1,5
2,6
1
0,5
0,8
2,5
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
(mm)
ß
45°
ß
37,5°
ß
30°
s
s
h
l
h
ß
b
s
b = l sin ß
s.
h = l cos ß
s.
h = s - h
s
s
s Material thickness
ß Angle of bevel (45°/37.5°/30°)
ls Length of bevel
hs Height of bevel
b Width of bevel
h Residual height
Length of bevel and angle of bevel
Fig. 11406
10 Setting work E254EN_03.DOC
3.2 Setting material thickness
45
54
52
4
7
45 Rest plate
47 Spindle
52 Carrier
54 Clamping screws
1. Place machine on the sheet (work position).
2. Loosen clamping screw (54).
3. Adjust the rest plate (45) to match the material thickness using
the spindle (47). Allow for 0.5 to 1 mm of play when doing so.
4. Lock the spindle (47) into place with the clamping screw (54).
Fig. 11408
E254EN_03.DOC Setting work 11
3.3 Adjusting the ram length
55
41
40
B
43
54
47
45
52
40 Stripper
41 Set screw (for clamping)
43 Wearing plate
45 Rest plate
47 Spindle
52 Carrier
54 Clamping screw
55 Set screw (for support)
B Reference edge
1. Release set screw (41).
2. Adjust the stripper (40) in such a way that the desired ram
length (scale on carrier (52)) is lined up with the reference
edge B.
3. Apply the set screw (55) lightly.
4. Screw the set screw (41) on tight.
Fig. 10980
12 Setting work E254EN_03.DOC
3.4 Selecting cutting tool
Cutting tool Standard High-tensile
sheets
Aluminum High-tensile
sheets 5575
Heavy-duty
cutting tool
ID No. 88503 89335 005014 005575 110399
Application General mild steels
up to 500 N/mm²
Higher-tensile
mild steels up to
approximately
650 N/mm²,
chromium steel
Aluminum alloys High-tensile
materials up to
approximately
800 N/mm²,
chromium steel
High-tensile
materials
A
E
A
E
E
A
E
A
E
A
E
A = machining direction
E = distinguishing feature
Regrinding
diagram
Regrinding
reserve
10 mm 10 mm 10 mm 10 mm 2 mm
Cutting tools for the TruTool TKF 104 beveler
Table 4
E254EN_03.DOC Setting work 13
3.5 Adjusting the height of the cutting tool
21
36
52
50
9
E
9 Cutting tool
21 Eccentric shaft
36 Clamping screw
50 Pressure die
52 Carrier
E Penetration depth = ca. 1 mm
Adjust the elevation of the cutting tool (9) in such a way that it
penetrates approximately 1 mm into the pressure die (50).
1. Rotate the eccentric shaft (21) until the cutting tool (9) has
achieved its lowest point (LDP = lower dead point).
2. Loosen clamping screw (36).
3. Rotate the carrier (52) by 360° as often as necessary until the
correct penetration depth "E" has been achieved.
4. Retighten clamping screw (36).
Fig. 11042
14 Operation E254EN_03.DOC
4. Operation
4.1 Working with the TruTool TKF 104
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 operate the machine away from your body.
¾ Do not operate the machine above your head.
1 Bracket 2 Lever
1. Press the bracket (1) to the front.
2. Press the lever (2) against the motor housing.
1. Position machine on the sheet.
2. Maintain a few centimeters of clearance between the cutting
tool and the sheet edge at first.
3. Switch on machine and slide against the sheet edge (piercing).
4. Slide the machine along the sheet. Take care while doing so
that the machine axis runs parallel to the sheet edge.
5 Press the machine against the sheet edge.
¾ Release the lever (2).
The lever springs back to the initial position and the compressed
air is interrupted.
Switching on the
TruTool TKF 104
Fig. 11424
Continuous operation
Working with the
TruTool TKF 104
Switching off the
TruTool TKF 104
E254EN_03.DOC Maintenance 15
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 incorrect repair work.
Machine does not work properly.
¾ Repair work may only be carried out by a qualified technician.
355
312 max. 15mm
313
314 M358
312 Grease nipple for lubrication of the motor bearing
313 Screw plug for the oil filling nozzle
314 O-ring (9.2 x 1.8) under the screw plug
355 Filter
358 Quick-release coupling
M Middle axle of the machine
max. Maximum height of the oil level when refilling the oil
(15 mm underneath the filling nozzle, when the middle
axle of the machine is in horizontal position)
Note
If more oil is filled in, then there will be an unnecessarily large
amount of oil expelled through the ventilation opening of the motor
housing.
Fig. 11425
16 Maintenance E254EN_03.DOC
Maintenance point Procedure and interval Recommended lubricant Lubricant
Order No.
Gearbox and gear head After 300 operating hours, arrange for a
qualified technician to relubricate or to
replace the lubricating grease.
Lubricating grease "G1" 139440
Wearing plate Replace as needed. - -
Motor bearing Lubricate every 10 hours of operation. Lubricating grease "G1" 0139440
Oil mist lubrication device Maintain daily in accordance with the
manufacturer's specifications
(see "Supplying with power and
guaranteeing lubrication", p. 19).
- -
Segments Have these checked and replaced if
necessary by a qualified specialist.
- -
Filter Clean every 10 operating hours or
when there is a decline in performance.
- -
Maintenance table
Table 5
E254EN_03.DOC Maintenance 17
5.1 Replace cutting tool
If the cutting tool is blunt, then it must be either reground or
replaced.
3
6
F
9
F
52
43
9 Cutting tool
36 Clamping screw
43 Wearing plate
52 Carrier
F Lubricating grease "S1"
(Order No. 121486)
Replacing the tool
1. Loosen clamping screw (36).
2. Rotate carrier (52) by 45°.
3. Pull carrier (52) out towards the bottom.
4. Remove cutting tool (9) by rotating it.
5. Check wearing plate (43).
6. Lightly lubricate the cutting tool and the die carrier bore hole
with lubricating grease "S1" (Order No. 121486).
7. Screw in the cutting tool.
8. Align the cutting tool to 45°.
9. Install carrier.
10. Check the depth of penetration of the cutting tool.
Fig. 10981
18 Maintenance E254EN_03.DOC
5.2 Regrinding cutting tools
The cutting tool for mild steel (Order No. 088503) and for high-
tensile sheets (Order No. 089335) has 2 cutting edges.
¾ If both cutting edges are blunt, regrind the cutting tool on the
grinding face (90°).
Note
Maintain the minimum length of the cutting tools (see Table 4,
p. 12). Do not use shorter cutting tools.
The cutting tools for aluminium and the heavy-duty cutting tools are
ground at an angle on the grinding face. Observe the
corresponding regrinding diagram (see Table 4, p. 12).
5.3 Checking/replacing the wearing plate
40
52
43
S
40 Stripper
43 Wearing plate
52 Carrier
S Grease nipple for regreasing the
cutting tool guide with a grease gun
(Order No. 068624)
Wearing plate
1. Remove the carrier (52).
2. Inspect the wearing plate (43) for running-in marks.
3. If the running surface has been run in by approximately
0.2 mm (note outer ring): lift out wearing plate with 2 screw-
drivers and turn over or replace.
Fig. 14194
E254EN_03.DOC Maintenance 19
5.4 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. Alternately, install
an oil mist lubrication device into the compressed air line.
Prerequisite
• Pressure regulating valve and connecting thread are set up
correctly.
1 Connecting thread
2 Oil mist lubrication device
3 Pressure regulating valve
4 Filter and water separator
5 Inside diameter of the
compressed air hose min.
18 mm or 3/4"
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.
• Secure the compressed air hose against undesired move-
ments using a compressed air safety device.
Supplying compressed air
Fig. 52385
20 Maintenance E254EN_03.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.
355
312 max. 15mm
313
314 M358
312 Grease nipple for lubrication of the
motor bearing
313 Screw plug for the oil filling nozzle
314 O-ring (9.2 x 1.8) under the screw
plug
355 Filter
358 Quick-release coupling
M Middle axle of the machine
max. Maximum height of the oil level
when refilling with oil
(15 mm underneath the filling
nozzle, with machine middle axle
in horizontal position)
There are 2 ways of lubricating the compressed-air motor:
1. Through the internal oil chamber with short operating times
or changing utilization sites.
– Before every start-up, check whether the oil chamber is
filled to the maximum oil level (see Fig. 11425, p. 20).
– Fill up the oil through the opening in the screw plug every
operating hour (313).
Information
The oil level in the machine may not exceed the maximum
height (max.).
If more oil is filled in, then there will be an unnecessarily large
amount of oil expelled through the ventilation opening of the
motor housing.
2. In cases of continuous operation, install an oil mist
lubrication device in the compressed air line (e.g. Atlas
Copco DIM 25).
Checking the oil supply
Lubricating the
compressed-air motor
Fig. 11425
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