Operator's manual

TruTool TKF 104 (1A2)

english
 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

2 Contents E254EN_03.DOC
 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.

Risk of fatal injury from electric shock.

¾ When working with the machine do not touch any electrical
lines. The machine is not insulated.
Danger

Risk of injury due to improper handling.

¾ Always remove the compressed air hose from the machine
prior to maintenance work.
Warning 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

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.
Warning ¾ Make sure the chips are emitted downwards.
¾ Use the chip bag.

E254EN_03.DOC Safety 3
 Risk of injury from falling machinery.
The entire weight of the machine must be taken up after
processing of the work workpiece.
Warning ¾ Use suspension bracket with balancer.
¾ Use suspension cable.

Risk of injury due to improper handling.

¾ Make sure the machine is always in a stable position when
operating it.
Warning 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.

Risk of injury from falling machinery.

The entire weight of the machine must be taken up after
processing of the work workpiece.
Warning ¾ User suspension bracket (optional) with balancer or safety
rope.

Damage to property due to improper handling.

The machine will be damaged or destroyed.
¾ Have servicing and inspections of hand-held compressed air
Caution tools carried out by a qualified technician. Only use original
TRUMPF accessories.

4 Safety E254EN_03.DOC
 2. Description

38

21

36

58

9 358

45
52 37 345

50

9 Cutting tool 38 Handle (can be mounted in 52 Carrier

21 Eccentric shaft 2 different positions) 46 Roller guide
36 Clamping screw for the die carrier 45 Rest plate 345 Lever
37 Cap screw (2 pieces ) for fastening 50 Pressure die 358 Quick-release coupling
the handle
Beveler TruTool TKF 104 Fig. 11422

E254EN_03.DOC Description 5
 2.1 Intended use

Risk of injury
¾ Only use the machine for work and materials as described
under "Intended use".
Warning

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.

6 Description E254EN_03.DOC
 2.2 Technical data

Other countries USA

Value Value

Max. length of bevel ls:

• Steel 400 N/mm². 11.0 mm 0.433 in
• Steel 600 N/mm². 8.5 mm 0.354 in
• Steel 800 N/mm². 6.0 mm 0.236 in
• Aluminum 250 N/mm². 12.0 mm 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 6 bar 87 psi
(flow pressure)

Air consumption at 6 bar 3.1 m³/min 110 cubic ft/min

Inside diameter of the 18 mm 0.7 in (3/4")

compressed air hose

Table 1

Vibration Measured values in accordance

with EN 50144
Hand-arm vibration ≤2.5 m/s²
Table 2

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 94 dB
work place LPA
Table 3

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.

E254EN_03.DOC Description 7
 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.

36

F
9

43

52

9 Cutting tool 52 Carrier

36 Clamping screw F Lubricating grease "S1"
43 Wearing plate (Order No. 121486)
Fig. 10981

Adjusting the angle of bevel 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).

8 Setting work E254EN_03.DOC

 b = ls . sin ß ß
hs = ls . cos ß b
h = s - hs

ls
hs
s
h

10,8 9,4 8
ls
6,5 5,1 3,7 (mm)
ß b
7,6 6,6 5,6 4,6 3,6 2,6 (mm)
45°
hs
7,6 6,6 5,6 4,6 3,6 2,6 (mm)

10,5 8,9 7,3 5,6 4 2,4 (mm)

ls
ß
b
6,4 5,4 4,4 3,4 2,4 1,4 (mm)
37,5°
hs
8,3 7 5,8 4,4 3,1 1,9 (mm)

ls
11 9 7 5 3 1 (mm)
ß
b
5,5 4,5 3,5 2,5 1,5 0,5 (mm)
30°
hs
9,5 7,8 6 4,3 2,6 0,8 (mm)

s Material thickness hs Height of bevel

ß Angle of bevel (45°/37.5°/30°) b Width of bevel
ls Length of bevel h Residual height
Length of bevel and angle of bevel Fig. 11406

E254EN_03.DOC Setting work 9

 3.2 Setting material thickness

52

45

54

47

45 Rest plate 52 Carrier

47 Spindle 54 Clamping screws
Fig. 11408

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).

10 Setting work E254EN_03.DOC

 3.3 Adjusting the ram length

55

41

40

43

54

45

47

52

40 Stripper 52 Carrier
41 Set screw (for clamping) 54 Clamping screw
43 Wearing plate 55 Set screw (for support)
45 Rest plate B Reference edge
47 Spindle
Fig. 10980

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.

E254EN_03.DOC Setting work 11

 3.4 Selecting cutting tool

Cutting tool Standard High-tensile Aluminum High-tensile Heavy-duty

sheets sheets 5575 cutting tool
ID No. 88503 89335 005014 005575 110399
Application General mild steels Higher-tensile Aluminum alloys High-tensile High-tensile
up to 500 N/mm² mild steels up to materials up to materials
approximately approximately
650 N/mm², 800 N/mm²,
chromium steel chromium steel

E E

E E

A A A A A
E E

A = machining direction
E = distinguishing feature

Regrinding
diagram

Regrinding 10 mm 10 mm 10 mm 10 mm 2 mm
reserve
Cutting tools for the TruTool TKF 104 beveler Table 4

12 Setting work E254EN_03.DOC

 3.5 Adjusting the height of the cutting tool

21

36

E
50

52

9 Cutting tool 50 Pressure die

21 Eccentric shaft 52 Carrier
36 Clamping screw E Penetration depth = ca. 1 mm
Fig. 11042

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).

E254EN_03.DOC Setting work 13

 4. Operation

4.1 Working with the TruTool TKF 104

Risk of injury due to improper handling.

¾ Make sure the machine is always in a stable position when
operating it.
Warning 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.

Switching on the
TruTool TKF 104

1 Bracket 2 Lever
Fig. 11424

Continuous operation 1. Press the bracket (1) to the front.

2. Press the lever (2) against the motor housing.

Working with the 1. Position machine on the sheet.

TruTool TKF 104
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.

Switching off the ¾ Release the lever (2).

TruTool TKF 104
The lever springs back to the initial position and the compressed
air is interrupted.

14 Operation E254EN_03.DOC
 5. Maintenance

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.
Warning

313
312 max. 15mm 314 M 358

355

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)
Fig. 11425

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.

E254EN_03.DOC Maintenance 15
Maintenance point
Gearbox and gear head
Wearing plate
Motor bearing
Procedure and interval Recommended lubricant Lubricant
Order No.
After 300 operating hours, arrange for a Lubricating grease "G1" 139440
qualified technician to relubricate or to
replace the lubricating grease.
Replace as needed. - -
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

16 Maintenance E254EN_03.DOC
 5.1 Replace cutting tool

If the cutting tool is blunt, then it must be either reground or

replaced.

36

F
9

43

52

9 Cutting tool 52 Carrier

36 Clamping screw F Lubricating grease "S1"
43 Wearing plate (Order No. 121486)
Replacing the tool Fig. 10981

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.

E254EN_03.DOC Maintenance 17
 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

S
40

43

52

40 Stripper S Grease nipple for regreasing the

43 Wearing plate cutting tool guide with a grease gun
52 Carrier (Order No. 068624)
Wearing plate Fig. 14194

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.

18 Maintenance E254EN_03.DOC
 5.4 Supplying with power and
guaranteeing lubrication

Damage to property due to improper handling.

Failure of the compressed air motor.
¾ Do not exceed the maximum operating pressure.
Caution
¾ Regularly lubricate the compressed air motor. Alternately, install
an oil mist lubrication device into the compressed air line.

Supplying compressed air Prerequisite

• Pressure regulating valve and connecting thread are set up
correctly.

1 Connecting thread 5 Inside diameter of the

2 Oil mist lubrication device compressed air hose min.
3 Pressure regulating valve 18 mm or 3/4"
4 Filter and water separator
Compressed air supply Fig. 52385

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.

E254EN_03.DOC Maintenance 19
 Checking the oil supply 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.

Lubricating the
compressed-air motor 313
312 max. 15mm 314 M 358

355

312 Grease nipple for lubrication of the 358 Quick-release coupling

motor bearing M Middle axle of the machine
313 Screw plug for the oil filling nozzle max. Maximum height of the oil level
314 O-ring (9.2 x 1.8) under the screw when refilling with oil
plug (15 mm underneath the filling
355 Filter nozzle, with machine middle axle
in horizontal position)

Fig. 11425

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).

20 Maintenance E254EN_03.DOC
 Lubricating speed limiters ¾ Lubricate speed limiters (324) and ball bearings with gear
and ball bearings lubricant during the regular maintenance of the machine
(see replacement parts list).

Note
Handle the speed limiter (324) with special care, because damage
could lead to excessive rpms.

Lubricating motor bearings ¾ Relubricate the ball bearing in the motor flange every
10 operating hours through the grease nipples (312) with a
grease gun (see Fig. 11425, p. 20).

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).

5.5 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.

5.6 Cleaning filter

To avoid throttling and/or a drop in performance:

¾ Clean the filter (355) every 10 operating hours (see Fig. 11425,
p. 20).

E254EN_03.DOC Maintenance 21
 6. Original accessories and
nonrepairable items

TruTool TKF 104 Supplied original Irreparable Options Order No.

accessories items
Cutting tool (mounted) + 141944
Rapid-release coupling (machine-side part)
Rapid-release coupling (hose-side part) + 141945
Handle + 103555
Sliding handle + 110400
Roller guide + 104305
Allen key DIN 911-12 + 067920
Allen key + 118860
Cap screw M14x25 DIN 912 + 099123
Cap screw M8x12 DIN 912 + 014907
2 cap screws M14x45 + 105083
for fastening the handle DIN 912
3 clamping sleeves 4x12 DIN 7344 + 070858
Lubricating grease "S1" (25 g) + 0121486
Grease gun + 068624
Operator's manual + 0128640
Safety instructions (printed in red) + 125699
Cutting tool (standard) + 088503
Cutting tool (high-tensile materials) + 089335
Cutting tool (aluminum) + 005014
Heavy-duty cutting tool specially designed + 110399
for machining high-tensile materials
Stripper 30° + 104313
Stripper 37.5° + 104314
Stripper 45° (40°) + 104315
Pressure die + 109921
Wearing plate + 104297
Chip bag + 116199
Punching and nibbling oil for steel (0.5 l) + 103387
Punching and nibbling oil for aluminum (1 l) + 125874
Case + 121585
Suspension bracket + 105001
Muffler for motor, complete + 114244
Sleeve + 0376078
Fin set (4 x) + 1440002
Table 6

22 Original accessories and nonrepairable items E254EN_03.DOC

 Ordering original parts and To ensure the correct and fast delivery of original parts and
nonrepairable parts nonrepairable parts:

1. Specify the order number.

2. Enter further order data:
– Voltage information
– Quantity
– Machine type
3. Specify the 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. Refer to
the address list at the end of the document for TRUMPF
service addresses.

E254EN_03.DOC Original accessories and nonrepairable items 23

24 Original accessories and nonrepairable items E254EN_03.DOC