Hainbuch hs dock, Operating Instructions Manual

Page 1: ...Operating instructions incl installation manual hs dock EN...

Page 2: ...hs dock 2 Order hotline 49 7144 907 333 Translation of the original operating instructions Order hotli ne 49 7144 907 333...

Page 3: ...icular hazards 16 2 6 Other safety instructions 17 2 7 Screws 19 2 8 Functionality 19 2 9 Environmental protection 20 3 Technical data 21 3 1 General information 21 3 2 Performance values 22 3 3 Balan...

Page 4: ...of the hydraulic port variant of the product on the underside of the product 39 7 5 3 Preparation of the hydraulic port variant on the side of the product 39 7 5 4 Preparation of the product for inst...

Page 5: ...riant of the product from the side of the product secured using clamping brackets 73 10 3 4 Removal of the tandem version 74 10 3 5 Removal of the product together with the installed clamping device 7...

Page 6: ...24 Table 5 Nomenclature for selection of hydraulic unit 28 Table 6 Clamping and release volumes 28 Table 7 Clamping release times on a 2 hydraulic assembly 29 Table 8 Clamping release times on a 4 hyd...

Page 7: ...of the product WARNING Serious injuries caused by individual products or by inappropriate combinations of them Read and pay attention to all operating instruc tions for individual products and combina...

Page 8: ...ple and damage to ma terials warns of stored energy for example involving springs warns of hand injuries draws attention to the fact that the operating instructions of the product must be read 1 3 Def...

Page 9: ...onditions of Business and the delivery terms of the manufacturer and all legislative stipula tions valid at the time of conclusion of this contract 1 5 Copyright This manual is protected by copyright...

Page 10: ...tool caused by an incorrect or defective spare parts Always use genuine spare parts made by the orig inal manufacturer NOTE Damage malfunctions or total failure of the prod uct or machine tool caused...

Page 11: ...No modifications must be made to the product The operator is wholly and solely responsible for any resultant personal injury and or damage to materials DANGER Serious injuries caused by parts being e...

Page 12: ...o identify and avoid potential haz ards Hydraulics specialist Hydraulics specialists are trained in the specific task profile for which they are employed and are familiar with the rele vant standards...

Page 13: ...d in this manual see Use chapter Furthermore an ex tended form of use can be agreed contractually between manufacturer and operator Only skilled staff from the appropriate specialist fields may instal...

Page 14: ...ct use of the product Only in a CE compliant machine tool with a sepa rating set of guards Only use for the type of use indicated see Use chapter Only skilled staff from the appropriate specialist fie...

Page 15: ...m coming into contact with moving machine parts Do not wear rings chains or other jewelry Safety footwear To protect the wearer from any heavy items that may fall and from losing their footing on slip...

Page 16: ...ealth hazards and to pre vent dangerous situations Moving parts WARNING Serious injuries caused by touching rotating and or moving parts Do not open guards while the system is operating During operati...

Page 17: ...ternating fashion to reduce clamping action to a minimum Do not open the screws secured with sealing lac quer WARNING Serious injuries caused by media escaping under high pressure due to missing damag...

Page 18: ...or their components and acces sories on a regular basis for visible signs of dam age see Inspections and Cleaning chap ters Use of damaged products their damaged compo nents and or their damaged acces...

Page 19: ...dard medium strength screw adhesive and tightened to the specified tightening torque see nomenclature or the Screw tightening torques chapter Before reinstallation clean and degrease the screw and int...

Page 20: ...ous substances enter the environment accidentally take immediate re medial action If in doubt notify the relevant municipal authori ties about the incident The following environmentally hazardous subs...

Page 21: ...5 6 0 139 x 62 56 35 5 7 7 5 18 5 230 x 62 51 45 Table 1 Technical data version without springs Version with springs Size Axial release stroke Axial clamping reserve Total weight Dimensions x length...

Page 22: ...es are no long legible refer to the operating instructions The achievable actuation forces may vary as a result of the maintenance status lubrication status and level of contami nation of the product...

Page 23: ...tion The following formula should be used to determine the sup ply pressure that needs to be set to achieve a defined level of actuating force INFORMATION The maximum supply pressure and the maxi mum...

Page 24: ...uat ing force of 20 kN a sup ply pressure of 33 bar must be present for size XXS 4 A F A Size XXS 4 A F B Size 5 7 3 6 Operating conditions Indication Value Unit Ambient temperature range 15 65 C Humi...

Page 25: ...e 2 Actuating unit The actuating unit provides a support for clamping devices The actuating unit was designed for stationary operation The actuating unit is screwed to the machine table The media guid...

Page 26: ...ine tool 4 3 Optional accessories The following optional accessories are available for different sizes of product 4 3 1 Spacer When using the tandem version of the product the spacer is needed to conn...

Page 27: ...nt supply pressure The tandem version doubles the piston surface area of the product and therefore also doubles the axial actuating force NOTE Damage to materials on the products used and or to the ma...

Page 28: ...me Refer to the following table for details of the clamping and release volume Size of the product Clamping volume 1 product Release volume 1 product XXS 4 A F 0 0252 0 0231 5 7 0 0352 0 0319 Table 6...

Page 29: ...he product Clamping release time 1 Product 2 Products 4 Products XXS 4 A F 0 756 1 512 3 024 5 7 1 056 2 112 4 224 Table 7 Clamping release times on a 2 hydraulic assembly Size of the product Clamping...

Page 30: ...r use appropriate load bearing equipment and lifting tackle WARNING Serious injuries caused by transporting off center equipment Pay attention to marks on the packaging items Attach the crane hook dir...

Page 31: ...n coat of grease if necessary 6 2 Symbols on the packaging Fragile Designates packaging items with fragile or breakable con tents Handle the packaging item with care Do not drop it and protect it agai...

Page 32: ...ged prod ucts 3 Attach load bearing equipment to the lifting tackle 4 Subject to weight use lifting gear to lift the product out of its packaging safely and place it down on a stable flat surface 5 Se...

Page 33: ...oid mechanical vibration Storage temperature 15 to 35 C Relative humidity Maximum 60 In the event of storage for more than 3 months On a regular basis check the general condition of all parts and pack...

Page 34: ...ing area of the machine WARNING Serious injuries caused by the escape of media under high pressure Shut down media delivery during installation and removal Relieve any pressure trapped in the system S...

Page 35: ...mage to materials caused by lifting gear left in the product Always remove lifting gear immediately after in stalling the product NOTE only for aluminum components Damage to materials can be caused by...

Page 36: ...tables show the specified values Knowledge of the applicable guidelines and design criteria is essential NOTE Damage to materials caused by defective screw tightening torques To secure the product to...

Page 37: ...ains the reduced screw tightening torques for securing aluminum components Thread designa tion Tightening torque Nm Minimum screw depth mm M6 10 12 M8 23 16 M10 46 20 Table 11 Screw tightening torques...

Page 38: ...ulic ports on the underside of the product are used for direct connection to the machine where necessary via a base plate Or the product is connected to the hydraulic supply via the ports on its side...

Page 39: ...g seals during installation removal of the cap plugs During installation removal of the cap plugs the cap plug seals must remain in the product 1 Remove the cap plug from the product 7 5 3 Preparation...

Page 40: ...hotline 49 7144 907 333 1 Remove the cap plugs and the cap plug seals from the product INFORMATION After being installed in its intended bore the expander must always be sealed using an appropriate d...

Page 41: ...l of the screw plugs During installation removal of the screw plugs the screw plug seals must remain in the product 3 Unfasten and remove the screw plugs Ensure while do ing so that the screw plug sea...

Page 42: ...ust remain in the product The following preparatory steps are needed to install product 2 installed on product 1 Product 2 is prepared in the same way as preparation for the use of lateral hydraulic p...

Page 43: ...rrectly The Clamping hydraulic ports on machine baseplate and product must be connected to gether The same applies to the Release ports WARNING Serious injuries can be caused by escaping media when se...

Page 44: ...ne was used 9 Check the position of the product relative to the position of the test surface ideally 0 01 mm and if necessary correct carefully with a plastic hammer 10 Tighten the product fixing scre...

Page 45: ...ous injuries caused by projectile workpieces ejected by incorrectly connected hydraulic ports The hydraulic connections on the machine and the baseplate must be connected up correctly The Clamping hyd...

Page 46: ...Fit the product to the machine table the base plate 6 Screw in the product fixing screws and tighten them gen tly 7 Unfasten and remove any lifting gear that may have been required 8 Remove the mounti...

Page 47: ...uries can be caused by escaping media when seals and damaged missing Replace missing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installation rem...

Page 48: ...If the face run out is greater than the maximum permitted value 1 Remove the product 2 Clean the locating face and the mating faces of the ma chine table the baseplate and the product 3 If there is a...

Page 49: ...it 2 Attach any lifting gear that may be required 3 If necessary fit the mounting aid onto a vertically sus pended spindle 4 Place the product on the machine table 5 Install the clamping brackets on t...

Page 50: ...seals and damaged missing Replace missing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installation removal and apply a thin coat of grease if nec...

Page 51: ...ulic unit 2 Before installation move product 1 into its rear limit stop position 3 Install product 1 see Installation of the hydraulic port variant of the product to the underside of the product chapt...

Page 52: ...tline 49 7144 907 333 INFORMATION Before screwing on product 2 product 1 must still be in its rear limit position 8 Screw product 2 firmly home on product 1 9 Turn back product 2 until the hole patter...

Page 53: ...and product 2 must be connected up properly Hydraulic ports for Clamping of product 1 and product 2 must be connected together which also same applies to connection of the Release hy draulic port WAR...

Page 54: ...the fixing screws for the product and the clamping device must match up Choose the screw length of the fixing screws for this combination in accordance with the build height The following steps are n...

Page 55: ...Installation of the later ally mounted hydraulic port variant of the product se cured by means of fixing screws chapter Attention must be paid to the following points The product is secured together...

Page 56: ...rking area of the machine WARNING Serious injuries caused by tools and items of test equipment being ejected centrifugally Prior to commissioning ensure that all tools and items of test equipment are...

Page 57: ...machine that might drop down For installation removal of the clamping device on a vertically suspended spindle in the machine use a suitable mounting aid if necessary due to the weight WARNING High le...

Page 58: ...a mesh width of 100 mi crons NOTE Damage to seals caused by using the wrong cool ant lubricants To clean the product never use a cooling lubri cant that attacks and damages the sealing ele ments insta...

Page 59: ...position INFORMATION If lifting gear needs to be used rotate the actuating unit and machine spindle to tighten untighten the clamping device 5 Screw the clamping device firmly home on the actuating un...

Page 60: ...e on a suit able test surface ideally 0 01 mm 12 Check the axial run out of the clamping device on a suit able test surface ideally 0 01 mm Whenever the face run out and or the axial run out is greate...

Page 61: ...ce must be removed and stored safely in accordance with the manufacturer s stipulations see operating instructions for the clamping device 1 As described in the Preparing the machine for re moval chap...

Page 62: ...from the clamp ing device 6 Move the actuating unit into its front limit stop position INFORMATION If lifting gear needs to be used rotate the actuating unit and machine spindle to tighten untighten t...

Page 63: ...ds with sufficient levels of corro sion inhibitor NOTE Damage to materials caused by dirty unprepared fluid For the product to function properly ensure that the fluid is cleaned processed and that it...

Page 64: ...nd races are chipped or show any signs of wear The speed set on the machine tool must not exceed the maximum speed of the product 0 on stationary products Always take the lowest value of all maximum s...

Page 65: ...safety door hood WARNING Eye injuries and cuts caused by failure to wear protective clothing during cleaning operation Never use compressed air to clean the product Also wear the following items of pe...

Page 66: ...up accidentally Set the machine tool into set up mode Remove all tools auxiliary equipment and items of test equipment immediately from the working area of the machine Remove all lifting gear from the...

Page 67: ...epending on weight use an appropriate mount ing aid for installation or installing on a vertically suspended machine spindle WARNING High level of physical strain due to the weight of the product or o...

Page 68: ...machine in two different ways Either to the machine using the hydraulic ports on the under side of the product if necessary with a base plate Or the product can be connected to the hydraulic supply us...

Page 69: ...ious injuries can be caused by escaping media when seals and damaged missing Replace missing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installa...

Page 70: ...44 907 333 NOTE Damage to materials caused by lost missing seals during installation removal of the cap plugs During installation removal of the cap plugs the cap plug seals must remain in the product...

Page 71: ...hat may be required 4 If necessary fit the mounting aid onto a vertically sus pended spindle 5 Where required remove the clamping brackets from the product and the machine table WARNING Serious injuri...

Page 72: ...hs dock Removal 72 Order hotline 49 7144 907 333 7 Unfasten and remove the fixing screws on the product 8 Remove the product from the machine table the baseplate...

Page 73: ...ng gear that may be required 4 If necessary fit the mounting aid onto a vertically sus pended spindle WARNING Serious injuries can be caused by escaping media when seals and damaged missing Replace mi...

Page 74: ...any lifting gear that may be required to product 2 4 If necessary fit the mounting aid onto a vertically sus pended spindle WARNING Serious injuries can be caused by escaping media when seals and dama...

Page 75: ...hs dock Removal Order hotline 49 7144 907 333 75 6 Unfasten and remove the fixing screws from product 2 7 Unscrew and remove product 2 from product 1...

Page 76: ...lic port variant of the product to the under side of the product chapter or the Removal of the lat erally mounted hydraulic port variant of the product se cured by means of fixing screws chapter Atten...

Page 77: ...ping elements 11 2 Maintenance schedule The following sections describe the maintenance work needed to ensure optimum and fault free operation If increased levels of wear are detected during regular c...

Page 78: ...et kit D Springs on version with springs E Piston E1 Gasket 1 piston gasket kit E2 Gasket 2 piston gasket kit F Shim 1 on version with springs G Shim 2 on version with springs WARNING Eye injuries and...

Page 79: ...chieving axial and face run out tolerances 1 Remove the clamping device from the product see Re moval of clamping device chapter 2 Remove the product from the machine see Removal of the product chapte...

Page 80: ...n under load Only apply lubricant to the mechanical mating sur faces Pay attention to notes about lubricants see Use of lubricants chapter Avoid too much lubricant on the locating face be cause this c...

Page 81: ...ping device from the product see Re moval of clamping device chapter 2 Remove the product from the machine see Removal of the product chapter 3 Clean all surfaces on the product that can be accessed w...

Page 82: ...rication points remove escaping consumed or surplus grease and dispose of it in accordance with lo cally enforceable legislative provisions 11 7 Use of lubricants To achieve ultimate performance from...

Page 83: ...ronment can result from incorrect disposal of environmentally haz ardous substances Lubricants auxiliary materials and operating flu ids are governed by legislation for the processing of special categ...

Page 84: ...al equipment press the Emergency Stop but ton on the machine tool immediately 2 Establish the cause of the fault 3 If troubleshooting requires work to be conducted in the danger area switch the machin...

Page 85: ...ged Replace damaged components Skilled special ist The clamping de vice is difficult to remove Connection thread is dirty Use force to release the clamping device and clean the actuating unit Skilled...

Page 86: ...al ist Face run out error on the actuating unit Check face run out of the clamp ing device and of the actuating unit and clean the mating surfaces if necessary Table 13 Fault table 13 3 Commissioning...

Page 87: ...racking hotline Current status of your order Just call 49 7144 907 222 24 hour emergency phone line Has a system crash occurred or some other technical emer gency Our experts are there for you around...

Page 88: ...hs dock Annex 88 Order hotline 49 7144 907 333...

Page 89: ...hs dock Annex Order hotline 49 7144 907 333 89...

Page 90: ...allation of the tandem version 42 Product 38 Installation safety 34 Intended use 13 K Key to symbols 7 L Layout 25 Liability 9 Lubricants 20 82 M Maintenance schedule 77 Misuse 14 O Operating conditio...

Page 91: ...er hotline 49 7144 907 333 91 Suitable fluid 63 Symbols on the packaging 31 T Technical data 21 Tests 64 Transport inspection 31 Transportation internal 32 Type designation 24 U Unpacking 32 Use 27 W...

Page 92: ...ations reserved HAINBUCH GMBH SPANNENDE TECHNIK Postfach 1262 71667 Marbach Erdmannh user Strasse 57 71672 Marbach Germany Tel 49 7144 907 0 Fax 49 7144 18826 verkauf hainbuch de www hainbuch com 24 h...