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MANOK plus
Removal

Order h49 7144.907-333

10.4 Removal of the clamping element

Clamping head [clamping element]

Special aids needed:



Changing fixture

1. As described in the »Preparing the machine for re-

moval« chapter, prepare for the following steps.

2. Move the clamping device into release position.

Summary of Contents for MANOK

Page 1: ...Operating instructions incl installation manual MANOK plus EN ...

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

Page 3: ...cular 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 21 3 3 Balancing quality 21 3 4 Speed 22 3 5 Clamping force diagram 22 3 5 1 Size 65 23 3 6 Conversion of actuating torque to actuating force 23 3 6 1 Nomenclature 23 3 6 2 Calculation 24 3 6 3 Sample calculation ...

Page 4: ...6 Sample calculation 46 6 Transport packaging storage 50 6 1 Safety transport packaging storage 50 6 2 Symbols on the packaging 51 6 3 Transport inspection 51 6 4 Unpacking and internal transportation 52 6 5 Packaging 52 6 6 Storage 53 6 7 Preservation 53 6 8 Return to storage 53 7 Installation 54 7 1 Installation safety 54 7 2 Preliminary remarks 55 7 3 Screw tightening torques 56 7 4 Preparation...

Page 5: ...emoval of the changing parts 81 10 3 1 Removal of the variant with direct screw connection 82 10 3 2 Removal of the variant x times with axial screw connection 82 10 3 3 Removal of the variant x times with axial screw connection bayonet 83 10 3 4 Removal of the central variant with axial screw connection 85 10 3 5 Removal of the radially clamped variant 86 10 4 Removal of the clamping element 87 1...

Page 6: ...cutting forces 39 Table 10 Friction coefficient for steel workpieces 40 Table 11 Clamping head mass and distance of mass center of gravity of clamping head segments to the rotational axis 41 Table 12 Maximum permitted tailstock force 43 Table 13 Maximum permitted cutting force 44 Table 14 Maximum permitted transverse force 45 Table 15 Maximum permitted torque due to transverse force 46 Table 16 Sc...

Page 7: ...on 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 combinations of them 1 2 Key to symbols Safety instructions in this manual are designated by sym bols The safety notices are invoked by signal words that ex press the level of hazard involved Always compl...

Page 8: ...eople 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 Definition of terms 1 3 1 Release setting Release setting means that the clamping device is released If the clamping device is released this also releases the workpiece 1 3 2 Complete clamping reserve ...

Page 9: ... the General Terms Conditions 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 and are only intended for internal use The dissemination of this manual to third parties reproduc tions in any shape or form even in part as well as com mercial use and or communic...

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 the machine tool caused by an incorrect or defective clamping elements Always use genuine clamping elements made by the original manufacturer Spare parts and accessories can be sourced from contract dealers or directly ...

Page 11: ...perator is wholly and solely responsible for any resultant personal injury and or damage to materials Excepted from this are changing parts that HAINBUCH ap proved explicitly for autonomous machining but specified limits must never be exceeded The achievable clamping forces may vary as a result of the maintenance status of the product lubrication status and level of contamination see Cleaning and ...

Page 12: ...y to 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 and legislative provisions Due to their vocational training and experience hydraulics specialists can work on hydraulic systems and can inde pendently identify and avoid potential hazards Pneumatic...

Page 13: ...bed 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 install operate maintain and clean the product see Per sonnel requirements chapter Never exceed the technical values stipulated for the product see General information and Operating conditions chapters Fu...

Page 14: ...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 fields may use the product see Personnel re quirements chapter Never exceed the technical data indicated on the product see General information and Operat ing conditions chapters Never exceed the limits for...

Page 15: ...arts It serves pri marily to protect the wearer from 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 slippery ground Protective goggles To protect the eyes from projectile parts and liquid splashes Hair net To protect long hair from getting snagged in ro...

Page 16: ...njuries caused by touching rotating and or moving parts Do not open guards while the system is operating During operation do not reach for rotating and or moving parts Pay attention to the gap dimensions of moving parts Before opening the guards ensure that none of the parts are moving any more Stroke WARNING Serious crushing injuries caused by the stroke of the product Never reach into an area wh...

Page 17: ...st field Also wear the following items of personal protec tive equipment in addition to the basic equip ment 2 6 Other safety instructions DANGER Serious injuries caused by workpieces being ejected centrifugally when clamping unit is re leased while still rotating Never release the clamping of the workpiece while it is still rotating WARNING Serious head injuries caused by bending into the working...

Page 18: ...otected against falling WARNING Serious injuries caused by the use of damaged products or by their components and accesso ries Check products 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 accessories is pro hibited Report damage to the operator immedi...

Page 19: ...ws and threaded pins fitted radially to the product that were bonded with adhesive need to be secured again using a standard 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 internal thread Radially mounted screws and threaded pins that were not bonded with...

Page 20: ...ardous 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 substances are used Lubricants auxiliary materials and operating fluids Lubricants such as grease and oil can contain toxic sub stances These must not enter the environment Dispose of environmentally h...

Page 21: ...pter On all products used do not exceed the lowest of the maximum performance values Only use product in machine tools with the same performance values INFORMATION Details of maximum performance values can be found on each product If due to abrasive wear those performance values are no long legible refer to the operating instructions The achievable actuation forces may vary as a result of the main...

Page 22: ...ng force diagram indicates the permitted range in which the radial clamping force is permitted to move in re sponse to axial actuating force The clamping force diagram indicates the influences of fric tion and of the clamping diameter WARNING Serious injuries caused by insufficient clamping force The values measured for radial clamping force Frad must be within the permitted range If the values re...

Page 23: ...mit value 3 6 Conversion of actuating torque to actuating force To find the right settings you need to convert from actuating torque to actuating force or vice versa 3 6 1 Nomenclature Brief des ignation Unit Explanation 𝐹𝑎𝑥 𝑘𝑁 Axial actuating force 𝐹𝑎𝑥 𝑚𝑎𝑥 𝑘𝑁 Maximum axial actuating force 𝑀 𝑁𝑚 Actuating torque 𝑀𝑚𝑎𝑥 𝑁𝑚 Maximum actuating torque Table 2 Nomenclature for conversion of actuating torqu...

Page 24: ... force 𝐹 𝑎𝑥 𝑚𝑎𝑥 can be taken from the General information chapter The following formula should be used to determine the actu ating force present at a given actuating torque setting 𝐹 𝑎𝑥 𝐹 𝑎𝑥 𝑚𝑎𝑥 𝑀 𝑀𝑚𝑎𝑥 INFORMATION The maximum actuating torque 𝑀𝑚𝑎𝑥 and the maxi mum actuating force 𝐹 𝑎𝑥 𝑚𝑎𝑥 can be taken from the General information chapter 3 6 3 Sample calculation Clamping head chuck MANOK plus size...

Page 25: ...torque of 45 Nm must be applied for size 65 A Size 65 3 7 Operating conditions Indication Value Unit Ambient temperature range 15 65 C Workpiece temperature 80 C Humidity 80 Table 3 Operating conditions 3 8 Type designation The type designation is on the product and it includes the following indications Manufacturer Product designation ID number marked with a symbol Build year Maximum actuating fo...

Page 26: ...lamping element was installed in the clamping device with an appropriate changing fixture and it clamps the work piece being machined The workpiece end stop can be screwed to the base end stop screwed on directly or fitted as a front mounted end stop The clamping device functions on the pull back principle When clamping the clamping element performs an axial movement towards the workpiece end stop...

Page 27: ...so with different profiles and bores 4 2 2 Workpiece end stop The workpiece end stop is produced with an end stop di mension that reflects customer wishes 4 3 Optional accessories The following optional accessories are available for different sizes of product 4 3 1 Jaw module The jaw module is an adaptation clamping device for the use with jaws It enables the diameter of the jaw clamping range to ...

Page 28: ...ugh Morse taper adaptation adaptation options are rendered possible with a Morse taper connection 4 3 5 Face driver adaptation Adaptation of the face driver makes it possible to machine the entire length of the workpiece 4 3 6 vario part end stop system The vario part end stop system operates on the same prin ciple as an end block box and its height can be adjusted in 1 mm increments with precisio...

Page 29: ...n the clamping head The changing fixture is ac tuated by manual force Depending on size the changing fixture may be designed for single handed or for two handed actuation The clamping head is clamped firmly in the changing fixture and can be installed in the mounted clamping device with the help of the changing fixture 4 4 3 Pneumatic changing fixture The pins on the changing fixture are installed...

Page 30: ...xplicit approval of the manufacturer The clamping device can be used as an end stop chuck It can be attached directly to the base end stop or a workpiece end stop can be mounted For this different connection points are provided on the clamping device The clamping device can be used as a through chuck for machining bar stock For this the base end stop must be re moved With the help of suitable adap...

Page 31: ...ration 𝐹𝑐 𝑁 Cutting force of drilling operation 𝐹𝑐 𝑚𝑎𝑥 𝑁 Maximum cutting force of drilling opera tion 𝑓𝑓𝑧 𝑁 Clamping force supplement for rotational compensation 𝐹𝐺 𝑁 Density of workpiece 𝑓𝑛 𝑚𝑚 Feed rotational movement of drilling op eration 𝐹𝑞 𝑁 Transverse force 𝐹𝑞 𝑚𝑎𝑥 𝑁 Maximum permitted transverse force 𝐹𝑟𝑎𝑑 𝑁 Radial clamping force 𝐹𝑟𝑎𝑑 𝑒𝑟𝑓 𝑁 Required radial clamping force 𝐹𝑠𝑘 𝑁 Clamping force ...

Page 32: ...nd length 𝐿𝑧 𝑚𝑚 Distance between Machining point clamping point when turning 𝑚 𝑘𝑔 Mass of the clamping head 𝑀𝐵 𝑁𝑚𝑚 Drilling operation torque 𝑀𝑞 𝑁𝑚 Torque due to lateral force on the chuck axis 𝑀𝑞 𝑚𝑎𝑥 𝑁𝑚 Maximum torque due to lateral force on the chuck axis 𝑚𝑤 𝑘𝑔 Workpiece mass 𝑚𝑤 𝑚𝑎𝑥 𝑘𝑔 Maximum workpiece mass 𝑛 𝑚𝑖𝑛 1 Speed 𝑃 Key indicators for machining 𝑟𝑠 𝑚 Distance between mass center of gravity...

Page 33: ...th out the aid of a back rest or a tailstock is 6 times the clamping diameter 5 2 3 Second limit workpiece mass The maximum workpiece mass depends on the size of the clamping head chuck see Table 5 These values apply to individual workpieces Special values apply to the machining of bar stock Size of the clamping head chuck Maximum workpiece mass 𝒎𝒘 𝒎𝒂𝒙 𝒌𝒈 Horizontal application Vertical applicatio...

Page 34: ...ng applies 𝐿𝑠𝑝 2 8𝑚𝑚 when using clamping heads with a smooth clamping bore 𝐿𝑠𝑝 13𝑚𝑚 when using clamping heads with longitu dinal and transverse grooves When using clamping heads with a closed first tunnel different details apply which may be even higher Consult the manufacturer for these details 𝐿𝑠𝑝 7𝑚𝑚 when using clamping heads with Z ser rations 𝐿𝑠𝑝 5𝑚𝑚 when using clamping heads with F serration...

Page 35: ...ess Pay attention to the following principles 1 Principle 𝑭𝒓𝒂𝒅 𝑭𝒓𝒂𝒅 𝒆𝒓𝒇 AND 2 Principle 𝑭𝒕 𝑭𝒕 𝒎𝒂𝒙 AND 3 Principle 𝑭𝒄 𝑭𝒄 𝒎𝒂𝒙 Relevant to turning and or to axial drilling operations AND 4 Principle 𝑭𝒒 𝑭𝒒 𝒎𝒂𝒙 Relevant to a radial drilling operation directed at the center and or for the application of an equivalent load If radial forces and the resultant torques are not directed at the cen ter due acc...

Page 36: ... operations need to be added together However it is rare for axial drilling and turning operations to be superimposed because their opposing directions of rota tion usually preclude them from running simultaneously For computational purposes the calculation should be based upon the point with the highest forces that is the least favorable machining moment If in doubt several blade en gagement situ...

Page 37: ...mping head chuck is used up the clamping force scatter width factor can be reduced by factor 0 85 example Size 52 𝑆 2 0 0 85 1 7 Table 6 Scatter widths of clamping force Contact factor Consult the following tables for the contact factor depending on the form of contact or the contact scenario Interference fit Saddle fit Edge fit The clamping diameter of the clamping head matches the clamping diame...

Page 38: ...ent For deviating workpiece materials and or for machining tasks in the boundary area of the clamping device the respective 𝑘𝑐 values of the workpiece material being machine needs to be determined precisely and or the supplier of the material needs to be consulted The following applies to drilling operations with a double bladed tool 𝑓 𝑓𝑛 2 Workpiece materials Specific cut ting forces 𝒌𝒄 𝑵 𝒎𝒎𝟐 at ...

Page 39: ...CrMo4 1 7225 34CrNiMo6 1 6582 2850 1960 1660 tool steels without alloys or with only a low alloy content unhardened C105W1 1 1545 3100 2100 1690 Machining steels 35S20 1 0726 60S20 1 0728 1700 1480 1400 Stainless steels 3600 2450 2100 Hardened steels 4800 Aluminum forging al loy 16 Si 1340 900 750 Aluminum casting alloy 16 Si 1520 1000 850 Brass 1300 850 700 For feed rates between 0 05 mm and 0 1 ...

Page 40: ...longi tudinal and transverse serrations Other versions of clamping head may get dam aged and lose their ability to achieve higher fric tion coefficients on soft materials Workpiece surface Clamping surface Smooth clamping head Clamping head with longitudi nal and trans verse serra tions Clamping head with Z serra tions Clamping head with F serra tions Finished ground 𝜇𝑡 0 06 𝜇𝑎 0 08 𝜇𝑡 0 07 𝜇𝑎 0 0...

Page 41: ... 42 0 021 0 70 52 0 022 1 00 65 0 027 2 20 80 0 032 2 70 100 0 045 3 60 125 0 061 9 10 140 0 062 9 10 160 0 075 12 20 Table 11 Clamping head mass and distance of mass center of gravity of clamping head segments to the rotational axis Determining the required clamping force INFORMATION 𝑆 from Table 6 𝑐 from Table 8 𝑘𝑐 from Table 9 𝜇𝑎 𝜇𝑡 from Table 10 𝑟𝑠 𝑚 from Table 11 I 𝐹𝑟𝑎𝑑 𝑒𝑟𝑓 𝑆 𝑐 1 6 𝐹 𝑠𝑧 𝐹𝑠𝑘 𝐹...

Page 42: ...𝑟𝑠 𝜋 𝑛 30 2 With reference to the principle defined at the start this means that the radial clamping force of the clamping head chuck equates to at least the computed level of radial clamp ing force required 𝐹𝑟𝑎𝑑 𝑒𝑟𝑓 to resolve this use of the clamping head chuck If this condition is not satisfied the clamping head chuck would not be suitable It would not then be possible to per form this machinin...

Page 43: ...inciple 2 𝑭𝒕 𝑭𝒕 𝒎𝒂𝒙 When using a tailstock due to the additional expanding force exerted on the clamping head chuck the permitted maxi mum tailstock force is limited to the following values in ac cordance with the size of the clamping head chuck Size of the clamping head chuck 𝑭𝒕 𝒎𝒂𝒙 𝒌𝑵 32 3 42 6 52 6 65 8 80 8 100 8 125 8 140 8 160 8 Table 12 Maximum permitted tailstock force NOTE Serious damage ...

Page 44: ...able 13 Maximum permitted cutting force On extended chuck versions the ratio of maximum permitted cutting force to chuck lengths needs to be reduced For ex ample size 32 with 𝐿 150𝑚𝑚 120𝑚𝑚 150𝑚𝑚 1900𝑁 1520𝑁 5 2 5 4 Further to Principle 4 𝑭𝒒 𝑭𝒒 𝒎𝒂𝒙 With drilling operations radial to the workpiece axis the feed force of the tool generates transverse forces that ultimately act on the clamping head ch...

Page 45: ...00𝑁 1760𝑁 5 2 5 5 Further to Principle 5 𝑴𝒒 𝑴𝒒 𝒎𝒂𝒙 With drilling operations that are radial to the workpiece axis the transverse force examined under Principle 4 exerts an additional torque 𝑀𝑞 on the clamping head and or on the chuck This moment must not rise in an unlimited way to pre vent damage to the clamping head chuck even if the clamp ing of the workpiece may still hold firmly The following...

Page 46: ...ample calculation Applied to a specific example Longitudinal turning of an offset shaft made of 16MnCr5 blank clamping diameter unsupported in a horizontal posi tion Workpiece data Clamping diameter 𝑑𝑠𝑝 60𝑚𝑚 Workpiece length 𝐿𝑤 150𝑚𝑚 151 5𝑚𝑚 blank Machining diameter of turning operation 𝑑𝑧 57 0𝑚𝑚 Workpiece mass 𝑚𝑤 3 3𝑘𝑔 𝐹𝐺 𝑚𝑤 9 81 𝑚 𝑠2 𝐹𝐺 33𝑁 Process data Speed𝑛 800𝑚𝑖𝑛 1 Feed 𝑓 0 25𝑚𝑚 Chip cutting...

Page 47: ...ck This more than satisfies the third condition which is that the workpiece must at least be clamped with 0 08 𝑑𝑠𝑝 0 08 60𝑚𝑚 4 8𝑚𝑚 with a clamping length of 𝐿𝑠𝑝 𝐿𝑠𝑝 𝑣 𝐿𝑣 20𝑚𝑚 3𝑚𝑚 17𝑚𝑚 To check the fourth condition the required level of clamping force needs to be established first in accordance with Prin ciple 1 INFORMATION 𝑆 from Table 6 𝑐 from Table 8 𝑘𝑐 from Table 9 interpolated for 𝑓 0 25𝑚𝑚 𝜇𝑎 ...

Page 48: ...ince the shaft should be surface turned at the front end of the shaft 𝐿𝑔 75𝑚𝑚 since the center of gravity is located centrally on the longitudinal axis of the work piece 𝐿𝑠𝑝 17𝑚𝑚 corresponds to the total clamping length less the front end length of the clamping head 𝑃 𝑑𝑧 2 57𝑚𝑚 2 28 5𝑚𝑚 because of a longitu dinal turning operation 𝐹𝑠𝑘 0 27 133𝑚𝑚 60𝑚𝑚 0 63 1226𝑁 133𝑚𝑚 33𝑁 75𝑚𝑚 2 1226𝑁 28 5𝑚𝑚 2 0 5 ...

Page 49: ...ore be used to deter mine this on the basis of the values for 𝐹 𝑎𝑥 𝑚𝑎𝑥 and 𝐹𝑟𝑎𝑑 𝑚𝑎𝑥 as indicated on the clamping head chuck or you can consult the clamping force diagram see Clamping force diagram chapter When full axial force is exerted on the clamping head chuck with 𝐹 𝑎𝑥 𝑚𝑎𝑥 45𝑘𝑁 nominal radial 105𝑘𝑁 forces are being applied to the workpiece In the example calculated here an axial force of at l...

Page 50: ...gear 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 directly above the center of gravity Raise carefully and correct the lifting points if nec essary WARNING Serious injuries caused by incorrect transport with lifting gear Never raise loads above peopl...

Page 51: ...ging items dry and protect them from the in gress of water Position designation Points to the correct upright position of the packaging item 6 3 Transport inspection Check the delivery on receipt immediately to ensure it is complete and has not been damaged in transit Proceed as follows if you find any externally visible signs of damage while in transit Refuse to accept the delivery or only subjec...

Page 52: ...rom rolling away 6 When transporting on a trolley or car ensure that the product is securely mounted on a non slip surface be fore starting to move it 6 5 Packaging The individual packaging items are packaged in an appropri ate manner for the type of transportation involved Always use environmentally compatible materials for packaging pur poses Packaging should protect individual components from d...

Page 53: ...the general condition of all parts and packaging If necessary refresh the preservation or replace it 6 7 Preservation 1 Clean and lubricate the product see Cleaning and Lubricating the product chapters 2 Apply a light coating of preserving oil to the inner and outer faces of the product Wipe away surplus preserv ing oil with a sort lint free tear resistant cloth 3 Pack product air tight in foil 4 ...

Page 54: ...orking 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 Shut down the system WARNING Serious crushing injuries and breakages caused by falling parts during incorrect installation or re moval Ensure that the product cannot roll away or fall If necessary u...

Page 55: ... and lifting tackle CAUTION Serious cut injuries caused by sharp edged changing parts and or clamping elements All installation removal of changing parts and clamping elements must be performed by skilled staff from the relevant specialist field NOTE Damage to materials caused by lifting gear left in the product Always remove lifting gear immediately after in stalling the product NOTE only for alu...

Page 56: ...ut greases see Use of lubricants chapter Do not damage the functional surfaces flat mating ta pered and sealing surfaces 7 3 Screw tightening torques The 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 the machine pay attention to the values specif...

Page 57: ...uminum components The following table contains 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 17 Screw tightening torques for aluminum components 7 4 Preparation of the machine for installation 1 Set the machine into set up mode 2 Remove cutting tools and or sharp objects from t...

Page 58: ...are for the following steps 7 5 1 Compatibility check Check the compatibility of the product and the connection point of the machine For this check that the connection point and the product share the same adaptation geometry Also check if the actu ating element coupling element is suitable It may be necessary to install an adapter between the actu ating element on the machine and the product 7 5 2...

Page 59: ... vertically sus pended spindle 4 Place the product on the machine table 5 Screw in the product fixing screws and tighten them gen tly 6 Unfasten and remove any lifting gear that may have been required 7 Remove the mounting aid on a vertically suspended spindle if one was used 8 Check the position of the product relative to the position of the test surface ideally 0 01 mm and if necessary correct c...

Page 60: ...duct and the machine table 11 Check face run out on the test surface of the product ideally 0 01 mm Whenever the face run out is greater than the maximum per mitted value 1 Remove the product 2 Clean the locating face and the mating faces of the ma chine table and the product 3 If there is a burr or slight damage to the locating face of the product and the machine table rub it down gently with an ...

Page 61: ...nt A Clamping head clamping element INFORMATION Before installing the clamping element install the changing part if necessary otherwise it can no longer be installed Special aids needed Changing fixture 1 As described in the Preparation of the machine for in stallation chapter prepare for the following steps 2 Move the clamping device into release position ...

Page 62: ... changing fixture During actuation never reach into the coupling slot area in the clamping head or into the chang ing fixture 3 Install the clamping head in the product with an appro priate changing fixture For this the anti twist devices in the clamping taper of the product and the grooves in the clamping head must be aligned 4 Unfasten and remove the changing fixture ...

Page 63: ...n D1 Fixing screw changing part variant central axial screw connection E Changing part variant radially clamped E1 Clamping screw changing part variant radially clamped The changing parts such as the workpiece end stop can be installed in different ways If necessary in addition to these operating instruc tions you should also read and follow the operating instructions for the relevant changing par...

Page 64: ... can for example be performed by marks or a cy lindrical pin and a bore or a groove 7 7 1 Installation of the variant screwed directly 1 Screw the changing part into the product using its thread and tighten it down 7 7 2 Installation of the variant x times with axial screw connection 1 Place the changing part onto the product ...

Page 65: ...bayonet axial screw connection INFORMATION Initial installation of the changing part with bayonet is in accordance with the variant with an x times axial screw connection see Installation of x times variant with axial screw connection After initial installation the changing part fixing screws remain in the clamping device 1 Place the changing part on the product so that the screw head on the chang...

Page 66: ...stallation 66 Order hotline 49 7144 907 333 2 Twist the changing part until firmly home 3 Screw in the changing part fixing screws and tighten to the specified tightening torque see Screw tightening torques chapter ...

Page 67: ...ng part into the product 2 Screw in the changing part fixing screw and tighten it to the specified tightening torque see Screw tightening torques chapter 7 7 5 Installation of the radially clamped variant INFORMATION To install remove the changing part in from the prod uct it may be necessary to use a grab handle or an appropriate auxiliary tool ...

Page 68: ...on the radially clamped changing part variant to engage in the groove in the changing part When installing the base end stop the ground side must face forwards 1 Place the changing part into the product 2 Screw in the clamping screws on the changing part and tighten to the specified tightening torque see Nomen clature 3 Unfasten and remove the grab handle if used or the auxiliary tool ...

Page 69: ...accessible 1 As described in the Preparation of the machine for in stallation chapter prepare for the following steps 2 Install the appropriate clamping element for the test specimen and changing part see Installation of clamp ing element and Installation of changing parts chap ters 3 Clamp the test specimen 4 Unfasten the fixing screws on the product a few turns without removing them 5 Align the ...

Page 70: ...gular intervals and correct if necessary WARNING Serious injuries can be caused if the machine tool starts up accidentally Prior to commissioning close all safety doors or hoods on the machine tool 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 removed from the working are...

Page 71: ... filtered with 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 installed Those installed sealing elements can be made of NBR Viton and PUR materials Never use cooling lubricants that contain ester or a polar solvent NOTE Damage to clamping elements caus...

Page 72: ...ts used are undamaged All fixing screws are present on the products and are tightened to the correct tightening torque None of the rubber segments on the clamping elements and attachments are torn or exhibit porous areas Serrations and grooved profiles must not be excessively rounded because this would prevent the friction coeffi cient from being achieved None of the edges and races are chipped or...

Page 73: ...rkpiece clamping is in sufficient Never utilize the full clamping reserve Do not exceed the permitted maximum clamping reserve stroke The remaining clamping reserve must always be adapted to suit the workpiece material provided and its possible distortions WARNING Crushing injuries to hands fingers is workpiece is installed incorrectly Do not place hands fingers between workpiece and clamping devi...

Page 74: ...function of the actuating wrench does not work or is impaired it must not be used until after a new spring has been installed INFORMATION The actuating wrench is equipped with a spring that presses the actuating wrench out of the product as soon as it is released 8 4 1 Clamping the workpiece To clamp the workpiece install the appropriate clamping el ement and or the appropriate changing parts see ...

Page 75: ...tuating key in the actuating screw and hold it firmly INFORMATION To assure uniform tension on the workpiece to tighten the drive use the torque wrench kit 4 Turn the actuating screw clockwise with the actuating key and tighten it to the permitted actuation torque de termined ...

Page 76: ...he actuating screw and remove it from the working area of the machine 6 Remove the workpiece mounting if one was used 8 4 2 Releasing tension on the workpiece 1 If necessary secure the workpiece to prevent it from fall ing 2 Install the actuating key in the actuating screw and hold it firmly ...

Page 77: ...e working area of the machine 5 Remove the workpiece from the product To do this re move the workpiece mounting if one was used 8 5 Procedure after a collision In the event of a collision the product and its components must be checked for cracks and damage before being used again For this remove the product from the machine see Re moval of the product chapter and dismantle it for level of disassem...

Page 78: ...d back on 3 Open the 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 personal protec tive equipment in addition to the basic equip ment 4 Clean the product of swarf and production residue with a soft lint free cloth and apply a light coating of oil 5...

Page 79: ...ts 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 product and from the working 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 pre...

Page 80: ...s in the working area of the machine with the potential to drop down Depending 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 of its components if not trans ported properly From a weight of 10 kg use appropriate transport equipment lifting gear and lifting ...

Page 81: ... variant x times axial screw connec tion C Changing part variant x times axial screw connection bayonet C1 Fixing screws changing part variant x times axial screw connec tion bayonet D Changing part variant central axial screw connection D1 Fixing screw changing part variant central axial screw connection E Changing part variant radially clamped E1 Clamping screw changing part variant radially cla...

Page 82: ...are for the following steps 2 Move the clamping device into release position 10 3 1Removal of the variant with direct screw connection 1 Unscrew the changing part from the product using its thread 10 3 2Removal of the variant x times with axial screw connection 1 Unfasten and remove the fixing screws on the changing part ...

Page 83: ... hotline 49 7144 907 333 83 2 Take the changing part off the product 10 3 3Removal of the variant x times with axial screw connection bayonet 1 Unfasten the fixing screws on the changing body a few turns without removing them ...

Page 84: ...NOK plus Removal 84 Order hotline 49 7144 907 333 2 Turn the changing part until the screw head on the changing part fixing screw fits through the bayonet opening 3 Take the changing part off the product ...

Page 85: ...s Removal Order hotline 49 7144 907 333 85 10 3 4Removal of the central variant with axial screw connection 1 Unfasten and remove the fixing screw on the changing part 2 Take the changing part out of the product ...

Page 86: ... variant INFORMATION To install remove the changing part in from the prod uct it may be necessary to use a grab handle or an appropriate auxiliary tool 1 Unscrew the clamping screws from the changing part until the changing part can be lifted out 2 Take the changing part out of the product ...

Page 87: ... 10 4 Removal of the clamping element A Clamping head clamping element Special aids needed Changing fixture 1 As described in the Preparing the machine for re moval chapter prepare for the following steps 2 Move the clamping device into release position ...

Page 88: ... caused by reaching into the coupling slot area in the clamping head or into the changing fixture During actuation never reach into the coupling slot area in the clamping head or into the chang ing fixture 3 Remove the clamping head from the product with an ap propriate changing fixture ...

Page 89: ... the product A Product A1 Fixing screws on the product A2 Transport thread on product B Clamping bracket a Test surface product face run out b Test surface position product 1 As described in the Preparing the machine for re moval chapter prepare for the following steps ...

Page 90: ...ne 1 Depressurize the hydraulic unit 2 Attach any lifting gear that may be required 3 If necessary fit the mounting aid onto a vertically sus pended spindle 4 Where required remove the clamping brackets from the product and the machine table 5 Unfasten and remove the fixing screws on the product ...

Page 91: ...MANOK plus Removal Order hotline 49 7144 907 333 91 6 Remove the product from the machine table ...

Page 92: ...owing sections describe the maintenance work needed to ensure optimum and fault free operation If increased levels of wear are detected during regular checks shorten the maintenance intervals to reflect the ac tual rate at which signs of wear appear Contact the manufacturer for questions relating to mainte nance work and maintenance intervals see Contact chap ter Interval Maintenance work daily Vi...

Page 93: ...hapter with storage See Storage chapter depending upon which stipulation is achieved first Table 18 Maintenance table 11 3 Cleaning A Base end stop A1 Clamping screws base end stop B Cover B1 Cover fixing screws C Housing D Basic limit stop carrier D1 Fixing screws on the basic limit stop carrier E Mounting block 1 E1 Mounting block fixing screws F Actuating screw G Rocker H Mounting block 2 H1 Mo...

Page 94: ...at contains ester nor a polar solvent NOTE Damage to clamping elements caused by the wrong solvent To clean the product never use a solvent that contains ester nor a polar solvent NOTE Damage to materials caused by incorrect installa tion of sealing elements Replace missing or damaged sealing elements Ensure that the sealing elements do not fall out or get damaged during installation removal and a...

Page 95: ...the thread of the housing When turning the actuating screw guide the rocker in a parallel manner 4 Clean all oil and grease residues off all components with an ester free non polar soft lint free cloth and check for visible signs of damage 5 Assemble the product as shown on the exploded draw ing Pay attention to the following during assembly Replace worn or damaged fixing screws Tighten all fixing...

Page 96: ...llel manner 6 Lubricate the product see Lubricating the product chapter 7 Check the total stroke of the clamping device see the Checking the total stroke chapter 11 4 Visual inspection Perform a daily visual inspection of the product to identify any damage to the product at an early stage Check the product for cracks and damage in particular on the clamping and end stop surfaces The rubber on the ...

Page 97: ... or assembled and also when required The product is equipped with grease nipples WARNING Collision impact and cut injuries can be caused by slipping when applying grease with a piston actu ated grease gun Ensure that the piston actuated grease gun is po sitioned correctly 1 With the help of the piston action grease gun not in cluded in the scope of delivery squeeze grease into the grease nipple un...

Page 98: ...re recommended GP 355 universal grease see the HAINBUCH product catalogue Alternatively Lubricants Manufacturer Product designa tion Grease MicroGleit GP 355 Klüber QNB 50 Zeller Gmelin DIVINOL SD24440 Bremer Leguill RIVOLTA W A P Table 19 Selection of lubricants NOTE Malfunction of the product due to a combination of different greases Never mix different greases with one another Clean the product...

Page 99: ... substances Lubricants auxiliary materials and operating flu ids are governed by legislation for the processing of special category waste All disposal to be per formed by authorized waste disposal specialists Catch exchanged oils and greases in suitable containers and dispose of them in accordance with applicable local provi sions The local municipal authority or specialist waste disposal companie...

Page 100: ...pital 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 machine tool into set up mode 4 Notify the person on location of the fault immediately 5 Depending on the type of fault get it remedied by au thorized and appropriately skilled specialists INFORMATION Th...

Page 101: ...is too great idling moment 5 Nm Lubricate the clamping device Incorrect lubrica tion condition Check lubrication of the clamping device and correct if necessary Axial actuating force is too weak Check the tightening torque of the actuating screw and correct if nec essary Stroke limitation by the workpiece end stop Use an appropriate workpiece end stop Clamping force is too high Axial actuating for...

Page 102: ...face Clamping force is too high Reduce the clamping force to the level applicable for the clamping device and the workpiece Skilled special ist Incorrect type of clamping element Use a suitable clamping element Dirty clamping ele ment Clean the clamping element Damaged clamp ing element Replace the clamping element Dimensional differ ence between workpiece diame ter and clamping elements is too gr...

Page 103: ...3 Tracking 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 the clock 49 7144 907 444 For advice or help you can contact the sales partners and service staff listed in www hainbuch com 14 2 Manufacturer certification Manufacturer certification is supplied w...

Page 104: ...MANOK plus Annex 104 Order hotline 49 7144 907 333 ...

Page 105: ...MANOK plus Annex Order hotline 49 7144 907 333 105 ...

Page 106: ...1 Faults 100 H Hazards 16 I Installation Changing part 63 Clamping element 61 Preparation of the machine 57 Preparation of the product 58 Product 58 Installation safety 54 Intended use 13 K Key to symbols 7 L Layout 26 Liability 9 Limits of use 30 Lubricants 20 98 M Maintenance schedule 92 Misuse 14 O Operating conditions 25 P Packaging 52 Performance values 21 Personnel requirements 11 Electricia...

Page 107: ...ew tightening torques Aluminum components 57 Metric control threads 56 Spare parts 10 Speed 22 Storage 53 Symbols on the packaging 51 T Technical data 21 Tests 72 Transport inspection 51 Transportation internal 52 Type designation 25 U Unpacking 52 Use 30 W Warranty 10 ...

Page 108: ...cations reserved HAINBUCH GMBH SPANNENDE TECHNIK Postfach 1262 71667 Marbach Erdmannhäuser Strasse 57 71672 Marbach Germany Tel 49 7144 907 0 Fax 49 7144 18826 verkauf hainbuch de www hainbuch com 24 hour emergency phone line 49 7144 907 444 ...

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Hainbuch MANOK, Operating Instructions Manual

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