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Installation manual - HAINBUCH America WORKHOLDING

1. nennen nennen 50 7 2 1 Disassembling the end stops ne ane inen 50 7 2 2 Disassembly of the TOROK ana 51 7 2 3 Disassembling the flange optional nnn nennen 52 7 3 Subsequent storage of the clamping device esses 53 TA Disposal RED 53 8 Malle ange a O e RR NER PNE 54 A All EE 54 o a are 56 8 3 Preserva NON ar 57 8 4 USS OF Wie ey m a ar 58 8 5 Maintenance Schedule aii nne 59 BO ele UE 60 9 Trouble SOON EORNM RD o CO aE ERARE EEE ETA 61 A KE ee E EE 61 9 2 Trouble SOONG aba an ecteen cess et nnadendstedauasacesemecbexeesteeees 62 e HAINBUCH 3 9 3 Start up after corrected faut 63 ENEE RR m Eege 64 19 1 Service e ul eS 64 10 2 Tt 64 10 2 1 EURO RE NND A 64 102 27 AMEN EE 67 TSI o He 67 10 24 MILI MERE RR 68 QU EAE SE LIU 6 ME 68 hiet RR m TRE 70 Translation of original installation manual 4 HA NBUCH 1 General 1 1 Information about this manual This manual enables safe and efficient handling of the clamping device The manual is a component of the clamping device and must be kept in the immediate vicinity of the clamping device where it is accessible for personnel at all times Personnel must have carefully read and un derstood this manual prior to starting all tasks The ba sic prerequisite for safe work is compliance with all the safety instructions and handling instructions in this manual
2. 32 T Transport inspection 32 Transport inner company 33 c 70 HA NBUCH Trouble shootirig teer eins 61 Trouble shooting table 62 Type designation 26 U UMPACRING Net TERNI PE 33 o HA NBUCH 71 HAINBUCH SPANNENDE TECHNIK HAINBUCH GMBH SPANNENDE TECHNIK PO Box 1262 DE 71667 Marbach Erdmannh user Stra e 57 DE 71672 Marbach Phone 49 7144 907 0 Fax 49 7144 18826 verkauf hainbuch de www hainbuch com 24h Emergency call 49 7144 907 444 10 2014 Part no 80001 0118 en Subject to technical modifications
3. e HAINBUCH SPANNENDE TECHNIK Installation manual EN Clamping device TOROK Table of contents ic MEER T rM SE 5 1 1 Information about this manual 5 1 2 EXplanalion ofsymbols uecnea ana a salenas dennen ae diene 5 1 3 Limitations Te see 6 VANE RR EE 7 ER RAMEN E o A E A 7 1 6 Scope of deliver E 8 Nef Spare PANS ida 8 1 8 Warranty WINS st ooo ade 8 A Ap A S 8 Gee te p Mee e 9 2 1 Responsibility or the CUM ui eet Eed Eer 9 2 2 Personnel EQUINA 9 Elle Ee US rada 10 2 4 Personal protective equipment eneen enen rrenen rnnr nne 11 Re E 13 Ke gn De an 15 2 7 Clamping OCB anne ere 16 2 8 O td E names teid 17 A PP aiei a a a a aai 17 2 10 Environmental ee E 18 3 Technical Urnen aa 19 3 1 Gengrallnformalan n nee ul 19 3 2 Clamping force diagram TOROR ana 20 3 2 1 Clamping force diagram TOROK size 52 RD 21 3 2 2 Clamping force diagram TOROK size 65 RD SE 22 3 2 3 Clamping force diagram TOROK size 100 RD SE 24 SEI eege an ee 26 3 4 Power Speeinalats e en 26 2 5 Dimensional SNC uniao Apis na sa rue 26 30 Type e AMON met ts 26 4 Structure and TUNCHON psi m T 27 4 1 Overview and brief description EE 27 4 2 Optional ACCES SOME sturende daaar doser edna RODAS da 28 4 2 1 Spi
4. 25 kN 105 kN 35 kN 150 kN 29 kN 60 kN 29 kN 60 kN Axial Radial force force max max 45 kN 120 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 20 kN 85 kN 25 kN 105 kN 35 kN 150 kN 29 kN 60 kN 29 kN 60 kN e HAINBUCH 23 3 2 3 Clamping force diagram TOROK size 100 RD SE Frac kN i ze 180 min Fax KN 170 y 160 p o 150 65 140 a 60 130 55 120 50 110 100 45 90 40 Bp eoe een apen 35 70 d Wen EE 30 60 25 50 20 40 15 30 20 10 10 5 0 k 5 10 20 30 40 50 60 65 x Torque M Nm Example Calculation example Fig 5 With a torque of 25 Nm the radial clamping force Fraa is depending on the maintenance state of the clamp ing device in the range between 55 5 kN and 81 kN When using an adaptation clamping device the axial force Fax is required When an axial force of 35 kN is required a torque of 28 Nm is needed Torque X x desired axial force axial force of the clamping device 50 Nm 3 Nm x 35 kN 65 kN 28 5 Nm 24 Q HAINBUCH In the diagram the influence of the friction and the clamping diameter are taken into account Under perfect conditions the values for Fraa are in the region of the upper limit with bad conditions in the re gion of the lower limit Remarks TOROK RD size 100 Add on clamping elements MANDO Adapt jaw module Size Clamping bridging Operating Axia
5. 8 2 Cleaning NOTE Material damage if cleaned with com pressed air CE Cleaning the clamping device with compressed air can force metal chips into thread and grooves This can damage or even destroy the clamping device Never clean the clamping device with com pressed air ua Auxiliary material required m Ester free non polar cleaning agent Soft lint free cloth 1 Disassemble the clamping device see section Disassembling the TOROK 2 Clean all the components listed below with clean ing agent and a cloth remove all oil and grease residues a Flange a Clamping device a Clamping element reception and coupling area a Cylindrical screws Risk of injury due to wrong assembly A wrong assembled safety ring may cause throwing out of parts m The safety ring at the actuating screw square must be completely inserted into the groove c 56 HA NBUCH 8 3 Preservation Special tools required Universal grease 2085 0003 a Grease gun a Oil stone a Soft lint free cloth 1 Hone all the bearing surfaces of the clamping de vice with an oil stone 2 Lightly grease all cylindrical screws Remove ex cess grease with a cloth 3 Screw all cylindrical screws into the clamping de vice again and tighten them hand tight For subsequent storage tightening the cylindri cal screws hand tight suffices This facilitates re commissioning and protects the cylindrical Screws 4 Lightly
6. Fax KN rim 35 30 25 20 15 10 5 20 30 40 50 60 65 Torque M Nm Fig 3 With a torque of 25 Nm the radial clamping force Fraa is depending on the maintenance state of the clamp ing device in the range between 27 5 kN and 39 kN No add on clamping elements possible In the diagram the influence of the friction and the clamping diameter are taken into account Under perfect conditions the values for Fra are in the region of the upper limit with bad conditions in the re gion of the lower limit a HA NBUCH 21 3 2 2 Clamping force diagram TOROK size 65 RD SE Fraa KN 120 110 100 Example Calculation example 40 35 30 25 Cn 20 30 40 50 60 65 Torque M Nm Fig 4 With a torque of 25 Nm the radial clamping force Fraa is depending on the maintenance state of the clamp ing device in the range between 39 kN and 47 kN When using an adaptation clamping device the axial force Fax is required With the same torque of 25 Nm an axial force F4 of 14 kN is reached Torque X x desired axial force axial force of the clamping device 50 Nm 2 Nm x 25 kN 45 kN 28 8 Nm 22 Q HAINBUCH Remarks TOROK RD size 65 In the diagram the influence of the friction and the clamping diameter are taken into account Under perfect conditions the values for Fraa are in the region of the upper limit with bad conditions in the re gion of the lower limit
7. Make sure that the clamping device is empty and leakage of hydraulic fluid is avoided NOTE Material damage due to damaged clamping de vices A damaged incomplete or unbalanced clamping de vice can significantly damage or even destroy the ma chine tool and the work piece Only install undamaged complete and precisely balanced clamping devices a If in doubt contact the manufacturer Ensure the following points prior to each installation and start up of the clamping device a All cylindrical screws of the clamping device must be present and tightened with the proper tightening torque The balance screws of the clamping device must all be present and undamaged All rubber segments must be intact this means that they are neither torn nor are they porous at any point a All edges and bearing surfaces are intact this means that they are neither broken nor do they show any signs of wear a he set speed of the machine tool should not ex ceed the maximum permissible speed of the clamp ing device m The maximum draw tube force specified on the perimeter of the clamping device must not be ex ceeded a HA NBUCH 47 The clamping pressure of the machine must be suf ficiently high a All mounting tools must be removed from the interi or of the machine a Clamping device and work piece must be compati ble check the clamping diameter regularly The work piece must be clamped into the clam
8. cedure NOTICE With high contamination of the clamping device the functionality is no longer guaranteed The cleaning and maintenance intervals must be observed a HAINBUCH 17 2 10 Environmental protection Lubricants y NOTE Environmental hazard due to incorrect han dling Incorrect handling of environmentally haz ardous substances particularly improper dis posal can cause significant environmental damage Always comply with the instructions cited be low a H environmentally harmful substances should inadvertently get into the environment initiate suitable measures immediately If in doubt notify the responsible municipal authority about the damage The following environmentally harmful substances are used Lubricants like greases and oils can contain toxic sub stances Ensure that they do not get into the environ ment The device must be disposed of by a specialized dis posal company To achieve trouble free operational performance of the clamping device only use HAINBUCH lubricants See the appendix for reference addresses 18 Q HAINBUCH 3 Technical data 3 1 General Information The clamping device is available in different sizes and variants Information about e g dimensions a weight you will find on the corresponding drawing that you can order at HAINBUCH Wei Dimensions Spindle flange Speed camping Clamping e eight a force force S
9. clamping taper 3 Adjust the clamping device in such a manner that the dial indicator shows the value 0 For exact adjustment if necessary loosen the cylindrical screws several turns and retighten in a cross pattern 6 3 4 Installing the end stops Base end stop Special tools required a Allen wrench fi The clamping head must always be removed from the chuck for assembly and disassembly a Insert the base end stop in the chuck a Screw in the 3 mounting screws and tighten them according to the torque table Work pieces can be directly attached on the surface of the base end stop or an additional end stop can be screwed into the thread of the base end stop Front end stop Special tools required a Allen wrench Ti Prior to assembling the front end stop the clamping head that is necessary for the next machining must be inserted a Place the front end stop on the flange m Screw in the mounting screws and tighten them ac cording to the torque table e HAINBUCH 43 6 3 5 Clamping the work piece in the chuck Special tools required um Actuating wrench After assembling the clamping head a work piece i2 may be clamped in the chuck The safety ring must be present and in correct D position UL um For clamping turn the actuating screw 7 clockwise by using the actuating wrench 12 i A Risk of injury L Tools and measuring equipment may spin out m m Remove all tools and measuring equipment be
10. the low est given RPM must always be used Note that the clamping force is influenced by the centrifugal force of the clamping elements m If necessary adjust the machining force This manual is protected by copyright and is provided exclusively for internal purposes Delivery of the operating manual to third parties dupli cation in any form including excerpts as well as ex ploitation and or communication of the content are not permitted except for internal use without written ap proval from the manufacturer Actions to the contrary make damage compensation mandatory We reserve the right to enforce additional claims a HA NBUCH 7 1 6 Scope of delivery 1 7 Spare parts 1 8 Warranty terms 1 9 CFK T All tools and accessories that are not included in the scope of delivery are marked as option al In scope of delivery of the clamping device a 1 TOROK a 1 Base end stop a 1 Socket wrench Optionally the scope of delivery of the clamping de vice includes a Flange a Clamping head Workpiece end stop m Eye bolts Control ring a Actuating key Torque wrench set WARNING Safety risk if the wrong spare parts are used Incorrect or defective spare parts can cause damage malfunction or total failure they can also impair safety Only use manufacturer s original spare parts Only purchase spare parts from authorized dealers or direct from the manufacturer Addresses are
11. Wrong clamping of the work piece WARNING Danger of injury due to moving parts Rotating parts of the clamping device can cause serious injuries Do not reach into moving parts or handle moving parts during operation m Note the gap dimensions of moving parts m Do not open covers when the device is in op eration a Be aware of after run time Prior to opening the covers ensure that all parts have come to a standstill Wear tight fitting protective work clothing in the danger zone Clamping position End position Position End position with workpiece 8 without workpiece WARNING Danger of injury due to incorrect clamping of the work piece Incorrect work piece clamping may lead to the ejection of the work piece and result in serious injuries The use of more than 75 of the clamping re serve stroke may lead to wrong clamping m Do not exceed the maximum permissible clamping reserve stroke Calculation basis X X1 x 75 Check the workpiece blanks dimension ran domly 14 Q HAINBUCH Missing changing parts Parts with sharp edges 2 6 Further warnings A A WARNING Danger of injury due to missing changing parts When operating the clamping device without changing parts segmented clamping bushing clamping heads work piece end stops there is a higher danger of crushing injuries due to the stroke of movable components of the clamping devic
12. grease all interior and outer surfaces of the clamping device Remove excess grease with a cloth 5 Pack the clamping device airtight in foil Place it on a level impact free storage location and safeguard it from falling e HAINBUCH 57 8 4 Use of lubricant With the usage of lubricant you may only use grease that corresponds to the requirements concerning bond pressure stability and solubility in lubricating coolant In addition no dirt particles may be in the grease they cause run errors if they come in in between two mating surfaces We recommend for this the following lubricant HAINBUCH grease see product information Alternatives Lubricant Manufacturer Product Universal MicroGleit GP 355 grease Kl ber QNB 50 Zeller amp Gmelin DIVINOL SD24440 Bremer amp Leguill RIVOLTA W A P Special grease Kl ber MICROLUBE GL 261 c 58 HA NBUCH 8 5 Maintenance schedule Maintenance tasks are described in the sections above that are required for optimal and trouble free operation If increased wear is detected during regular inspec tions then reduce the required maintenance intervals according to the actual indications of wear Contact the manufacturer see the service address on the back if you have questions concerning mainte nance tasks and intervals Interval Maintenance task Daily Visual check especially at the clamping and bearing surfaces to d
13. in the ap pendix The warranty terms are included in the manufacturer s terms and conditions In case of visible damage or visible wear of the carbon parts Further processing only after consultation with HAINBUCH c 8 HA NBUCH This section provides an overview o fall the important safety aspects for optimal protection of personnel as well as for safe and trouble free operation 2 1 Responsibility of the customer The device is used in industrial applications Conse quently the owner of the device is subject to legal in dustrial safety obligations In addition to the safety instruction in this manual generally valid safety and accident protection guide lines and environmental protection guidelines as well as the machines manual must be adhered to and complied with for the area of implementation of the device The achievable clamping forces can vary due to the maintenance condition of the clamping device or the adapter lubrication condition and degree of contami nation see chapter Maintenance Pay attention to chapter 3 2 clamping forces TOROK 2 2 Personnel requirements WARNING Danger of injury due to insufficient qualifi cation Improper handling of the clamping device can cause serious injury or material damage Only have activities performed by personnel who are qualified to perform these activities The following qualifications are cited in the operating manual for the various a
14. inserted in the spindle bores Turn each clamping cam clockwise so that the camlock bolts can be tensioned o HA NBUCH 41 6 3 3 Checking and adjusting the face run and the concentricity NOTE Material damage due to insufficient face run and concentricity Due to insufficient face run and concentricity work pieces can be damaged during process ing After each mounting check and if necessary readjust the face run and concentricity of the clamping device Checking face run Special tools required Dial indicator Plastic tip hammer 1 Place the magnetic base of the dial indicator on the inside of the machine 2 Place the dial indicator for face run on the face of the clamping unit 3 Use a plastic tip hammer to carefully knock the clamping unit into position 4 Tighten the cylindrical screws with a torque wrench in a cross pattern see section Screw tightening torque fi For exact adjustment if necessary loosen the cylindrical screws several turns and retighten ina cross pattern 5 Wipe off the taper of the the clamping element re ception with a soft lint free cloth and remove all oil and grease residues Checking concentricity Special tools required a Dial indicator a Plastic tip hammer Torque wrench 42 eo HAINBUCH 1 Place the magnetic base of the dial indicator on the inside of the machine 2 Place the dial indicator for concentricity on the
15. mm 22 Nm 29 kN 60 kN e HAINBUCH 25 3 3 Operating conditions Environment Specification Value Unit Temperature range 15 65 ue Mechanical actuating In each possible operating condition the maximum draw force and compressive force may not be ex ceeded 3 4 Power specifications y NOTE Material damage if the power specifications do not agree If the power specifications of clamping device machine adapter and machine do not agree severe damage extending to total damage can occur Only operate clamping devices and adapters in machines with the same power specifica tions Information on maximum clamping force and draw tube force is provided on the clamping device and the adapter 3 5 Dimensional sheet Dimension sheets for the respective product can be requested from HAINBUCH 3 6 Type designation The type designation is on the product and includes 7 the following information 1 ID no marked with the symbol 2 Maximum speed rpm 3 Maximum clamping force kN c 26 HA NBUCH 4 Structure and function 4 1 Overview and brief description Fig 7 1 Spindle flange 3 Clamping head 2 TOROK 4 Wrench Brief description The TOROK manual chuck is primarily used in tool prototyping on machines without a clamping cylinder Basically it is implemented wherever users are reluc tant to sacrifice the accustomed SPANNTOP quality even without a clamping cylinder And best of all du
16. much lubricant on the bearing surface as this can cause face runout a Seal rings e g o ring quad ring seal and sealing surfaces must be lubricated Note the information in the chapter Maintenance m Note that the function surfaces plate surface mat ing surface cone surface and seal surface may not be damaged CAUTION Wear safety shoes during the assembly and maintenance work Make sure that the starting of the spindle is im possible The total weight of the clamping device consisting of spindle flange and clamping unit depends on the size and can be as much as 40 kg see technical data Depending on the weight to safely lift the clamping device out of the package and position it in the ma chine it must be hooked into a crane WARNING Danger of injury due to falling components When mounting components can fall and cause severe injury and material damage m Two people are always required for this task Use a crane Damage caused by contaminated surfaces CE Contaminated contact surfaces and scratches can lead to impairment of axial and radial run out accuracy Clean the bearing surfaces and oil them gen tly Check the bearing surfaces for scratches and other damage If necessary contact the man ufacturer a HA NBUCH 37 6 3 Installation A A A WARNING Danger of injury due to unintentional start up of the tool spindle Unexpected start up of the tool sp
17. r e 60 Brief description eror eerta 27 C Carbon CFK coiere patente pta ooi 8 Changing fixture eere Marta lirios 29 PASEN acia 29 Clamping head iii 29f E ln Le m s 56 Control of the stroke position 48 D Dimensional sheet 26 Ru e EE ue 52 TORO EN 51 DIS POS A una 53 E Environmental protection 18 G IE c fia HP 30 CC aa den 30 l pa D Prepara Soren enensens 37 Intended use 10 J Ee El EN L Rs o EE 13 M Maintenance schedule 59 MISUS 6 ee 11 O Operating conditions 26 OVERVIEW usa boiada adiar cid 21 P Packaging 34 Personal protective equipment Hard ALs RR sn 12 Protective gloves eeee 12 Protective goggles 12 Protective work clothing 12 Safety footwear uus 12 Personnel requirements 9 Power specifications 26 Preservaci n 57 R Representatives nnen PRCA oisi cu RR RR e DV 68 AMECA Seege Rd een 67 IANS E 67 PANO dig eenen e 68 EUROS EE 64 S Scope of delivery acom 8 ie een E 8 Special MANGES suas sacas ass ttes 13 ONNIE MER eege 35 TIT 2310 incitar 27 Subsequent storage 49 Symbols on the packaging
18. Add on clamping elements MANDO Adapt jaw module Size TOROK RD 65 MANDO Adapt XXS MANDO Adapt XS MANDO Adapt S MANDO Adapt 0 MANDO Adapt 1 MANDO Adapt 2 MANDO Adapt 3 MANDO Adapt 4 Jaw module 145 Jaw module 215 TOROK SE size 65 Clamping diameter 4 65 mm 8 13 mm 13 18 mm 16 21 mm 20 28 mm 26 38 mm 36 54 mm 50 80 mm 70 100 mm 25 115 mm 25 195 mm bridging region 0 50 mm 0 15 mm 0 25 mm 0 25 mm 0 25 mm 0 25 mm 0 35 mm 0 35 mm 0 50 mm 0 50 mm 0 50 mm Operating torque max 50 Nm 11 Nm 11 Nm 11 Nm 11 Nm 11 Nm 22 Nm 28 Nm 39 Nm 32 Nm 32 Nm Add on clamping elements MANDO Adapt jaw module Size TOROK SE 65 MANDO Adapt XXS MANDO Adapt XS MANDO Adapt S MANDO Adapt O MANDO Adapt 1 MANDO Adapt 2 MANDO Adapt 3 MANDO Adapt 4 Jaw module 145 Jaw module 215 Clamping diameter 4 65 mm 8 13 mm 13 18 mm 16 21 mm Y 20 28 mm 26 38 mm 36 54 mm 50 80 mm Q 70 100 mm Q 25 115 mm Q 25 195 mm bridging region 0 50 mm 0 15 mm 0 25 mm 0 25 mm 0 25 mm 0 25 mm 0 35 mm 0 35 mm 0 50 mm 0 50 mm 0 50 mm Operating torque max 50 Nm 11 Nm 11 Nm 11 Nm 11 Nm 11 Nm 22 Nm 28 Nm 39 Nm 32 Nm 32 Nm Axial Radial force force max max 45 kN 105 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 10 kN 42 kN 20 kN 85 kN
19. Illustrations in this manual are provided for a basic un derstanding and may deviate from the actual model of the clamping device It is assumed that the reader is familiar with standard procedures such as cleaning the mounting surfaces 1 2 Explanation of symbols Safety instructions Safety instructions are indicated by symbols in this operating manual The safety instructions are intro duced by signal words that express the scope of the hazard The safety instructions must be strictly adhered to You must act prudently to prevent accidents personal injury and material damage DANGER indicates an imminent dangerous situation than can result in death or serious injury if it is not avoided WARNING indicates a possible dangerous situation that can result in death or serious injury if it is not avoided CAUTION indicates a possible dangerous situation that can result in minor or light injury if it es not avoided a HA NBUCH 5 Tips and recommen dations y NOTE o indicates a possible dangerous situation that can result in material damage if it is not avoided T indicates useful tips and recommendations as well as information for efficient and trou ble free operation 1 3 Limitations of liability All information and instructions in this operating manu al have been provided under due consideration of ap plicable standards and regulations the current state of technology as we
20. UCH clamping devices is only en sured when using original HAINBUCH segmented clamping bushings Lubricating grease and grease gun are required for cleaning and preservation of the clamping device The lubricating grease is also specially matched for protec tion of the vulcanized segments of the segmented clamping bushings and increase their service life and elasticity by a significant factor 28 Q HAINBUCH 4 2 1 Spindle flange Fig 8 4 2 2 Changing fixture Fig 9 T Fig 10 4 2 3 Clamping head Fig 11 The spindle flange serves for adaption of the seg mented mandrel to the machine Depending on the order the spindle flange can be in cluded in the delivery or provided by the customer Manual changing fixture The pins of the changing fixture are inserted in the matching holes in the clamping head The changing fixture is tensioned via hand force The clamping head is firmly clamped in the changing fixture and can be inserted into the mounted clamping device with the aid of the changing fixture Pneumatic changing fixture The pins of the changing fixture are inserted in the matching holes in the clamping head The changing fixture is tensioned via compressed air The clamping head is firmly clamped in the changing fixture and can be inserted into the mounted clamping device with the aid of the changing fixture The clamping heads are used to accommodate the work piece that will be machine
21. achine in set up mode Remove fuels and auxiliary materials as well as residual processing materials and dispose of these items in an environmentally responsible manner DANGER Life threatening danger if restarted without authorization When disassembling there is danger of the en ergy supply being switched on inadvertently This poses a life threatening hazard for per sons in the danger zone Prior to starting the tasks switch off all energy supplies and safeguard them from being switched on again A WARNING Danger of injury due to falling components When mounting components can fall and Cause severe injury and material damage m Two people are always required for this task Use a crane For assembly on a vertically suspended spin dle always use a Suitable mounting aid a HA NBUCH 49 WARNING Risk of injury due to stored energy The clamping device can be designed with disc springs These disc springs are under perma nent tension The release of the stored energy can cause injuries By loosening the corresponding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum Particularly cautious approach is required For cleaning and maintenance disassemble the clamping device from the machine Always wear personal protective equipment 7 2 Disassembling the clamping device 7 2 1 Disassembling the end stops Front end stop Spec
22. alia Australia Romheld Automation Pty Ltd Unit 30 115 Woodpark Road Smithfield NSW 2164 Phone 61 297211799 Fax 61 297211766 E mail sales romheld com au Internet www romheld com au 10 2 5 Africa South Africa South Africa Retecon PTY Ltd P O Box 1472 1620 Kempton Park Phone 27 119768600 Fax 27 113942471 E mail tools retecon co za Internet www retecon co za Japan NK Works Co LTD 2 17 17 Iwamoto cho Chiyoda ku Tokyo 101 0032 Phone 81 338645411 Fax 81 338646752 E mail info nk works co jp Internet www nk works co jp Malaysia Singapore amp Vietnam Jebsen amp Jessen Technology S Pte Ltd Process Engineering Division 18 Enterprise Road Singapore 629824 Phone 65 63053692 Fax 65 63053699 E mail phillip lee jjsea com Internet www jjsea com Thailand HAINBUCH Thailand Co Ltd WORKHOLDING SOLUTIONS 2 25 Sukhapiban 2 Road Prawet Prawet Bangkok 10250 Phone 7662329 0622 23 Fax 662329 0624 E Mail info hainbuch co th Internet www hainbuch com Q HAINBUCH TOROK Appendix englisch a Order Hotline 49 7144 907 333 HAINBUCH 69 11 Index A A DU co MN 28 Add on clamping elements 31 ASES un SRS RR usns mata conuat Add on clamping element jaw adaptei PNEU 45 Add on clamping element MANDO AA E 45 Concentricity and face run 42 e 40 Lubricating the clamping element re CODON P M 46 TORO Cv 40 B Bo
23. at 20 3690 Zutendaal Phone 32 89518890 Fax 32 89518899 E mail info bistechnics com Internet www bistechnics com Denmark J rn B Herringe A S Ramsgmagle Syvvejen 31 4621 Gadstrup Phone 45 46170000 Fax 45 46170001 E mail sales jbh tools dk Internet www jbh tools dk Austria GGW Gruber amp Co GmbH Kolingasse 6 1090 Vienna Phone 43 13107596 0 Fax 43 13107596 31 E Mail office ggwgruber com Internet www ggwgruber com Czech Republic TMC CR s r o Masn 27 9 60200 Brno Phone 420 533433722 Fax 420 548217219 E mail info tmcer cz Internet www tmccr cz Estonia Latvia Lithuania DV Tools O Peterburi tee 34 4 11415 Tallinn Phone 372 6030508 Fax 372 6030508 E mail info dv tools ee Internet www dv tools ee 64 Y HAINBUCH Finland Oy Maanter Ab PL 70 Keinum enkuja 2 01510 Vantaa Phone 358 29006130 Fax 358 290061130 E mail maantera maantera fi Internet www maantera fi France Representative for Haute Savoie Utilis France Sarl 597 Avenue du Mont Blanc 74460 Marnaz Phone 33 450963630 Fax 33 450963793 E mail contact utilis com Internet www utilis com Greece PAPET Papadopoulos GbR Martinstrasse 68 DE 73061 Ebersbach Fils Phone 49 71635858 530668 Fax 49 716352265 E mail paris papet technologies de Ireland HAINBUCH UK Ltd WORKHOLDING TECHNOLOGY 6 Newmarket Keys Business Village Keys Park Road Hednesford Staffordshire WS12 2HA Ph
24. ces are not clamped properly a l safety regulations are disregarded and persons are working at the clamping device without addition al protective devices e g for machining a f the clamping device is used for machines or tools for which it is not intended 2 4 Personal protective equipment Wearing of personal protective equipment is required to minimize health hazards when working with the de vice a Always wear the protective equipment necessary for the respective task when working with the device a Follow the instructions that have been posted in the work area a HAINBUCH 11 Always wear oo For special tasks wear O e For all tasks always wear Protective work clothing is tight fitting work clothing with low resistance to tear ing with tight sleeves and without projecting parts It is primarily used to protect against entanglement by moving machine parts Do not wear rings chains or other jewelry Safety footwear for protection against heavy falling parts and slipping on slippery substrates Special protective equipment is required when exe cuting special tasks Separate reference is made to this equipment in the specific sections of this manual This special protective equipment is explained below Hard hat to protect against falling and flying parts and materi als Protective goggles to protect eyes from flying parts and liquid splashes Protective gloves t
25. ctivity areas Specialized personnel are personnel who due to their specialized training skills and experience as well as knowledge of the applicable regulations are capable of executing the tasks assigned to them and of recognizing and avoiding possible hazards on their own a HAINBUCH 9 2 3 Intended use Hydraulic specialist The hydraulic specialist has been trained for the particular task area in which he is active and is fa miliar with the relevant standards and regulations Due to his specialized training and experience the hydraulic specialist can perform tasks on hydraulic equipment and recognize and avoid possible dan gers on his own Electric specialist The electric specialist has been trained for the par ticular task area in which he is active and is familiar with the relevant standards and regulations Due to his specialized training and experience the electric specialist can perform tasks on electric equipment and recognize and avoid possible dan gers on his own Only persons from whom it can be expected that they reliably execute their work are considered as person nel Persons whose capability to react is impaired for instance through drugs alcohol or medication are not approved Comply with age specific and job specific regula tions that are applicable at the installation site when selecting personnel The clamping device is designed for installation in a machine tool according to CE c
26. d They consists of hard steel and rubber segments that are connected via a vulcanizing process Depending on the requirements of the work piece there are clamping heads in different sizes and with different profiles and bores e HAINBUCH 29 4 2 4 Clamping head Fig 13 4 2 6 4 2 7 Grease gun Fig 15 The clamping heads are used to accommodate the work piece that will be machined They consists of hard steel and rubber segments that are connected via a vulcanizing process Depending on the requirements of the work piece there are clamping heads in different sizes and with different profiles and bores The work piece end stop is manufactured with a end stop dimension according to the customers request In combination with the clamping head and the chuck it provides a functional unit The universal grease for chuck and mandrel lubrica tion is supplied in a 1000g can The order number for the universal grease is 2085 0003 it can be ordered from HAINBUCH The grease gun is filled with universal grease which is pressed into the clamping device The grease gun has a pointed mouthpiece The order number for the grease gun is 2086 0004 it can be ordered from HAINBUCH o 30 HA NBUCH 4 2 8 Add on clamping elements Mandrel MANDO Adapt T211 The CENTREX quick change over interface al lows a p accurate adaption of the adapt clamping device without adjusting the B Top3 chuck a Clamp
27. d bonus It results in a concentricity of less than 0 005 mm from the mandrel body to the chuck taper Simple and effective Quick change over from outside to inside clamping Concentricity lt 0 005 mm for chuck taper Available in five different mandrel sizes for each of the chuck sizes 42 100 For further information read the installation manual of the MANDO Adapt 6 3 7 Add on clamping element jaw adapter With the SPANNTOP combi pull back chuck with axi ally mounted base joint base end stop and the jaw adapter you can now also clamp in front of the chuck This combination opens totally new possibilities that previously required a jaw chuck For example you now can a realize considerably larger clamping diameters drill or mill in between the jaws And don t worry it won t tip A clever mechanism will see to that And speaking of clever you don t even need a changing fixture to insert the jaw adapter A tapered bolt spreads the segments into the coupling Removal is in reverse Unscrew the tapered bolt and you will hold the entire jaw adapter in your hands With the aid of the loading plug the soft jaws can be machined to the required dimension The jaws have a serration on the back allowing for a 6 mm adjustment of the clamping diameter For further information read the installation manual of the MANDO Adapt a HA NBUCH 45 6 3 8 Lubricating the clamping element reception ii Reduced clamping f
28. da Representative for Ontario Qu bec J Winkel amp Associates Inc 6516 Warbler Lane L5N 6E1 Mississauga Ontario U S A Phone 1 4143589550 Fax 14143589560 E mail sales hainbuchamerica com Internet www hainbuch com USA HAINBUCH America Corp WORKHOLDING TECHNOLOGY W129 N10980 Washington Dr Germantown WI 53022 Phone 1 4143589550 Fax 1 4143589560 Se habla espanol Tel 1 2143268081 E mail sales hainbuchamerica com Internet www hainbuch com India M la Sales Corporation 5 Yeshwantnagar Telco Century Enka Road Pimpri Pune 411018 Phone 91 20 27477405 Fax 91 20 27464249 E mail info mla sales com Internet www mla sales com Indonesia PT STAHL ARBEIT WTC Mangga Dua 2nd Floor A 6 JL Mangga Dua Raya No 8 Level 2 Blok C No 41 45 Jakarta 14430 Phone 62 21 3777 6622 Fax 62 21 3001 8070 E mail info stahl arbeit com Internet www stahl arbeit com a HA NBUCH 67 Israel M T M Machine Tools Marketing Ltd 26 Hakishor St Holon 58867 Phone 972 36479560 Fax 972 36479578 E mail sales mtm co il Internet www mtm co il Korea Kimi Co B 101 98 Okgucheondongro Siheung Si 429 925 Gyeonggi Do Phone 82 24137911 Fax 82 24137910 E Mail kimi kimigroup co kr Taiwan GSTC Technology Co Ltd No 418 Youn Chun East 1st Rd Taichung City 40877 Taiwan Phone 88 6423805678 Fax 88 6423805511 E mail gstc seed net tw Internet www gstctech com tw 10 2 4 Austr
29. e m The clamping process may not be initiated without assembled segmented clamping bushing and or work piece end stop WARNING Risk of injury When screwing in individual components such as for example work piece end stops threaded adapters and similar devices that are equipped with an external thread or wear caused by burrs there is risk of cutting The operation must be done only by qualified personnel Wearing of gloves PSA is required CAUTION Risk of injury A special use dependent or job based design can result in variations in the clamping strokes and thus the clamping force m he notes on the associated clamping situa tions or product drawing must always be ob served WARNING Risk of injury Never reach for the clamping device while the spindle is rotating Before starting to work on the mandrel make sure the machine spindle cannot be put in motion e HAINBUCH 15 2 7 Clamping force A A WARNING Risk of injury Falling down of the clamping device or its parts can cause severe bruises and fractures The dead weight of the clamping device or its parts can lead to high physical stress WARNING Risk of injury By repeated reworking or wear and tear of the clamping surfaces sharp edges and burrs may appear and lead to severe cutting damages WARNING Damage of clamping device The clamping device may be released exclu sively in the standing condition The achie
30. e to its easy manual activation you can safely and deli cately clamp in the customary manner when used on grinding machines Le iG FAA AT 432 a Order Hotline 49 7144 907 333 HA NBUCH 27 With the new TOROK you can also use all clamping device adaptations such as the MANDO Adapt man drel in the chuck or the jaw adapter In the future you can also rely completely on the HAINBUCH modular system even for your manual chuck Key advantages a Sensitive manual clamping is possible Manual activation a clamping cylinder is not re quired Concentric precision 0 01 mm possible Minimal inertia loss Standard flanges available with adjustable bolt Camlock upon request Typical HAINBUCH features such as user friendly set up full passage parallel clamping optimal pow er conversion extreme rigidity and superior holding power as well as minimal wear and tear Work piece stabilization through axial draw force applied against the work piece end stop Prepared for work piece end stop and front end stop Inner end stop or full through bore possible Short and stable clamping 2 clamping geometries are attainable SE hexago nal and RD round 4 2 Optional Accessories The accessories described here are not included in the scope of delivery Specially developed segmented clamping bushings match to the respective maximum RPM are available for each clamping device Trouble free and precise function of HAINB
31. e or sensitive contents Handle the packed goods with care do not allow them to fall and do not subject them to impact Protect from moisture Keep packed goods dry and protected against mois ture 5 3 Transport inspection Check delivery immediately upon receipt to ensure that delivery is complete and to identify any transport dam age Proceed as follows it there is apparent external dam age a Do not accept the delivery or only accept it with reservation 32 Q HAINBUCH m Note the extend of transport damage on the trans port documents or on the transport company s deliv ery ticket Submit a complaint 1 Report any defect as soon as it is detected Claims for damage compensation can only be enforced during the applicable periods for giv ing notice of lack of conformity 5 4 Unpacking and inner company transport 1 Usually the clamping device is packed vertical ly Depending on the size it has threaded bores in the circumference of the clamping device for assembling the eye bolts In these threaded bores lifting eye bolts can be screwed in To safely lift the clamping device out of the package it must be hooked into a crane de pending on the weight For transporting with transport trolley the clamping device must be positioned in stand ing condition Make sure that a non slip pad has been laid All tools and accessories which are not in scope of delivery are marked as optional in the operat
32. ed leakage of fluids can lead to se vere injuries m Open the pressure relief screw and drain re maining liquid m Discard the liquid 1 NOTE Improper disposal causes environmental damage Lubricants and other auxiliary materials are subject to treatment as special waste and should only be disposed of by approved spe cialist companies 1 NOTE Composite materials For disposal clamping devices which include composite materials mineral cast CFK must be returned at HAINBUCH Local municipal authorities or specialized disposal companies provide information on environmentally re sponsible disposal a HA NBUCH 53 8 Maintenance Environmental Comply with the following instructions for environmen protection tal protection when performing maintenance work At all lubricating points where lubricant is applied by hand remove escaping used or excess grease and dispose of it in accordance with applicable local regulations a Collect used oil in suitable containers and dispose of itin accordance with applicable local regulations 8 1 General Cleanliness of the appropriate end stop as well as the guidance diameters are conditions for reaching the concentricity and perpendicularity tolerances Clean these surfaces with an appropriate cleaner CAUTION Danger of injury due to improper handling of cleaners Improper handling of cleaners can cause health impairments Always comply with the safety da
33. embly 1 Loosen and remove all cylindrical screws by using an allen wrench 2 Turn each clamping cam anti clockwise so that the camlock bolts can be tensioned 3 Remove the spacer flange 8 and the chuck from the machine spindle Fig 28 7 2 3 Disassembling the flange optional The task requires two people Special tools required a Allen wrench 1 Put the machine in set up mode 2 Wipe off the mating surfaces of the machine spin dle with a soft lint free cloth and remove all oil and grease residues 3 Deposit the clamping device with the flange down 4 Loosen and remove the mounting screws 4 5 Take the clamping device from the flange NOTE Damage due to contaminated and or damaged bearing surfaces m Check the two bearing surfaces for damages replace them if necessary m Clean the two bearing surfaces from contami nation o 52 HA NBUCH 7 3 Subsequent storage of the clamping device The clamping device must be cleaned and treated with corrosion protection for subsequent storage see section Cleaning NOTE The storage conditions are specified in the section Transport packaging and storage 7 4 Disposal If a return or disposal agreement has not been con cluded then recycle disassembled components CAUTION Risk of injury due to leaking fluids Hydraulically or pneumatically operated clamp ing devices may contain residues of liquids Uncontroll
34. esponsible manner Comply with locally applicable disposal guidelines If necessary commission a spe cialized company to dispose of packaging c 34 HA NBUCH 5 6 Storing Storage of packages Subsequent storage of the clamping device T Under certain circumstances instructions for storage and subsequent storage are affixed to the packages that extend beyond the require ments cited here Comply with these instructions accordingly Only store packages under the following conditions m Do not store outdoors m Store in a dry and dust free location m Do not expose to aggressive media m Protect from direct sunlight a Avoid mechanical vibration a Storage temperature 15 bis 35 C a Relative humidity max 60 96 For storage periods longer than 3 months Check the general condition of all parts and the packaging at regular intervals m Touch up or re apply anti corrosion agents as needed Only re store the clamping device under the following conditions a Thoroughly clean the clamping device prior to sub sequent storage see section Cleaning m Thoroughly oil and grease the clamping device see section Cleaning Store the clamping device in airtight foil The clamping device must be stored securely in po sition If this is not guaranteed use a suitable con tainer for the clamping device or equip the shelf with a circumferential securing edge a HA NBUCH 35 6 Assembly WARNING Du
35. etermine damages at the clamping de vice and at the vulcanization of the clamping ele ments early With heavy contamination complete cleaning see chapter Cleaning Every 36 operating Clean the clamping unit see section Cleaning hours Clean the taper reception and coupling area see sec tion Cleaning Grease the clamping unit see section Preservation If necessary Manufacturer service For proper operation of the coolant feed a pre filtering with duplex filter mesh size 100 um PI 3754 is necessary The duplex filter is mount ed on the coolant cleaning system a HA NBUCH 59 8 6 Bolt torque Metric ISO thread The guide values for bolt tightening torque for achiev ing the highest permissible pre tension for metric ISO thread are specified in Nm in the table Total friction coefficient Uu 0 12 Torque for screw Diameter quality 10 9 Nm mm M 4 7 3 4 M5 8 4 7 M6 10 5 12 M 8 13 6 25 M 10 17 8 50 M 12 19 10 100 M 16 24 14 220 M 20 30 17 400 M 24 36 19 600 The table shows the prescribed values Knowledge of the applicable guidelines and configu ration criteria are the prerequisites Q 60 HAINBUCH 9 Trouble shooting Possible fault causes and the tasks to correct these faults are described in the following section If faults occur more frequently the maintenance inter vals must be shor
36. fore machining from the machine a When working with a hand chuck always use a protective cover for protection from flying chips m The use of eye protection is mandatory Remark for the work piece Work pieces may not be too out of round The minimum clamping depth may not be exceed ed To release the clamping pressure turn the actuation screw 7 anti clockwise by using the actuating key 12 Hold the work piece firmly to prevent it from fall ing off the chuck A WARNING Risk of injury due to spinning out tools and or measuring equipment When the chuck will be set into rotation the actuating key 12 may never stuck in the chuck The actuating key 12 is provided with a spring that pushes the key out of the chuck as soon as it is released a f the spring is damaged or the function may be impaired or missing insert a functional spring into the key before using it again c 44 HA NBUCH 6 3 6 Add on clamping element MANDO Adapt Changing from outside to inside clamping without tak ing the chuck off the machine No problem with MAN DO Adapt Place the mandrel on the SPANNTOP chuck tighten the three screws screw in the draw bolt to actuate the segmented bushings and an in genious mechanism adapts to the coupling that nor mally grips the clamping head That s all there is to it You save a considerable amount of time and the MANDO Adapt delivers superb rigidity and precision as an adde
37. ial tools required a Allen wrench Disassembly m Loosen and remove the mounting screws Remove the front end stop from the surface Base end stop Special tools required a Allen wrench Before assembly and disassembly always re move the clamping head from the chuck m Loosen and remove the 4 mounting screws Remove the base end stop from the chuck 50 Q HAINBUCH 7 2 2 Disassembly of the TOROK Two people are required for this task Special tools required a Allen wrench a Crane a Eye bolts 1 Put the machine in set up mode 2 Remove all tools from the interior of the machine 3 Set the clamping pressure of the machine tool on the lowest setting 4 Move the draw tube of the machine tool into front stop position Disassembly of the chuck from a spacer flange with standing bolt in accordance with DIN 55027 Risk of injury Screw in the eye bolts before disassembly 1 Loosen and remove all cylindrical screws by using an allen wrench 2 Loosen the collar nuts of the stud bolts 9 on the bayonet disk 3 Turn the bayonet disk 11 on the spindle an ti clockwise on the block as viewed from the ma chining area of the machine 4 Remove the spacer flange 8 and the chuck from the machine spindle o HA NBUCH 51 Disassembly of the chuck from the spacer flange with camlock bolt in accordance with DIN 55029 Risk of injury Screw in the eye bolts before disass
38. in the mounting screws 4 and tighten them slightly in cross alternation 6 3 2 Assembly of the TOROK Co Two people are required for this task Special tools required a Allen wrench a Crane m Eye bolts 1 Put the machine in set up mode Remove all tools from the interior of the machine Set the clamping pressure of the machine tool on the lowest setting 4 Move the drawtube of the machine tool into front stop position N 40 HAINBUCH Fig 21 Fig 22 Assembly of the chuck for the spacer flange with standing bolt in accordance with DIN 55027 1 Place the spacer flange 8 and the chuck on the machine spindle in such a manner that the torsion al safety of the spindle engages in the positioning bore 10 in the flange and so that the camlock bolts 9 of the spacer flange can be inserted in the spindle bores Turn the bayonet disk 11 on the spindle counter clockwise on the block as viewed from the machin ing area of the machine Place the collar nuts of the stud bolts 9 on the bayonet disk and tighten with fork wrench Assembly of the chuck for the spacer flange with camlock bolt in accordance with DIN 55029 1 Place the spacer flange 8 and the chuck on the machine spindle in such a manner that the torsion al safety of the spindle engages in the positioning bore 10 in the flange and so that the camlock bolts 11 of the spacer flange can be
39. indle can cause severe injury Prior to switching on automatic mode close all protective doors or hoods that are present on the machine tool Unscrew all eye bolts from the clamping de vice and remove them from the interior of the machine Only run the machine in set up mode or jog mode Always remove immediately all the tools and wrenches from the clamping device after use WARNING Risk of injury By operating the clamping device without changing parts clamping head segmented clamping bushing work piece end stops there is an increased risk of crushing injuries by the stroke of the moving components of the clamping device By uncontrolled discharge of the clamping process e g by incorrect installation of the en ergy supply or faulty programming there is an increased danger WARNING Risk of injury Bending in the working area of the machine can cause severe head injuries CAUTION Risk of injury Unexpected start up of the tool spindle can cause severe injury m Make sure that the system is pressure free and that a restart of the machine can be ex cluded 38 Q HAINBUCH Risk of injury Contamination of the mechanism can influ ence reduce the stroke thus the clamping force is reduced and thus the work piece is not properly tightened and can be thrown out Clean the product regularly see chapter Maintenance and service Risk of injury If the clamping pressure is to
40. ing instructions Two people are required for this task Special tools required a Crane and lifting eye bolts from weight 15 kg 1 Screw lifting eye bolts into the thread in the circum ference of the clamping device 2 Hook the load handling equipment into the lifting eye bolts 3 Use a crane to carefully lift the clamping device out of the transport packaging and put it down on a stable level substrate 4 Prevent the clamping device against rolling away a HA NBUCH 33 5 5 Packaging About the packaging Individual packages are packed according to the ex pected transport conditions Environmentally friendly materials have been used exclusively for the packag ing Packaging should protect the specific components from transport damage corrosion and other damage until installation Therefore do not destroy the packag ing remove it just before installation 1 The packed goods are sealed in foil airtight and packed in cartons See the Technical Data section for the specific weight of the re spective sizes Handling packaging Dispose of packaging materials in accordance with materials the respectively valid statutory regulations and local guidelines y NOTE a Improper disposal causes environmental damage Packaging materials are valuable raw materi als and in many cases they can be reused or they can be effectively treated and recycled m Dispose of packaging materials in an envi ronmentally r
41. ing range Y 20 80 mm possible by four sizes of mandrel a Vibration damping by vulcanized segmented clamping bushings Work piece stabilization by axial traction to the work piece end stop a wide bridging area by vulcanized clamping ele ments The MANDO Adapt can be ordered at HAINBUCH 4 2 9 Jaw adapter The facts a significant expansion of the clamping range a processing is possible between the jaws milling or drilling The jaw adapter consists of Adjustable jaws with serration Threaded pin to secure the jaw adapter Hardened oylindrical roller for optimum support Screw with integrated locking Base body and can be ordered at HAINBUCH QE Go h A OO HAINBUCH 31 5 Transporting packaging storing 5 1 Safety instructions for transporting Unbalanced package WARNING Danger of falling due to an unbalanced package Packed goods can have an unbalanced pack age If attached incorrectly the package can tip and cause life threatening injuries m Note the markings on the packages m Attach the crane hook in such a manner that itis located above the center of gravity m Carefully lift and see if the load tilts If neces sary change the attachment Transport m For transport always use a suitable clamping means crane Make sure that a rolling falling of the clamp ing device is not possible 5 2 Symbols on the packaging Fragile Identifies packages with fragil
42. ize o x Length connection max kg in mm vo in mm 1 min Fe Meteo LS KN kN 52 RD 20 200 x 110 IP 160 7000 80 35 65 RD 19 200 x 115 IP 160 6000 105 45 65 SE 19 200 x 115 IP 160 6000 120 45 100 RD 36 260 x 130 IP 240 5000 150 65 100 SE 36 260 x 130 IP 240 5000 172 65 IP Inner fit dimensions Fa max can only be reached in lubricated condition In unlubricated condition Frau max is much lower e HAINBUCH 19 WARNING Risk of injury Using false technical data can lead to serious personal injury and property damage m The technical data label on the product as sembly drawing must be observed and may not be modified by the operator 3 2 Clamping force diagram TOROK In the diagrams the effects of friction and the clamp ing diameter are included NOTE The measured values for the radial clamping force Fay may not leave the permitted area Un der optimal conditions the values for Fraa are below the top in bad conditions above the low er limit a f the measured clamping forces are outside the allowed range the maintenance is mandatory to perform After servicing the clamping forces have to be re examined If the clamping force even after the mainte nance is not in the permitted area please contact the manufacturer 20 Q HAINBUCH 3 2 1 Clamping force diagram TOROK size 52 RD Frad kN 20 Example Remarks n 20
43. l bim bazafirm pl Russia ROSNA Engineering LLC Sveaborgskaya street 12 Letter A office 20N 196105 Saint Petersburg Phone 7 812 4016767 Fax 7 812 4016767 E mail rosna rosna spb ru Internet www rosna spb ru Slovenia Elmetool d o o Prvomajska ulica 62 5000 Nova Gorica Phone 386 53303300 Fax 386 53303304 E mail info elmetool si Sweden HAINBUCH Svenska AB SP NNANDE TEKNIK Kemistv gen 17 18379 T by Phone 46 87327550 Fax 46 87327650 E mail hainbuch hainbuch se Internet www hainbuch com Turkey Hidkom Organize Sanayi B lgesi 75 Yil CD Demirciler Sit B Blok No 2 16159 Nil fer Bursa Phone 90 2242438292 Fax 90 2242436365 E mail hidkom tr net Internet www hidkom com Romania Banatech srl connecting technologies Ep Miron Cristea 26 325400 Caransebes Caras Severin Phone 40 255517175 Fax 40 355814125 Mobile 40 749220553 E mail office banatech ro Internet www banatech ro Slovakia NS s r o V cka ulica 4109 10 01841 Dubnica N V Phone 421 424450873 Fax 421 424440406 E mail tns tnssro sk Internet www tnssro eu Spain Portugal ATM S L C Gran Bretanya 16 Pol Ind Pla de Llerona 08520 Les Franqueses del Vall s Barcelona Phone 34 938700885 Fax 34 938606572 E mail atm sl gatmbarcelona com Switzerland Utilis M llheim AG Pr zisionswerkzeuge Kreuzlinger Strasse 22 CH 8555 M llheim Phone 41 527626262 Fax 41 527626200 E mai
44. l info utilis com Internet www utilis com Q HAINBUCH 10 2 2 America Argentina HAINBUCH America Corp WORKHOLDING TECHNOLOGY W129N10980 Washington Dr Germantown WI 53022 U S A Phone 1 4143589550 Fax 1 4143589560 E mail sales hainbuchamerica com Internet www hainbuchamerica com Canada HAINBUCH America Corp WORKHOLDING TECHNOLOGY W129 N10980 Washington Dr Germantown WI 53022 U S A Phone 1 4143589550 Fax 1 4143589560 E mail sales hainbuchamerica com Internet www hainbuch com Mexico HAINBUCH America Corp WORKHOLDING TECHNOLOGY W129 N10980 Washington Dr Germantown WI 53022 Phone 1 4143589550 Fax 1 4143589560 E mail sales hainbuchamerica com Internet www hainbuch com 10 2 3 Asia China HAINBUCH Shanghai Co Ltd WORKHOLDING TECHNOLOGY Room 611 612 BaoHong Center No 7755 Zhongchun Road Minhang District Shanghai 201101 Phone 86 2120916384 Fax 86 2120916383 E mail sales hainbuch cn Internet www hainbuch cn India A H Rao Technical Consultant to HAINBUCH Ground Floor 4157 14th Main HAL 2nd Stage Indiranagar Bangalore 560 008 Phone 91 8041463972 Mobile 91 9986997959 E Mail ahr rao gmail com Brasil SSanposs Tecnologia Suprimentos e Consultoria Internacional Ltda Rua C ndia n 65 Jardim do Mar CEP 09726 220 S o Bernardo do Campo S o Paulo Phone 55 1141266711 Fax 55 11 41266710 E mail tsci sanposs com br Internet www sanposs com br Cana
45. l Radial diameter region torque max force force max max TOROK RD 100 42 100 mm 1 0 mm 50 Nm 65 kN 150 kN MANDO Adapt XXS Q 8 13 mm 0 15 mm 7 5 Nm 10 kN 42 kN MANDO Adapt XS Q 13 18 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt S 16 21 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt 0 Y 20 28 mm 0 25 mm 7 5 Nm 10 KN 42 kN MANDO Adapt 1 26 38 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt 2 36 54 mm 0 35 mm 15 5 Nm 20 kN 85 kN MANDO Adapt 3 50 80 mm 0 35 mm 19 Nm 25 kN 105 kN MANDO Adapt 4 70 100 mm 0 50 mm 27 Nm 35 kN 150 kN Jaw module 145 25 115 mm 1 0 mm 22 Nm 29 kN 60 kN Jaw module 215 25 195 mm 1 0 mm 22 Nm 29 kN 60 kN TOROK SE size 100 Add on clamping elements MANDO Adapt jaw module Size Clamping bridging Operating Axial Radial diameter region torque force force max max max TOROK SE 100 42 100 mm 1 0 mm 50 Nm 65 kN 172 kN MANDO Adapt XXS Y 8 13 mm 0 15 mm 7 5 Nm 10 kN 42 kN MANDO Adapt XS Q 13 18 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt S Q 16 21 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt 0 Y 20 28 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt 1 Y 26 38 mm 0 25 mm 7 5 Nm 10 kN 42 kN MANDO Adapt 2 36 54 mm 0 35 mm 15 5 Nm 20 kN 85 kN MANDO Adapt 3 50 80 mm 0 35 mm 19 Nm 25 kN 105 kN MANDO Adapt 4 70 100 mm 0 50 mm 27 Nm 35 kN 150 kN Jaw module 145 25 115 mm 1 0 mm 22 Nm 29 kN 60 kN Jaw module 215 25 195 mm 1 0
46. ll as our many years of experience The manufacturer assumes no liability for damage due to Failure to follow the instructions in the manual Non intended use Deployment of untrained personnel Unauthorized conversions Technical changes Use of non approved spare parts The actual scope of delivery can vary from the expla nations and graphic representations provided in this manual in the case of special versions if supplemental order options are desired or on the basis of the latest technical changes The agreed obligations in the delivery contract the general terms and conditions as well as delivery con ditions of the manufacturer and the statutory regula tions valid at the time the contract was concluded ap ply Q 6 HAINBUCH 1 4 Max RPM 1 5 Copyright CAUTION Our clamping devices are balanced with bal ance quality G 4 in one level n 1 The data on the rotation balance refers to rota tionally symmetrical work pieces The clamping of not rotationally symmetrical work pieces may not be clamped and or only be clamped after consultation with the manu facturer Balancing bolts and balancing weights at the clamping devices may not be removed disas sembled CAUTION The maximum permissible speed is marked on the product By the combination of a clamping device and an add on clamping element a reduction of the maximum permissible speed may be neces sary Of all RPMs of the groups specified
47. mping surface original form Marks on the Point or linear work Replace with a clamping Specialist clamping piece clamping head that has a smoother surface clamping surface Wrong clamping head Replace the clamping Specialist type head Excessive dimensional Replace with a clamping Specialist difference between the work piece diameter and the clamping bore head that has a suitable clamping bore 9 3 Start up after corrected fault After correcting the fault execute the following steps to start up again 1 Reset the emergency stop device 2 Acknowledge the fault on the machine tool con troller 3 Ensure that no one is in the danger zone 4 Start the machine tool e HAINBUCH 63 10 Appendix 10 1 Service Hotline Order Hotline Quickly ordered and delivered A call is all it takes 49 7144 907 333 Schedule Hotline Current status of your order Just call 49 7144 907 222 24h emergency call Has there been a crash or other technical emergency Our experts are at your service around the clock 49 7144 907 444 10 2 Representatives The sales partners and service employees listed be low are available for further consultation or support 10 2 1 Europe Austria HAINBUCH in Austria GmbH SPANNENDE TECHNIK Pillweinstr 16 5020 Salzburg Phone 43 662 825309 E mail verkauf hainbuch at Internet www hainbuch com Belgium BIS Technics bvba sprl Zevenputtenstra
48. nd head move the drawtube not open or the clamping unit back and clean the the release coupling area stroke is see section Disassem insufficient bling the clamping head Clamping Work piece is under di Replace with a suitable Specialist force is too mensioned clamping head low Excessive mechanical Check idle moment Hydraulic friction 3 5 Nm specialist Defective clamping Contact the machine Machine cylinder or blocked manufacturer manufacturer drawtube Compression springs Replace compression Specialist fatigued at permanent springs tension Eccentric Concentricity error of Check the concentricity on Specialist dimensional the clamping unit the clamping taper and deviation on correct it if necessary the work see section Checking piece and adjusting the face run and concentricity of the clamping unit Dimensional Contaminated coupling Clean the coupling area of Specialist deviation on area the clamping unit see the work section Cleaning piece Contaminated clamping Remove the clamping Specialist taper head and clean the clamping taper see section Cleaning 62 HA NBUCH Fault Possible cause Fault correction Corrected by Formal defect Elastic deformation of Use feedstock with fewer Specialist on the work feedstock that is subject formal defects piece to formal defects After Use a clamping head with machining the work several sharp teeth in the piece returns to its cla
49. ndle EE 29 4 2 2 Changing Kat 29 AZ Camping HEA M 29 4 24 Clamping hed esse M m 30 4 2 5 Work piece End iii 30 EAS rc 30 2 HA NBUCH EE 30 4 2 8 Add on clamping elements ss iisssseneas nnnnenenennn 31 ARA JaW ADEN ans 31 5 Transporting packaging ION toria fold 32 5 1 Safety instructions for transporting an ae 32 5 2 Symbols on the Packaging rn 32 As TS CRT eem ee 32 5 4 Unpacking and inner company Transport 33 5 9 tre ad a 34 9 O SIONN Le iii a NEP 35 A o A aca eee 36 6 1 Pre consideration iaa 36 A A O dd EUR d 3f 6 3 rcc AU OP c id 38 6 3 1 Assembling the flange optional nnee nennen 40 6 3 2 Assembly or ihe TOROR u euere 40 6 3 3 Checking and adjusting the face run and the concentricity 42 6 3 4 Installing the end stops nn 43 6 3 5 Clamping the work piece in the chuck nnen nennen 44 6 3 6 Add on clamping element MANDO Adapt seen 45 6 3 7 Add on clamping element jaw adapter nanne eenen 45 6 3 8 Lubricating the clamping element reception nnn 46 6 4 coste a wensen E 47 6 5 Control or the stroke POSO sun 48 6 6 Activities after production is concluded ie 48 7 Disassembly subsequent storage disposal eee 49 HEC A A 49 7 2 Disassembling the clamping device
50. o low clamped work piece may be thrown out If the clamping pressure is too high severe damages of the components of the clamping device may occur the throwing out of the work piece m Before operation set the operation pressure back to operation level m he operating pressure should be checked and adjusted regularly The dimension of the work pieces should be checked regularly clamping g Transport For transport always use a suitable clamping means crane m Make sure that a rolling falling of the clamp ing device is not possible a HA NBUCH 39 6 3 1 Assembling the flange optional Fig 19 y NOTE Material damage due to wrong tightening torque of the cylindrical screws in the spin dle flange The tightening torque of the cylindrical screws is prescribed by the spindle or machine manu facturer Incorrect tightening torque of the Cylindrical screws in the flange can cause sig nificant material damage on the clamping de vice and on the machine Only tighten the cylindrical screws of the spindle with the torque prescribed by the spindle or machine manufacturer 1 Put the machine in set up mode 2 Wipe off the mating surfaces of the machine spin dle with a soft lint free cloth and remove all oil and grease residues 3 Place the spacer flange 8 on the table with the cylindrical fit facing up 4 Place the manual chuck with the 1 D fit on the flange 5 Screw
51. o protect hands from friction abrasion puncture wounds or deeper injuries as well as from contact with hot surfaces 12 eo HAINBUCH 2 5 Special dangers Horizontal lying parts Suspended loads In the following section residual risks are cited that occur due to installation of the clamping device in a machine tool In each case the residual risks that have been determined based on a risk analysis of the machine must be specified by the customer Follow the safety instructions listed here and the warnings in the other sections of this manual to re duce health hazards and to avoid dangerous situa tions WARNING Danger of injury due to horizontal parts Before transporting the clamping device in hor izontal condition Put the clamping device on a non slip pad m Screw in the eye bolts WARNING Life threatening danger due to suspended loads Some clamping devices must be lifted with a crane When lifting the clamping device there is a life threatening hazard due to falling parts or parts swinging out of control Never step under suspended loads Comply with the instructions concerning the intended attachment points Ensure that the sling gear is securely seated m Do not attach lifting gear in projecting com ponents Only use approved hoists and sling gear with sufficient bearing capacity m Do not use rope and belts that are torn or frayed a HAINBUCH 13 Moving parts
52. ompliant Within the machine tool the clamping device is designed exclu sively as a through bore chuck for bar work and or as an end stop chuck for chuck work The clamping device should only be mounted operat ed maintained and cleaned by instructed special ized personnel Intended use also includes compliance with all the in structions in this manual The clamping device is to be used for the case of ap plication contractually agreed between the producer deliverer and the user as well as such cas es of application described in the product description which are also in accordance with the technical val ues 10 Q HAINBUCH The safe function of the clamping device is as far as it can be foreseen guaranteed when it is used for the intended purpose in accordance with the appropriate safety regulations Any use that extends beyond the intended use or any other use of the clamping device is considered to be misuse and can cause dangerous situations WARNING Danger due to misuse Misuse of the clamping device can cause dan gerous situations Particularly refrain from the following uses of the clamping device Use in machines other than machine tools Use in machine tools with technical data oth er than that specified on the clamping device Claims of any type due to damage arising from non intended use are excluded Unintended and improper use of the Power Chuck is for example a f workpie
53. one 44 1543 278731 Fax 44 1543 478711 Mobile 44 7980212784 E mail nick peter hainbuch co uk Internet www hainbuch com Netherlands BIS Specials Brandenburg Industry Service Dongen BV Dreef 7 6996 BA Drempt Phone 31 313482566 Fax 31 313482569 E mail info bisspecials com Internet www bisspecials com France HAINBUCH France SNC Equipements de machines outils Zl Lons Perrigny 1600 Route de la Li me 39570 Lons le Saunier Phone 33 384876666 Fax 33 384876677 E mail info hainbuch fr Internet www hainbuch com Great Britain HAINBUCH UK Ltd WORKHOLDING TECHNOLOGY 6 Newmarket Keys Business Village Keys Park Road Hednesford Staffordshire WS12 2HA Phone 44 1543 278731 Fax 44 1543 478711 Mobile 44 7980212784 E mail nick peter hainbuch co uk Internet www hainbuch com Hungary GIMEX Hydraulik GmbH Selyem utca 1 9025 Gy r Phone 36 96525588 Fax 36 96427239 E mail info gimex hu Internet www gimex hut Italy HAINBUCH Italia srl Via Caduti di Nassiriya 5 22036 Cantu Co Phone 39 0313355351 Fax 39 031611570 E mail info hainbuchitalia it Internet www hainbuchitalia it Norway Onstad Maskin A S Chr H Blomsgt 13 3717 Skien Phone 47 35532373 74 Fax 47 35532375 E mail postmaster onstadmaskin no Internet www onstadmaskin no a HA NBUCH 65 Poland BIM Sp z o o Ztotniki ul Kobaltowa 6 62 002 Suchy Las Phone 48 616232041 Fax 48 616232040 E mai
54. orce by inadequate lubrica tion of the clamping element reception By lack of lubrication the maximum clamping force is smaller by about 20 This can lead to deviations of the workpiece m To prevent this lubricate the clamping device daily Special tools required m Grease gun a Grease Put the clamping head into the clamping device by using a suitable changing fixture Put the work piece into the clamping head clamp the clamping head 1 2 Lubricate the clamping element reception by the grease nipple till the grease leaks from the grease nipple WARNING Risk of injury Tools and gages that are thrown out of the ma chine can cause injury Remove all tools and gages from the working area of the machine before the machine is started up Risk of injury If the clamping pressure is too low clamped work piece may be thrown out If the clamping pressure is too high severe damages of the components of the clamping device may occur the throwing out of the work piece Before operation set the operation pressure back to operation level m he operating pressure should be checked and adjusted regularly 46 Q HAINBUCH 6 4 Inspections WARNING Slipping danger due to escaping hydraulic fluid Escaping sprayed out hydraulic oil can cause serious injuries Make sure that all o rings seals for the hy draulic pneumatic interfaces are available and in undamaged condition
55. ping device with sufficient work piece tension Do a pressure loss test and a measurement of clamping force 6 5 Control of the stroke position WARNING Crushing danger from moving parts Crushing danger from moving parts during controlling the stroke position Gaps caused while controlling the stroke posi tion can cause severe injury Only do the controlling of the stroke position with assembled changing parts Only run the machine in set up mode or jog mode Do not reach into moving parts or handle moving parts during operation Note the gap dimensions of moving parts Wearing of gloves PSA is required 6 6 Activities after production is concluded 1 Move the clamping device into unclamped position 2 Switch off the machine tool and safeguard it from being switched on again 3 Open the protective door or hood 4 Clean the clamping device and a possibly mounted adaptation clamping device and adapter of chips and production residues using a soft lint free cloth and oil them lightly 5 Close the protective door or hood 48 Q HAINBUCH 7 Disassembly subsequent storage disposal 7 1 Safety Safeguarding against restart If there is break in production that lasts longer than 3 days the clamping device must be disassembled and properly stored in accordance with the manufacturer s specifications see section Transport packaging storage Prior to disassembling m Put the m
56. ring the initial installation of the clamping device severe injuries may occur m The initial installation must be done only by qualified personnel a All screws remaining in the clamping must be tightened firmly m All tools and keys must be removed after in stallation WARNING Risk of injury due to stored energy The clamping device can be designed with disc springs These disc springs are under perma nent tension The release of the stored energy can cause injuries By loosening the corresponding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum m Particularly cautious approach is required For cleaning and maintenance disassemble the clamping device from the machine Always wear personal protective equipment 6 1 Pre consideration a Screws are tightened according to the size of the screw and the general torque To avoid axis parallel warpage under load and to get stiffness turn in the screws evenly To avoid precision error clean the screw joint sur faces and also the mating surfaces see Mainte nance The ex works wetting of the plate surfaces and the clamping element is only corrosion protection It s not functionally lubricated a he insertion of lubricant is provided only on the mechanical surfaces Pay attention to the instruc tions for lubricants in the chapter Maintenance c 36 HA NBUCH 6 2 Preparations a Avoid too
57. ta sheets and guidelines provided by the manufacturer of the cleaning agent for handling using the cleaners CAUTION Danger of injury due to loss of clamping force Fouling of the clamping device can cause the clamping device to lose considerable clamping force Always comply with the maintenance and cleaning intervals specified in this manual a In conjunction with the maintenance inter vals regularly check the maintenance status of the clamping device through clamping force measurements c 54 HA NBUCH gt gt NOTE Material damage due to use of the wrong cleaning agent cleaner Seals and clamping elements can be damaged due to use of the wrong seals and clamping el ements Do not use any solvents that contain ester or polar solvents for cleaning purposes Risk of injury Slipping while the lubricating with a grease gun can lead to severe cuts WARNING Risk of injury due to stored energy The clamping device can be designed with disc springs These disc springs are under perma nent tension The release of the stored energy can cause injuries By loosening the corresponding screws they have to be operated continuously alternately to reduce the clamping pressure to a mini mum m Particularly cautious approach is required For cleaning and maintenance disassemble the clamping device from the machine Always wear personal protective equipment a HA NBUCH 95
58. tened to correspond to the actual system load Contact the manufacturer if there are faults that can not be corrected by following the instructions below see the service address on the back of this operating instruction 9 1 Safety Trouble shooting The following always applies 1 For faults that pose a direct danger for personnel and or property immediately execute the emergen cy stop function of the machine 2 Determine the cause of the fault 3 If correction of the fault requires work in the danger zone put the machine in set up mode 4 Immediately inform the responsible parties at the installation site of the fault 5 Depending on the type of fault either have autho rized specialized personnel correct the fault or correct it yourself The trouble shooting table provided below lists personnel who are authorized to correct the fault 6 If there is a fault that was not caused by the clamp ing device the cause of the fault may be in the ma chine area See the operating manual for the ma chine in this regard a HA NBUCH 61 9 2 Trouble shooting table Fault Possible cause Fault correction Corrected by Clamping The change gap Rework the work piece Specialist head cannot between the clamping end stop be replaced head coupling and work piece end stop is insuf ficient Clamping Fouling between the Remove the clamping Specialist device does draw mechanism a
59. ved clamping force can vary due to the main tenance condition of the clamping device state of lubri cation and degree of contamination see chapter Maintenance The clamping force must be checked at regular inter vals This requires the use of static clamping force measuring devices CAUTION Damages due to excessive draw and com pressive force An excessive draw force and or compressive force may damage the clamping device The max draw force and compressive force may not be exceeded 16 Q HAINBUCH 2 8 Screws Moving parts 2 9 Functionality WARNING Danger of injury due to screws and stud screws being accelerated out of the device Screws and stud screws radially attached to the product can be accelerated out of the de vice and cause severe injuries At the product radially mounted screws and stud screws which were loosened for assem bly and maintenance must be re tightened with the correct tightening torque The tightening torque is given at the product itself near the screw or threaded pin and or given in chapter Bolt torque All screws or stud screws that are not marked with a tightening torque specification are tightened with the prescribed tightening torque and locked medium strength bonding in the factory and should only be unscrewed after consultation with the manufacturer If in doubt you must contact the manufacturer im mediately do determine the subsequent pro

Installation manual - HAINBUCH America WORKHOLDING

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