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Hainbuch hs dock Operating Instructions Manual

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Operating instructions
[incl. installation manual]
hs dock
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Summary of Contents for Hainbuch hs dock

  • Page 1 Operating instructions [incl. installation manual] hs dock...
  • Page 2 Translation of the original operating instructions Order hotli ne + 49 7144.907-333 Order hotline +49 7144.907-333...

  • Page 3: Table Of Contents

    Contents General ........................ 7 1.1 Information about this manual ..............7 1.2 Key to symbols .................... 7 1.3 Definition of terms ..................8 1.3.1 Release setting ................8 1.3.2 Complete clamping reserve ............8 1.4 Limitation of liability ..................9 1.5 Copyright .....................
  • Page 4 5.1 Use......................27 5.1.1 Use of the tandem version of the product ........27 5.2 Aid to selection of the hydraulic unit ............27 5.2.1 Nomenclature ................28 5.2.2 Clamping and release volume ............. 28 5.2.3 Clamping / release times ............. 29 Transport, packaging, storage ................
  • Page 5 Removal ......................66 10.1 Safe removal ..................... 66 10.2 Preparing the machine for removal ............67 10.3 Removal of the product ................68 10.3.1 Removal of the hydraulic port variant of the product to the underside of the product .............. 68 10.3.2 Removal of the hydraulic port variant of the product from the side...
  • Page 6 Directory of tables Technical data – version »without springs« ........21 Table 1: Technical data – version »with springs« ........21 Table 2: Nomenclature conversion supply pressure – actuating force ..23 Table 3: Table 4: Operating conditions ..............24 Table 5: Nomenclature for selection of hydraulic unit .........

  • Page 7: General

    General 1 General 1.1 Information about this manual This manual enables you to work safely and efficiently with the product. This manual is part of the product and must be kept in a lo- cation directly beside the product that is accessible to the personnel at all times.

  • Page 8: Definition Of Terms

    General Tips and recommenda- INFORMATION tions … highlights useful tips and recommendations as well as information for efficient and problem-free opera- tion. … refers to other documents relating to personal and general safety. Warning symbols may appear on the product or its compo- nents.

  • Page 9: Limitation Of Liability

    Infringements oblige the offending party to pay compensa- tion. Without restriction on further claims. 1.6 Scope of delivery The scope of delivery of this product includes:  hs dock actuating unit The operating instructions  Additionally needed and included as optional items in the scope of delivery: Clamping device ...

  • Page 10: Spare Parts And Accessories

    General 1.7 Spare parts and accessories WARNING Serious injuries can be caused by incorrect or de- fective spare parts! Always use genuine spare parts made by the orig-  inal manufacturer. WARNING Serious injuries can be caused by incorrect or...

  • Page 11: Safety

    Safety 2 Safety This section provides an overview of all the important safety aspects for optimum protection of personnel, and for safe and problem-free operation. 2.1 Responsibility of the operator The product is used in the industrial sector. The operator of the product is therefore governed by the provisions of Health &...
  • Page 12 Safety WARNING Serious injuries caused by unauthorized presence of unauthorized personnel in the working area!  Keep unauthorized people away from the working area. If in doubt, speak to people and direct them to  leave the working area.

  • Page 13: Intended Use

    Safety Trainees Trainees can only work on the machine under the supervi- sion and direction of staff skilled in the relevant specialist field. The only people admitted as personnel are those who can reasonably be expected to carry out their work to a reliable standard.
  • Page 14 Safety DANGER Serious injuries caused by misuse 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 ...

  • Page 15: Personal Protective Equipment

    Safety 2.4 Personal protective equipment During work, it is essential to wear personal protective equip- ment to minimize the health hazards. Always wear the required personal protective equipment when working on any given job. Always pay attention to any notices about personal protec- tive equipment displayed in the working area.

  • Page 16: Particular Hazards

    Safety Hard hat To protect against falling and projectile parts and materials. 2.5 Particular hazards The following section names residual risks resulting from the installation of the product in a machine tool. In all cases, the residual risks detected during a risk assessment of the ma- chine tool need to be named by the operator.

  • Page 17: Other Safety Instructions

    Safety Sharp-edged parts WARNING Serious cut injuries caused by sharp-edged parts and burrs!  All installation of individual parts must be per- formed by skilled staff from the relevant specialist field. Also wear the following items of personal protec- ...
  • Page 18 Safety WARNING Serious injuries caused by snagging body parts on the rotating machine spindle!  Never reach into the product while the machine spindle is still rotating. Before working on the product, ensure that the  machine spindle is unable to start up.

  • Page 19: Screws

    Safety NOTE Damage to materials caused by untightening the wrong screws!  Do not open the screws secured with sealing lac- quer. 2.7 Screws WARNING Serious injuries caused by radially installed screws being ejected centrifugally if installed in-...

  • Page 20: Environmental Protection

    Safety 2.9 Environmental protection NOTE Substantial damage to the environment can result from non-compliant handling or incorrect dis- posal of environmentally hazardous substances! If environmentally hazardous substances enter  the environment accidentally, take immediate re- medial action. If in doubt, notify the relevant municipal authori- ...

  • Page 21: Technical Data

    Technical data 3 Technical data 3.1 General information Version »without springs« XXS-4 / A-F Ø 139 x 62 18.5 Ø 230 x 62 Technical data – version »without springs« Table 1: Version »with springs« XXS-4 / Ø 139 x 62 18.7...

  • Page 22: Performance Values

    Technical data 3.2 Performance values NOTE Material damage to the products use and/or to the machine tool caused by exceeding the maximum performance values! Do not exceed the maximum performance values  [see »General information« chapter]. On all products used, do not exceed the lowest of ...

  • Page 23: Conversion Of Supply Pressure - Actuating Force

    ������ mum actuating force �� can be taken from the ���� ������ »General information« chapter. 3.5.3 Sample calculation Clamping head chuck hs dock size XXS-4 / A-F  Actuating force Actuating force to be set �� = 20����  ����...

  • Page 24: Supply Pressure Diagram - Actuating Force

    Technical data 3.5.4 Supply pressure diagram - actuating force Scan sample 1: At a supply pressure of 30 bar, the axial actuating force for size xXS-4 / A-F is 18 kN and 26 kN for size 5-7. Scan sample 2:...

  • Page 25: Layout And Function

    Layout and function 4 Layout and function 4.1 Overview and brief description Clamping device Actuating unit The actuating unit provides a support for clamping devices. The actuating unit was designed for stationary operation. The actuating unit is screwed to the machine table.

  • Page 26: Accessories Required

    Layout and function 4.2 Accessories required Clamping devices 4.2.1 The clamping device is secured to the product to adapt it to the machine tool. 4.3 Optional accessories The following optional accessories are available for different sizes of product.

  • Page 27: Use And Limits Of Use

    Use and limits of use 5 Use and limits of use 5.1 Use The product is there solely to support HAINBUCH clamping devices on chip-cutting machine tools. The product can only be used in conjunction with a suitable clamping device from HAINBUCH.

  • Page 28: Nomenclature

    0.0352 0.0319 Table 6: Clamping and release volumes Here is a sample calculation to explain the values. Example: Hs dock size XXS-4 / A-F  Stroke [release stroke] �� = 4.0����  Maximum axial actuating force �� = 35���� ...

  • Page 29: Clamping / Release Times

    Use and limits of use 5.2.3 Clamping / release times Refer to the following tables of clamping and release times for details of the hydraulic unit fitted. The volumetric flow rate of the hydraulic unit is a factor here.

  • Page 30: Transport, Packaging, Storage

    Transport, packaging, storage 6 Transport, packaging, storage 6.1 Safety, transport, packaging, storage 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 ...

  • Page 31: Symbols On The Packaging

    Transport, packaging, storage NOTE Damage to materials caused by falling parts if transported incorrectly!  Ensure that the product cannot roll away or fall. Place on a non-slip surface.  When using lifting gear, use appropriate load- ...

  • Page 32: Unpacking And Internal Transportation

    Transport, packaging, storage Initiate a complaint  INFORMATION Raise a complaint for every defect as soon as it is dis- covered. Compensation claims can only be enforced during the applicable complaint periods. 6.4 Unpacking and internal transportation The total weight of the product depends on its size.

  • Page 33: Storage

    Transport, packaging, storage NOTE Damage to the environment caused by improper disposal of packaging materials!  Dispose of packaging materials in an environ- mentally responsible manner. Pay attention to local disposal regulations and, if  necessary, appoint a specialist waste disposal company with this work.

  • Page 34: Installation

    Installation 7 Installation 7.1 Installation safety WARNING Serious injuries caused by unskilled staff during installation / removal! Installation and removal must be performed by  skilled staff from the relevant specialist field. WARNING Serious injuries can be caused if the machine tool starts up accidentally! Set the machine tool into set-up mode.

  • Page 35: Preliminary Remarks

    Installation WARNING Serious head injuries caused by bending into the working area of the machine!  Only ever bend into the working area of the ma- chine if there are no cutting tools or sharp objects in it, or if these are covered.

  • Page 36: Screw Tightening Torques

    Damage to materials caused by defective screw tightening torques!  To secure the product to the machine, pay attention to the values specified by HAINBUCH and by the machine manufacturer for screw tightening torques. If the machine manufacturer stipulates different values, you must consult HAINBUCH.

  • Page 37: Preparation Of The Machine For Installation

    Installation Tightening torque at screw quality [Nm] Thread designa- tion 10.9 12.9 Table 10: Screw tightening torques, metric control threads Aluminum components The following table contains the reduced screw tightening torques for securing aluminum components. Thread designa- Tightening torque...

  • Page 38: Installation Of The Product

    Installation 7.5 Installation of the product Expander Cap plug Cap plug seals Swivel joints Screw plugs D1 Screw plug seals Product Fixing screws on the product Transport thread on product Spacer [on tandem version] Clamping bracket Test surface, product face run-out...

  • Page 39: Preparation Of The Hydraulic Port Variant Of The Product On The Underside Of The Product

    Installation 7.5.2 Preparation of the hydraulic port variant of the product on the underside of the product The product is supplied in assembled condition. The following preparatory steps are needed to install the product. NOTE Damage to materials caused by lost / missing...
  • Page 40 Installation Remove the cap plugs and the cap plug seals from the product. INFORMATION After being installed in its intended bore, the expander must always be sealed using an appropriate device. Install the expanders. Order hotline +49 7144.907-333...
  • Page 41 Installation NOTE Damage to equipment caused by lost / missing seals during installation / removal of the screw plugs!  During installation / removal of the screw plugs, the screw plug seals must remain in the product. Unfasten and remove the screw plugs. Ensure while do- ing so that the screw plug seals remain in the product.

  • Page 42: Preparation Of The Product For Installation Of The Tandem Version

    Installation 7.5.4 Preparation of the product for installation of the tandem version For installation of the tandem version, the product is needed twice. The product is supplied in assembled condition. The following preparatory steps are needed to install product 1, installed on the machine table / the base plate.
  • Page 43 Installation If necessary, fit the mounting aid onto a vertically sus- pended spindle. DANGER Serious injuries caused by projectile workpieces when the hydraulic ports are connected up incor- rectly! The hydraulic connections on the machine / the ...
  • Page 44 Installation Screw in the product fixing screws and tighten them gen- tly. Unfasten and remove any lifting gear that may have been required. Remove the mounting aid on a vertically suspended spindle if one was used. Check the position of the product relative to the position of the test surface [ideally ≤...

  • Page 45: Installation Of The Hydraulic Port Variant Of The Product To The Side Of The Product - Secured Using Fixing Screws

    Installation If the face run-out is greater than the maximum permitted value: Remove the product. Clean the locating face and the mating faces of the ma- chine table / the baseplate and the product. If there is a burr or slight damage to the locating face of the product and the machine table / the baseplate, rub it down gently with an oil stone.
  • Page 46 Installation Fit the product to the machine table / the base plate. Screw in the product fixing screws and tighten them gen- tly. Unfasten and remove any lifting gear that may have been required. Remove the mounting aid on a vertically suspended spindle if one was used.
  • Page 47 Installation DANGER Serious injuries caused by projectile workpieces when the hydraulic ports are connected up incor- rectly!  The hydraulic connections on the machine / the baseplate and the product must be connected up correctly. The »Clamping« hydraulic ports on machine / ...
  • Page 48 Installation 12. Where required, install the clamping brackets needed on the product and the machine table. 13. Check face run-out on the test surface of the product [ideally ≤ 0.01 mm]. If the face run-out is greater than the maximum permitted value: Remove the product.

  • Page 49: Installation Of The Hydraulic Port Variant Of The Product To The Side Of The Product - Secured Using Clamping Brackets

    Installation 7.5.7 Installation of the hydraulic port variant of the product to the side of the product - secured using clamping brackets Depressurize the hydraulic unit. Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle.
  • Page 50 Installation DANGER Serious injuries caused by projectile workpieces when the hydraulic ports are connected up incor- rectly!  The hydraulic connections on the machine / the baseplate and the product must be connected up correctly. The »Clamping« hydraulic ports on machine / ...

  • Page 51: Installation Of The Tandem Version

    Installation Clean the locating face and the mating faces of the ma- chine table / the baseplate and the product. If there is a burr or slight damage to the locating face of the product and the machine table / the baseplate, rub it down gently with an oil stone.
  • Page 52 Installation INFORMATION Before screwing on product 2, product 1 must still be in its rear limit position. Screw product 2 firmly home on product 1. Turn back product 2 until the hole patterns on products 2 and 1 match up.
  • Page 53 Installation 10. Screw the product fixing screws into product 2 and tighten to the specified tightening torque [see »Screw tightening torques« chapter]. 11. Unfasten and remove any lifting gear that may have been required. 12. Remove the mounting aid on a vertically suspended spindle if one was used.

  • Page 54: Installation Of The Product Together With The Installed Clamping Device

    Installation 15. Check the position of product 2 relative to the position of the product test surface [ideally ≤ 0.01 mm]. Whenever the face run-out and/or the position is greater than the maximum permitted value: Remove product 2.
  • Page 55 Installation Install the product together with the clamping device to the machine table / the base plate [see »Installation of the hydraulic port variant of the product to the underside of the product« chapter, or the »Installation of the later- ally mounted hydraulic port variant of the product- se- cured by means of fixing screws«...

  • Page 56: Use

    8 Use 8.1 Use-related safety WARNING Serious injuries caused by unskilled personnel during the installation / removal of the clamping device! Installation / removal of the clamping device must  be performed by skilled specialists from the rele- vant field.
  • Page 57 WARNING Serious crushing injuries caused by inappropriate machine movement during installation / removal of the clamping device!  Machine movements are only permitted in set-up mode during installation and removal of the clamping device. Never reach into the gap.

  • Page 58: Installation Of The Clamping Device

    NOTE Damage to materials caused by contaminated / unprocessed cooling lubricants!  For the product to function properly, in particular for internal flushing with cooling lubricants and/or when using tools with internal flushing, ensure that the cooling lubricant is cleaned / processed, and that it contains no particles measuring >100...
  • Page 59 If necessary, fit the mounting aid onto a vertically sus- pended spindle. Move the actuating unit into its front limit stop position. INFORMATION If lifting gear needs to be used, rotate the actuating unit and machine spindle to tighten / untighten the clamping device.
  • Page 60 Screw the fixing screws into the clamping device and tighten them to their specified tightening torque [see the »Screw tightening torques« chapter]. Unfasten and remove any lifting gear that may have been required. 10. Remove the mounting aid on a vertically suspended spindle if one was used.

  • Page 61: Removal Of The Clamping Device

    8.3 Removal of the clamping device Clamping device Fixing screws clamping device If a break in production occurs that lasts for more than three days, the clamping device must be removed and stored safely in accordance with the manufacturer's stipulations [see operating instructions for the clamping device].
  • Page 62 Unfasten and remove the fixing screws from the clamp- ing device. Move the actuating unit into its front limit stop position. INFORMATION If lifting gear needs to be used, rotate the actuating unit and machine spindle to tighten / untighten the clamping device.

  • Page 63: Suitable Fluid

    8.4 Suitable fluid The oil grades to be used are described in ISO 3448 Type HM 32. NOTE Damage to components caused by fluids without sufficient levels of corrosion inhibitor! The components made of steel materials must be ...

  • Page 64: Tests

    8.5 Tests NOTE Serious damage to, or destruction of, the machine tool and the workpiece caused by damaged, in- complete or incorrectly installed products! Only install undamaged and complete products  properly. If in doubt, contact the manufacturer.

  • Page 65: Activities After End Of Production

    Activities after end of production 9 Activities after end of production Switch off machine tool and secure it to prevent it from being switched back on. 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.

  • Page 66: Removal

    Removal 10 Removal If a break in production occurs that lasts for more than three days, the product must be removed and stored safely in ac- cordance with manufacturer's stipulations [see »Transport, packaging, storage« chapter]. 10.1 Safe removal...

  • Page 67: Preparing The Machine For Removal

    Removal WARNING Serious crushing injuries caused by improper ma- chine movement during installation or removal!  Machine movements are only permitted in set-up mode during installation and removal. Never reach into a gap.  Pay attention to the gap dimensions of moving ...

  • Page 68: Removal Of The Product

    Removal 10.3 Removal of the product Expander Cap plug Cap plug seals Swivel joints Screw plugs D1 Screw plug seals Product Fixing screws on the product Transport thread on product Spacer [on tandem version] Clamping bracket Test surface, product face run-out...
  • Page 69 Removal Unfasten and remove the fixing screws on the product. WARNING Serious injuries can be caused by escaping media when seals and damaged / missing! Replace missing or damaged sealing elements.   Ensure that the sealing elements do not fall out or get damaged during installation / removal, and apply a thin coat of grease if necessary.
  • Page 70 Removal NOTE Damage to materials caused by lost / missing seals during installation/removal of the cap plugs!  During installation/removal of the cap plugs, the cap plug seals must remain in the product. Install the cap plug in the product.

  • Page 71: Removal Of The Hydraulic Port Variant Of The Product From The Side Of The Product - Secured Using Fixing Screws

    Removal 10.3.2 Removal of the hydraulic port variant of the product from the side of the product - secured using fixing screws Move the product into its rear limit stop position. Depressurize the hydraulic unit. Attach any lifting gear that may be required.
  • Page 72 Removal Unfasten and remove the fixing screws on the product. Remove the product from the machine table / the baseplate. Order hotline +49 7144.907-333...

  • Page 73: Removal Of The Hydraulic Port Variant Of The Product From The Side Of The Product - Secured Using Clamping Brackets

    Removal 10.3.3 Removal of the hydraulic port variant of the product from the side of the product - secured using clamping brackets Move the product into its rear limit stop position. Depressurize the hydraulic unit. Attach any lifting gear that may be required.

  • Page 74: Removal Of The Tandem Version

    Removal Remove the product from the machine table. 10.3.4 Removal of the tandem version Move the product into its rear limit stop position. Depressurize the hydraulic unit. Attach any lifting gear that may be required to product 2.
  • Page 75 Removal Unfasten and remove the fixing screws from product 2. Unscrew and remove product 2 from product 1. Order hotline +49 7144.907-333...

  • Page 76: Removal Of The Product Together With The Installed Clamping Device

    Removal Remove the spacer from product 1. Remove product 1 [see »Removal of the hydraulic port variant of the product from the underside of the product« chapter, or the »Removal of the laterally mounted hy- draulic port variant of the product« chapter as applica- ble].

  • Page 77: Maintenance

    Maintenance 11 Maintenance 11.1 Maintenance safety WARNING Serious injuries caused by parts being ejected centrifugally after a loss of clamping power! Maintain the maintenance and cleaning intervals  of the product at all times. It is essential to check the maintenance status of ...

  • Page 78: Scheduled Maintenance

    Maintenance 11.3 Scheduled maintenance Housing Housing fixing screws Housing gasket [gasket kit] Cap plug Cap plug seals Cover C1 Cover fixing screws C2 Cover gasket [gasket kit] Springs [on version »with springs«] Piston Gasket 1 piston [gasket kit] Gasket 2 piston [gasket kit] Shim 1 [on version »with springs«]...
  • Page 79 Maintenance NOTE Damage to seals caused by the wrong solvent!  To clean the product, never use a solvent that at- tacks and damages the sealing elements in- stalled. Those installed sealing elements can be made of NBR, Viton and PUR materials.
  • Page 80 Maintenance Assemble the product in accordance with the exploded drawing and lubricate during assembly [see »Lubricating the product« chapter]. Pay attention to the following dur- ing assembly: Replace worn or damaged fixing screws.  Tighten all fixing screws to the specified tightening ...

  • Page 81: Cleaning

    Maintenance 11.4 Cleaning 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-...

  • Page 82: Lubricating The Product

    For this, the following lubricants are recommended: Special grease GL 261 [see the HAINBUCH product catalogue] NOTE Malfunction of the product due to a combination of different greases! Never mix different greases with one another.

  • Page 83: Disposal

    Disposal 12 Disposal If no agreement exists for return or disposal, send disman- tled components off for recycling. CAUTION Injuries caused by the accidental escape of media! Open the pressure relief screws and drain off the  remaining media.

  • Page 84: Faults

    Faults 13 Faults The following chapter describes possible causes for faults, and the work involved in remedial action. If multiple faults occur, shorten the maintenance intervals in accordance with actual load levels. Contact the manufacturer if faults occur that cannot be rem- edied by following these instructions [see »Contact«...

  • Page 85: Fault Table

    Faults 13.2 Fault table Fault Possible cause Remedial action Remedied by Remove and clean the clamping Dirt in the parts in device and, if necessary, disas- the power flow semble and clean the actuating Skilled special- unit Incorrect clamping...

  • Page 86: Commissioning After A Fault Has Been Remedied

    Faults Fault Possible cause Remedial action Remedied by Axial run-out error Check axial run-out of the clamp- on the actuating ing device and the actuating unit unit and correct if necessary Geometry devia- Skilled special- tion on the work-...

  • Page 87: Annex

    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 with the product and with this manual.
  • Page 88 Annex Order hotline +49 7144.907-333...
  • Page 89 Annex Order hotline +49 7144.907-333...
  • Page 90 Index directory Lubricants ........20, 82 Accessories, needed Clamping devices ......26 Maintenance schedule ...... 77 Accessories, optional Misuse ..........14 Multiple clamping plate ....26 Spacer .......... 26 Operating conditions ......24 Balancing quality ....... 22 Packaging ......... 32 Brief description ........
  • Page 91 Suitable fluid ........63 Type designation ....... 24 Symbols on the packaging ....31 Unpacking ......... 32 Technical data........21 Use ............ 27 Tests ..........64 Transport inspection ......31 Warranty ..........10 Transportation, internal ..... 32 Order hotline +49 7144.907-333...
  • Page 92 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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