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Hainbuch TOPlus mini Operating Instructions Manual

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Operating instructions
[incl. installation manual]
TOPlus mini / TOPlus premium pull-back
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Summary of Contents for Hainbuch TOPlus mini

  • Page 1 Operating instructions [incl. installation manual] TOPlus mini / TOPlus premium pull-back...
  • Page 2 TOPlus mini / TOPlus premium pull-back Translation of the original operating instructions Order hotli ne + 49 7144.907-333 Order hotline +49 7144.907-333...

  • Page 3: Table Of Contents

    TOPlus mini / TOPlus premium pull-back Contents General ......................... 8 1.1 Information about this manual ..............8 1.2 Key to symbols ..................... 8 1.3 Definition of terms ..................9 1.3.1 Release setting ................9 1.3.2 Complete clamping reserve ............9 1.4 Limitation of liability ..................
  • Page 4 TOPlus mini / TOPlus premium pull-back 4.2.3 Clamping head ................31 4.2.4 Workpiece end-stop ..............31 4.2.5 Test kit ..................31 4.3 Optional accessories .................. 31 4.3.1 Jaw module .................. 31 4.3.2 Magnet module ................32 4.3.3 MANDO Adapt ................32 4.3.4...
  • Page 5 TOPlus mini / TOPlus premium pull-back 7.5 Installation of the product ................63 7.5.1 Compatibility check ............... 64 7.5.2 Preparation of the product ............64 7.5.3 Installation of the drawtube adapter ..........66 7.5.4 Installation of a spindle flange that cannot be aligned ....67 7.5.5...
  • Page 6 TOPlus mini / TOPlus premium pull-back 11.3 Cleaning ....................108 11.4 Visual inspection ..................111 11.5 Lubricating the product ................111 11.6 Use of lubricants ..................112 Disposal ......................113 Faults ........................ 114 13.1 Procedure with faults................114 13.2 Fault table ....................114 13.3 Commissioning after a fault has been remedied ........
  • Page 7 TOPlus mini / TOPlus premium pull-back Directory of tables Table 1: Technical data ................23 Table 2: Operating conditions ..............29 Table 3: Nomenclature application limits ............. 37 Table 4: Maximum workpiece mass ............38 Table 5: Scatter widths of clamping force ............ 42 Table 6: Contact forms / scenarios ..............

  • Page 8: General

    TOPlus mini / TOPlus premium pull-back 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 9: Definition Of Terms

    TOPlus mini / TOPlus premium pull-back 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 10: Limitation Of Liability

    TOPlus mini / TOPlus premium pull-back General 1.4 Limitation of liability All details and notices in this manual were compiled with due reference to applicable standards and specifications, state- of-the-art technology and our many years of expertise and experience. The manufacturer accepts no liability for damage arising...

  • Page 11: Spare Parts And Accessories

    TOPlus mini / TOPlus premium pull-back 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 de- fective clamping elements! ...

  • Page 12: Safety

    No modifications must be made to the product. The operator is wholly and solely responsible for any resultant personal injury and/or damage to materials. Excepted from this are changing parts that HAINBUCH ap- proved explicitly for autonomous machining, but specified limits must never be exceeded.

  • Page 13: Personnel Requirements

    TOPlus mini / TOPlus premium pull-back Safety 2.2 Personnel requirements WARNING Serious injuries caused by incorrect handling of the product by insufficiently skilled or trained per- sonnel! All activities must be performed by skilled staff  from the relevant specialist field.

  • Page 14: Intended Use

    TOPlus mini / TOPlus premium pull-back Safety Electricians Electricians are trained in the specific task profile for which they are employed, and are familiar with the relevant stand- ards and legislative provisions. Due to their vocational training and experience, electricians can work on electrical systems and can independently iden- tify and avoid potential hazards.
  • Page 15 TOPlus mini / TOPlus premium pull-back 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«...

  • Page 16: Personal Protective Equipment

    TOPlus mini / TOPlus premium pull-back Safety NOTE Damage to materials caused by incorrect use of the product!  Only in a CE-compliant machine tool with a sepa- rating set of guards. Only use for the type of use indicated [see »Use«...

  • Page 17: Particular Hazards

    TOPlus mini / TOPlus premium pull-back Safety Safety footwear To protect the wearer from any heavy items that may fall, and from losing their footing on slippery ground. Protective goggles To protect the eyes from projectile parts and liquid splashes.
  • Page 18 TOPlus mini / TOPlus premium pull-back Safety Moving parts WARNING Serious injuries caused by touching rotating and/or moving parts!  Do not open guards while the system is operating. During operation, do not reach for rotating and/or  moving parts.

  • Page 19: Cfrp Products

    TOPlus mini / TOPlus premium pull-back 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 20 TOPlus mini / TOPlus premium pull-back Safety 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 21: Screws

    TOPlus mini / TOPlus premium pull-back Safety CAUTION Cut injuries caused by sharp edges and burrs re- sulting from wear and/or repeated rework!  Remove sharp edges and burrs. If necessary, replace worn components with gen-  uine parts made by the manufacturer.

  • Page 22: Functionality

    TOPlus mini / TOPlus premium pull-back Safety 2.9 Functionality WARNING Serious injuries caused by severe contamination of the product! Always comply with the cleaning instructions and  intervals [see »Cleaning« chapter]. 2.10 Environmental protection NOTE Substantial damage to the environment can result...

  • Page 23: Technical Data

    TOPlus mini / TOPlus premium pull-back Technical data 3 Technical data 3.1 General information 4.1- 2.0- Ø 114.0-128.0 4-26 2.0 1.0 0.6 0.6 10000 16 x 100.0-190.0 6.0- 2.5- Ø 132.0-163.0 4-40 2.0 2.0 0.5 0.8 7000 103 4/1 10.5 x 106.0-190.0...

  • Page 24: Balancing Quality

    TOPlus mini / TOPlus premium pull-back Technical data INFORMATION Details of maximum performance values can be found on each product. If, due to abrasive wear, those performance values are no long legible, refer to the operating instructions. The achievable actuation forces may vary as a result of the maintenance status [lubrication status and level of contami- nation] of the product [see »Maintenance schedule«...

  • Page 25: Speed

    TOPlus mini / TOPlus premium pull-back Technical data 3.4 Speed The product is authorized for rotational operation. The maximum speed when using standard clamping heads is written on the product [maximum speed, see »General in- formation« chapter]. If special clamping heads are used, this reduces the permitted maximum speed [see »Permitted...

  • Page 26: Size 26

    TOPlus mini / TOPlus premium pull-back Technical data 3.5.1 Size 26 Scan sample: At an axial actuation force �� of 12.5 kN, the radial ���� clamping force �� is in a ������ range of between 13 kN and 31 kN.

  • Page 27: Size 52

    TOPlus mini / TOPlus premium pull-back Technical data 3.5.3 Size 52 Sample scan: At an axial actuation force �� of 25 kN, the radial �� �� clamping force �� is in a ������ range of between 31 kN and 67.7 kN.

  • Page 28: Size 80

    TOPlus mini / TOPlus premium pull-back Technical data 3.5.5 Size 80 Sample scan: At an axial actuation force of 25 kN, the radial clamping force is in a range of between 33 kN and 65.7 kN. lower limit value upper limit value 3.5.6 Size 100...

  • Page 29: Operating Conditions

    TOPlus mini / TOPlus premium pull-back Technical data 3.6 Operating conditions Indication Value Unit Ambient temperature range 15 - 65 °C ≤ 80 Workpiece temperature °C ≤ 80 Humidity Table 2: Operating conditions 3.7 Type designation The type designation is on the product and it includes the...

  • Page 30: Layout And Function

    TOPlus mini / TOPlus premium pull-back Layout and function 4 Layout and function 4.1 Overview and brief description Spindle flange Base end-stop Coupling Functional unit Clamping head [clamping element] The clamping device can be used as a through-chuck for machining bar stock and also as an end-stop chuck.

  • Page 31: Accessories Required

    TOPlus mini / TOPlus premium pull-back Layout and function 4.2 Accessories required 4.2.1 Spindle flange The spindle flange helps to adapt the clamping device to suit the machine tool. Depending on the scope of delivery, the spindle flange can either be supplied with the unit or provided by the customer.

  • Page 32: Magnet Module

    TOPlus mini / TOPlus premium pull-back Layout and function 4.3.2 Magnet module The magnet module is an adaptation clamping device for ferromagnetic materials for grinding or turning. 4.3.3 MANDO Adapt Through adaptation of the MANDO Adapt, internal clamp- ing of the workpiece can be achieved.

  • Page 33: Swarf Baffle Ring

    TOPlus mini / TOPlus premium pull-back Layout and function 4.3.6 Swarf baffle ring To use the clamping device as a through-chuck, the exist- ing base end-stop can be replaced by a swarf baffle ring. 4.3.7 Base end-stop with swarf baffle ring To use the clamping device as a limit stop chuck, the exist- ing base end-stop can be replaced with a swarf baffle ring.

  • Page 34: Special Aids

    TOPlus mini / TOPlus premium pull-back Layout and function 4.4 Special aids 4.4.1 Manual changing fixture The pins on the changing fixture are installed in the chang- ing bores in the clamping head. The changing fixture is ac- tuated by manual force. Depending on size, the changing fixture may be designed for single-handed or for two- handed actuation.

  • Page 35: Use And Limits Of Use

    TOPlus mini / TOPlus premium pull-back Use and limits of use 5 Use and limits of use 5.1 Use The product is a clamping device that may only be used to clamp a rotationally symmetrical workpiece to enable it to be machined.
  • Page 36 TOPlus mini / TOPlus premium pull-back Use and limits of use Brief des- Unit Explanation ignation Feed / rotational movement of turning op- �� ���� eration Feed / cutting-drilling operation �� ���� Axial actuating force ���� �� �� Feed force of drilling operation ��...

  • Page 37: Nomenclature Application Limits

    TOPlus mini / TOPlus premium pull-back Use and limits of use Brief des- Unit Explanation ignation �� ���� Total clamping length ���� �� �� ���� Workpiece length �� �� ���� Clamping head, front-end length �� Distance between »Machining point - ��...

  • Page 38: First Limit [Workpiece Length]

    TOPlus mini / TOPlus premium pull-back Use and limits of use The graphic in the sketch below shows the forces and mo- ments used in the following sample calculations: �� [ �� ] = �� [ ���� ] ∗ 9.81 [ ��...

  • Page 39: Third Limit [Clamping Length]

    [when using clamping heads with WS Workpiece ���� F serrations] If HAINBUCH uses a different and shorter clamping length in this clamping situation drawing, this will have been checked against the specific parameters for this type of ap- plication and found to be sufficient.
  • Page 40 TOPlus mini / TOPlus premium pull-back Use and limits of use the centrifugal forces caused by the weight of the clamp- ing head d) where necessary, tailstock forces Principles for the forces exerted externally WARNING Serious injuries caused by failure to comply with...

  • Page 41: Scatter Widths Of Clamping Force

    TOPlus mini / TOPlus premium pull-back Use and limits of use 5.2.5.1 Further to Principle 1: �� ≥ �� ������ ������ ������ Determining the required clamping force The following equations are used to determine the required clamping force �� at rotational speed.

  • Page 42: Contact Forms / Scenarios

    TOPlus mini / TOPlus premium pull-back Use and limits of use Radial clamp- Clamping Size of the Clamping ing reserve in force scatter force scatter clamping width factor �� the diameter width factor �� head chuck [mm] »verified« If as a consequence of dimensionally accurate workpieces, only...

  • Page 43: Specific Cutting Forces

    TOPlus mini / TOPlus premium pull-back Use and limits of use Contact form Machining Interfer- Contact factor �� conditions ence fit Edge fit and sad- dle fit Smooth clamping head Wet* / MMS** Clamping head with longitudinal and trans- verse grooves...
  • Page 44 TOPlus mini / TOPlus premium pull-back Use and limits of use Specific cut- Specific cut- Specific cut- Workpiece materials ting forces ting forces ting forces �� �� �� �� ] at �� = �� ] at �� = �� ] at �� = ��...

  • Page 45: Friction Coefficient For Steel Workpieces

    TOPlus mini / TOPlus premium pull-back Use and limits of use Friction coefficients With workpieces made from a material other than steel, mul- tiply these values by the correction values listed below. When the workpiece is made of hardened steel, the values for smooth clamping heads always apply to ground work- piece surfaces.
  • Page 46 TOPlus mini / TOPlus premium pull-back Use and limits of use Clamping head mass �� [ ���� ] and distance of mass center of gravity of clamping head segments to the rotational [ �� ] axis �� �� Distance to mass...
  • Page 47 TOPlus mini / TOPlus premium pull-back Use and limits of use �� ∗�� +2∗�� �� +�� = 1.3 ∗ √ ( �� �� �� �� �� �� ���� �� ∗�� �� ���� �� �� Turning [inner and outer] �� = 1.3 ∗ ��...

  • Page 48: Maximum Permitted Tailstock Force

    TOPlus mini / TOPlus premium pull-back Use and limits of use whereby, although based upon components �� = 0 and ���� �� = 0, a simplified form [just transverse force] can be used: ���� �� = �� ∗ �� ∗ 1.6 ∗ ��...

  • Page 49: Maximum Permitted Cutting Force

    TOPlus mini / TOPlus premium pull-back Use and limits of use 5.2.5.3 Further to Principle 3: �� ≤ �� �� �� ������ The cutting force for turning operations can achieve very high levels, especially if the workpiece does not protrude far, although machining involves no slip or leverage forces that could displace the workpiece.

  • Page 50: Maximum Permitted Transverse Force

    TOPlus mini / TOPlus premium pull-back Use and limits of use Size of the clamp- Up to total chuck �� [ �� ] �� ������ length �� [ ���� ] ing head chuck < 120 1800 < 125 3600 < 125 4200 <...

  • Page 51: Sample Calculation

    TOPlus mini / TOPlus premium pull-back Use and limits of use On extended chuck versions, the ratio of maximum permitted torque to chuck lengths needs to be reduced. For example, size 26 with �� = 150���� 120���� ∗ 90���� = 72����...
  • Page 52 TOPlus mini / TOPlus premium pull-back Use and limits of use INFORMATION �� from Table 5 �� from Table 7 �� from Table 8 [interpolated for �� = 0.25����] �� �� , �� from Table 9 �� �� �� , �� from Table 10 ��...
  • Page 53 TOPlus mini / TOPlus premium pull-back Use and limits of use �� �� +0.63)∗ √ (�� + ( �� ∗�� ) (0.27∗ ∗�� +�� ∗�� �� �� �� �� �� �� ���� �� ���� 0.5∗(0.67∗(1.9∗�� −4.5����)+�� ∗�� ���� �� ����...

  • Page 54: Permitted Maximum Speed

    TOPlus mini / TOPlus premium pull-back Use and limits of use the clamping force diagram [see »Clamping force diagram« chapter]. When full axial force is exerted on the clamping head chuck with �� = 45����, nominal radial 120���� forces are being ����...

  • Page 55: Transport, Packaging, Storage

    TOPlus mini / TOPlus premium pull-back 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 56: Symbols On The Packaging

    TOPlus mini / TOPlus premium pull-back 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 57: Unpacking And Internal Transportation

    TOPlus mini / TOPlus premium pull-back Transport, packaging, storage 6.4 Unpacking and internal transportation The total weight of the product depends on its size. Depending on the weight involved, it may be necessary to use lifting gear to lift the product or its components out of the packaging safely, to transport them and to position and in- stall them in the machine tool or on the machine table.

  • Page 58: Storage

    TOPlus mini / TOPlus premium pull-back Transport, packaging, storage 6.6 Storage INFORMATION The packaged items may display information relating to storage and readmission to storage that extend be- yond the scope of these requirements. Pay attention to these notices. Store packaged items under the following conditions: Safe for storage.

  • Page 59: Installation

    TOPlus mini / TOPlus premium pull-back 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 60 TOPlus mini / TOPlus premium pull-back 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 61: Preliminary Remarks

    TOPlus mini / TOPlus premium pull-back Installation 7.2 Preliminary remarks In accordance with their thread size and strength class,  screws must be tightened crosswise to the specified tightening torque [see »Screw tightening torques« chap- ter]. When tightening the screws, do so evenly to prevent any distortion under load.

  • Page 62: Screw Tightening Torques, Metric Control Threads

    TOPlus mini / TOPlus premium pull-back Installation Metric control threads The following table contains the guide values in Nm for screw tightening torques for achieving the highest permitted pre- load for metric control threads. Total friction coefficient �� = 0.12 ...

  • Page 63: Preparation Of The Machine For Installation

    TOPlus mini / TOPlus premium pull-back Installation 7.4 Preparation of the machine for installation Set the machine into set-up mode. INFORMATION The minimum operating pressure is reached when the drawtube can still just be moved without triggering an error message.

  • Page 64: Compatibility Check

    TOPlus mini / TOPlus premium pull-back Installation 7.5.1 Compatibility check Check the compatibility of the product and the connection point of the machine. For this, check that the connection point and the product share the same adaptation geometry. Also check if the actu- ating element / coupling element is suitable.
  • Page 65 TOPlus mini / TOPlus premium pull-back Installation Unfasten and remove the functional unit fixing screws with the screwdriver bit with tip guide. INFORMATION To install the functional unit on the machine, you need to know if this product can or cannot be aligned.

  • Page 66: Installation Of The Drawtube Adapter

    TOPlus mini / TOPlus premium pull-back Installation 7.5.3 Installation of the drawtube adapter INFORMATION Depending on the geometry of the drawtube adapter, it must be installed either on the machine drawtube or in the functional unit. Screw the drawtube adapter into the functional unit us- ing its thread or screw it to the machine drawtube and tighten it down.

  • Page 67: Installation Of A Spindle Flange That Cannot Be Aligned

    TOPlus mini / TOPlus premium pull-back Installation 7.5.4 Installation of a spindle flange that cannot be aligned Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning.
  • Page 68 TOPlus mini / TOPlus premium pull-back Installation 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 face run-out on the test surface of the spindle flange [ideally ≤...

  • Page 69: Installation Of A Spindle Flange That Can Be Aligned

    TOPlus mini / TOPlus premium pull-back Installation 7.5.5 Installation of a spindle flange that can be aligned Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. INFORMATION The positioning block on the machine spindle and the positioning bore in the spindle flange can be used for positioning.
  • Page 70 TOPlus mini / TOPlus premium pull-back Installation 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 face run-out on the test surface of the spindle flange [ideally ≤...

  • Page 71: Installation Of The Functional Unit Of An Alignable Clamping Device

    TOPlus mini / TOPlus premium pull-back Installation 7.5.6 Installation of the functional unit of an alignable clamping device Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. Move the machine drawtube to the front limit stop.
  • Page 72 TOPlus mini / TOPlus premium pull-back Installation WARNING Serious injuries caused by incorrectly installed clamping screws being ejected centrifugally! If the bores for the fixing screws in the spindle  flange are not fully covered by the functional unit, the clamping screws must always be located be- tween the bores for the fixing screws in the spin- dle flange.
  • Page 73 TOPlus mini / TOPlus premium pull-back Installation Screw in the functional unit fixing screws with the screw- driver bit with tip guide and tighten them gently. 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 74: Installation Of The Functional Unit Of A Non-Alignable Clamping Device

    TOPlus mini / TOPlus premium pull-back Installation Whenever the face run-out is greater than the maximum per- mitted value: 13. Remove the functional unit. 14. Clean the locating face and the mating faces of the spin- dle flange and the functional unit.
  • Page 75 TOPlus mini / TOPlus premium pull-back Installation Screw the functional unit firmly home on the machine drawtube. WARNING Serious injuries caused by incorrectly installed clamping screws being ejected centrifugally! If the bores for the fixing screws in the spindle ...
  • Page 76 TOPlus mini / TOPlus premium pull-back Installation Screw in the functional unit fixing screws with the screw- driver bit with tip guide and tighten them to the specified tightening torque [see »Screw tightening torques« chap- ter]. Unfasten and remove any lifting gear that may have been required.

  • Page 77: Installation Of The Clamping Element

    TOPlus mini / TOPlus premium pull-back Installation 7.6 Installation of the clamping element Clamping head [clamping element] INFORMATION Before installing the clamping element, install the changing part if necessary, otherwise it can no longer be installed. Special aids needed: Changing fixture ...
  • Page 78 TOPlus mini / TOPlus premium pull-back Installation WARNING Serious crushing injuries caused by reaching into the coupling / slot area in the clamping head or into the changing fixture! During actuation, never reach into the coupling /  slot area in the clamping head or into the chang- ing fixture.

  • Page 79: Installation Of The Changing Parts

    TOPlus mini / TOPlus premium pull-back Installation 7.7 Installation of the changing parts Changing part variant direct screw connection Changing part variant x-times axial screw connection Fixing screws changing part variant x-times axial screw connec- tion Changing part variant x-times axial screw connection bayonet...

  • Page 80: Installation Of The Variant, Screwed Directly

    TOPlus mini / TOPlus premium pull-back Installation 7.7.1 Installation of the variant, screwed directly Screw the changing part into the product using its thread, and tighten it down. 7.7.2 Installation of the variant x-times with axial screw connection Place the changing part onto the product.

  • Page 81: Installation Of The Variant X-Times With Bayonet Axial Screw Connection

    TOPlus mini / TOPlus premium pull-back Installation Screw in the changing part fixing screws on the chang- ing part and tighten to the specified tightening torque [see »Screw tightening torques« chapter]. 7.7.3 Installation of the variant x-times with bayonet axial screw connection...
  • Page 82 TOPlus mini / TOPlus premium pull-back Installation Twist the changing part until firmly home. Screw in the changing part fixing screws and tighten to the specified tightening torque [see »Screw tightening torques« chapter]. Order hotline +49 7144.907-333...

  • Page 83: Installation Of The Central Variant With Axial Screw Connection

    TOPlus mini / TOPlus premium pull-back Installation 7.7.4 Installation of the central variant with axial screw connection Place the changing part into the product. Screw in the changing part fixing screw and tighten it to the specified tightening torque [see »Screw tightening torques«...

  • Page 84: Installation Of The Radially Clamped Variant

    TOPlus mini / TOPlus premium pull-back Installation 7.7.5 Installation of the radially clamped variant INFORMATION To install / remove the changing part in / from the prod- uct, it may be necessary to use a grab handle or an appropriate auxiliary tool.
  • Page 85 TOPlus mini / TOPlus premium pull-back Installation Screw in the clamping screws on the changing part and tighten to the specified tightening torque [see Nomen- clature]. Unfasten and remove the grab handle if used, or the auxiliary tool. Order hotline +49 7144.907-333...

  • Page 86: Aligning The Clamping Device With The Test Specimen

    TOPlus mini / TOPlus premium pull-back Installation 7.8 Aligning the clamping device with the test specimen INFORMATION When using a TOPlus premium clamping tool, the fol- lowing steps must be performed using the test kit and the clamping device should ideally be aligned to ≤...

  • Page 87: Commissioning

    TOPlus mini / TOPlus premium pull-back Commissioning 8 Commissioning For commissioning purposes, set the operating pressure to the permitted, established machining value. The machine tool must not start up until full operating pres- sure has built up. 8.1 Commissioning safety...
  • Page 88 TOPlus mini / TOPlus premium pull-back Commissioning NOTE Damage to components caused by cooling lubri- cants with sufficient levels of corrosion inhibitor!  The components made of steel materials must be protected before the usual oxidation process. Only ever use cooling lubricants with sufficient ...

  • Page 89: Checking The Total Stroke

    TOPlus mini / TOPlus premium pull-back Commissioning 8.2 Checking the total stroke WARNING Serious crushing injuries caused by moving parts when stroke positions are being tested! Set the machine into set-up mode.  Reduce the operating pressure to a minimum.

  • Page 90: Workpiece

    TOPlus mini / TOPlus premium pull-back Commissioning Pay attention to the level of actuating force established  to enable the workpiece to be clamped with sufficient clamping force. Do not exceed the maximum actuating force indicated  product. Always take the lowest value of all actuating forces indi- cated for combined products.

  • Page 91: Procedure After A Collision

    TOPlus mini / TOPlus premium pull-back Commissioning 8.5 Procedure after a collision In the event of a collision, the product and its components must be checked for cracks and damage before being used again. For this, remove the product from the machine [see »Re- moval of the product«...

  • Page 92: Activities After End Of Production

    TOPlus mini / TOPlus premium pull-back Activities after end of production 9 Activities after end of production Move product into release position. Switch off machine tool and secure it to prevent it from being switched back on. Open the safety door / hood.

  • Page 93: Removal

    TOPlus mini / TOPlus premium pull-back 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].
  • Page 94 TOPlus mini / TOPlus premium pull-back 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. ...

  • Page 95: Preparing The Machine For Removal

    TOPlus mini / TOPlus premium pull-back Removal 10.2 Preparing the machine for removal Set the machine into set-up mode. INFORMATION The minimum operating pressure is reached when the drawtube can still just be moved without triggering an error message. Reduce the operating pressure to a minimum.

  • Page 96: Removal Of The Variant With Direct Screw Connection

    TOPlus mini / TOPlus premium pull-back Removal INFORMATION To be able to remove the changing part, it may be nec- essary to remove the clamping element first. As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps.

  • Page 97: Removal Of The Variant X-Times With Axial Screw Connection Bayonet

    TOPlus mini / TOPlus premium pull-back Removal Take the changing part off the product. 10.3.3 Removal of the variant x-times with axial screw connection bayonet Unfasten the fixing screws on the changing body a few turns without removing them. Order hotline +49 7144.907-333...
  • Page 98 TOPlus mini / TOPlus premium pull-back Removal Turn the changing part until the screw head on the changing part fixing screw fits through the bayonet opening. Take the changing part off the product. Order hotline +49 7144.907-333...

  • Page 99: Removal Of The Central Variant With Axial Screw Connection

    TOPlus mini / TOPlus premium pull-back Removal 10.3.4 Removal of the central variant with axial screw connection Unfasten and remove the fixing screw on the changing part. Take the changing part out of the product. Order hotline +49 7144.907-333...

  • Page 100: Removal Of The Radially Clamped Variant

    TOPlus mini / TOPlus premium pull-back Removal 10.3.5 Removal of the radially clamped variant INFORMATION To install / remove the changing part in / from the prod- uct, it may be necessary to use a grab handle or an appropriate auxiliary tool.

  • Page 101: Removal Of The Clamping Element

    TOPlus mini / TOPlus premium pull-back Removal 10.4 Removal of the clamping element Clamping head [clamping element] Special aids needed: Changing fixture  As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps. Move the clamping device into release position.
  • Page 102 TOPlus mini / TOPlus premium pull-back Removal WARNING Serious crushing injuries caused by reaching into the coupling / slot area in the clamping head or into the changing fixture! During actuation, never reach into the coupling /  slot area in the clamping head or into the chang- ing fixture.

  • Page 103: Removal Of The Product

    TOPlus mini / TOPlus premium pull-back Removal 10.5 Removal of the product Drawtube adapter Spindle flange Fixing screws, spindle flange Transport thread spindle flange Functional unit C1 Fixing screws functional unit C2 Screwdriver bit with tip guide C3 Transport thread functional unit...
  • Page 104 TOPlus mini / TOPlus premium pull-back Removal Unfasten and remove the functional unit fixing screws with the screwdriver bit with tip guide. Using the least possible force and speed, move the drawtube on the machine to its front limit stop [see »Pre- paring the machine for removal«...

  • Page 105: Removal Of The Spindle Flange

    TOPlus mini / TOPlus premium pull-back Removal 10.5.2 Removal of the spindle flange Attach any lifting gear that may be required. If necessary, fit the mounting aid onto a vertically sus- pended spindle. Unfasten and remove the fixing screws on the spindle flange.

  • Page 106: Removal Of The Drawtube Adapter

    TOPlus mini / TOPlus premium pull-back Removal 10.5.3 Removal of the drawtube adapter If the drawtube adapter was mounted on the machine drawtube, use its thread to unscrew and remove it from the machine drawtube. Order hotline +49 7144.907-333...

  • Page 107: Maintenance

    TOPlus mini / TOPlus premium pull-back 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.

  • Page 108: Cleaning

    TOPlus mini / TOPlus premium pull-back Maintenance Interval Maintenance work Lubricate the product [see »Lubricating the product« chapter] Completely clean the product [see »Cleaning« chapter] six-monthly or after 1500 operating hours* Lubricate the product [see »Lubricating the product« chapter] with storage See »Storage«...
  • Page 109 TOPlus mini / TOPlus premium pull-back Maintenance 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- ...
  • Page 110 TOPlus mini / TOPlus premium pull-back Maintenance WARNING Serious injuries caused by imbalance resulting from incorrect reassembly!  The product components must be installed back in the same position. If necessary, mark out the relative positions of  components prior to disassembly.

  • Page 111: Visual Inspection

    TOPlus mini / TOPlus premium pull-back Maintenance Lubricate the product [see »Lubricating the product« chapter]. 11.4 Visual inspection Perform a daily visual inspection of the product to identify any damage to the product at an early stage. Check the product for cracks and damage, in particular on the clamping and end-stop surfaces.

  • Page 112: Use Of Lubricants

    TOPlus mini / TOPlus premium pull-back Maintenance 11.6 Use of lubricants To achieve ultimate performance from the products, use the specified lubricants. Only use grease that complies with the fundamental require- ments governing adhesion, pressure resistance and solubil- ity in coolants. Furthermore, there must be no particles of dirt in the grease because these cause an operational malfunc- tion if they come between two interference fit surfaces.

  • Page 113: Disposal

    Substantial damage to the environment can result from incorrect disposal of environmentally haz- ardous substances! Products containing composites [mineral casting,  CFK] must be returned to HAINBUCH for dis- posal. NOTE Substantial damage to the environment can result from incorrect disposal of environmentally haz- ardous substances! ...

  • Page 114: Faults

    TOPlus mini / TOPlus premium pull-back 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 115 TOPlus mini / TOPlus premium pull-back Faults Fault Possible cause Remedial action Remedied by Workpiece outside the clamping width Use a suitable clamping element diameter Axial actuating Check machine setting and cor- force on drawtube rect if necessary too weak...

  • Page 116: Commissioning After A Fault Has Been Remedied

    TOPlus mini / TOPlus premium pull-back Faults Fault Possible cause Remedial action Remedied by Dirty clamping ele- Clean the clamping element ment Damaged clamp- Replace the clamping element ing element Dimensional differ- ence between Use clamping element with a suit-...

  • Page 117: Annex

    TOPlus mini / TOPlus premium pull-back Annex 14 Annex 14.1 Contact The following hotlines are available to you for orders, sched- ule tracking and emergencies. Order hotline Ordered quickly, supplied swiftly. Just phone: +49 7144. 907-333 Tracking hotline Current status of your order? Just call: +49 7144.
  • Page 118 TOPlus mini / TOPlus premium pull-back Index directory Accessories required Hazards ..........17 Test kit .......... 31 Accessories, optional Installation Base end-stop with swarf baffle ring Changing part ....... 79 ..........33 Clamping element ......77 Face driver adaptation ....32 Preparation of the machine ...
  • Page 119 TOPlus mini / TOPlus premium pull-back Clamping element ....... 101 Spare parts ........11 Preparation of the machine ... 95 Speed ..........25 Product ........103 Storage ..........58 Spindle flange ......105 Symbols on the packaging ....56 Removal of changing parts ....95 Technical data ........
  • Page 120 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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