MANDO G211 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 .....................
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MANDO G211 Use and limits of use ..................28 5.1 Use......................28 5.2 Limits of use ....................28 5.2.1 Nomenclature ................28 5.2.2 First limit [workpiece length] ............28 5.2.3 Second limit [workpiece mass] ............ 29 5.2.4 Third limit [clamping length] ............29 5.2.5...
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MANDO G211 8.5 Procedure after a collision ................. 63 Activities after end of production ............... 64 Removal ......................65 10.1 Safe removal ..................... 65 10.2 Preparing the machine for removal ............67 10.3 Removal of the changing parts ..............67 10.3.1 Removal of the variant x-times with axial screw connection ..
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MANDO G211 Directory of tables Table 1: Technical data ................22 Table 2: Operating conditions ..............24 Table 3: Nomenclature application limits ............ 28 Table 4: Maximum workpiece mass ............29 Table 5: Screw tightening torques, metric control threads ......38 Table 6: Screw tightening torques for aluminum components ....
MANDO G211 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.
MANDO G211 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.
MANDO G211 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...
MANDO G211 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-...
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.
MANDO G211 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. WARNING Serious injuries caused by unauthorized presence...
MANDO G211 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.
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MANDO G211 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 ...
MANDO G211 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« chapter].
MANDO G211 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. Hair net To protect long hair from getting snagged in rotating parts on the machine tool.
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MANDO G211 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. Pay attention to the gap dimensions of moving ...
MANDO G211 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- ...
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MANDO G211 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.
MANDO G211 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. NOTE...
MANDO G211 Safety 2.8 Functionality WARNING Serious injuries caused by severe contamination of the product! Always comply with the cleaning instructions and intervals [see »Cleaning« chapter]. 2.9 Environmental protection NOTE Substantial damage to the environment can result from non-compliant handling or incorrect dis-...
MANDO G211 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 ...
MANDO G211 Technical data 3.4 Speed The product is authorized for rotational operation. The maximum speed is written on the product [maximum speed, see »General information« chapter]. DANGER Serious injuries caused by parts being ejected centrifugally due to a non-compliant combination...
MANDO G211 Layout and function 4 Layout and function 4.1 Overview and brief description Spindle flange Adapter kit Functional unit Workpiece end-stop Segmented clamping bushing [clamping ele- ment] Tension bolt The spindle flange is mounted on the machine spindle. The clamping device is screwed to the drawtube on the ma- chine tool through the drawtube adapter and is screwed to the spindle flange.
MANDO G211 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.
MANDO G211 Layout and function 4.3.3 ms dock stationary actuating unit The actuating unit is used for manual actuation of the MANDO segmented mandrels. 4.3.4 Adapter kit for a standard spindle flange / hs dock / ms dock The adapter kit is used to adapt segmented mandrel G211 to a standard spindle flange or to an actuating unit hs dock / ms dock.
MANDO G211 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. As well as for its general field of application, this product...
MANDO G211 Use and limits of use 5.2.3 Second limit [workpiece mass] The maximum mass of workpiece depends on the cutting cir- cle diameter of the mandrel tip on the product. Maximum workpiece Cutting circle diame- [ ] mass ...
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MANDO G211 Use and limits of use The clamping forces must be adapted to reflect the work- piece materials. The torque exerted on the clamping device during machining of the workpiece must never exceed the maximum level of transmissible torque resulting from the radial clamping force.
MANDO G211 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 ...
MANDO G211 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- ...
MANDO G211 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.
MANDO G211 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.
MANDO G211 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.
MANDO G211 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.
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.
MANDO G211 Installation 7.5 Installation of the product Drawtube adapter Spindle flange Fixing screws on spindle flange Transport thread on spindle flange Adapter kit ring C1 Adapter kit fixing screws Adapter for adapter kit Screw plug Functional unit Fixing screws on functional unit...
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MANDO G211 Installation If the prepared flushing bores of the product are to be used, the following preparatory steps are needed to install the product. INFORMATION A pre-assembled drawtube adapter and / or a pre-in- stalled adapter kit for the adapter must be removed, if fitted, before the screw plug can be removed.
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MANDO G211 Installation If the adapter kit is installed on the clamping device, no pre- paratory steps are needed for installation of the product. If the adapter kit is provided in the scope of delivery, or is already present, the following preparatory steps are needed for installation of the product.
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MANDO G211 Installation INFORMATION The adapter in the adapter kit is needed to install the product on an actuating unit. When using a standard spindle flange, depending on the design of the drawtube adapter, the adapter kit adapter is also required.
MANDO G211 Installation INFORMATION To install the functional unit on the machine, you need to know if this product can or cannot be aligned. Check the order confirmation. If the clamping device can be aligned, the order confirmation will have a note to this effect.
MANDO G211 Installation 7.5.4 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.
MANDO G211 Installation 7.5.5 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.
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MANDO G211 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 ≤ 0.005 mm].
MANDO G211 Installation 7.5.6 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.
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MANDO G211 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 ≤ 0.005 mm] and, if necessary, correct carefully with a plastic hammer.
MANDO G211 Installation 7.5.7 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.
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MANDO G211 Installation WARNING Serious crushing injuries caused by improper ma- chine movement during installation! Never reach into the gap between machine tool, spindle flange and functional unit. Using the least possible force and speed, move the drawtube on the machine to its front limit stop [see »Pre- paring the machine for installation«...
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MANDO G211 Installation 11. Tighten the fixing screws on the functional unit to the specified tightening torque [see »Screw tightening tor- ques« chapter]. 12. Check face run-out on the test surface of the functional unit [ideally ≤ 0.01 mm]. Whenever the face run-out is greater than the maximum per- mitted value: 13.
MANDO G211 Installation 7.5.8 Installation of the functional unit of a non-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.
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MANDO G211 Installation WARNING Serious crushing injuries caused by improper ma- chine movement during installation! Never reach into the gap between machine tool, spindle flange and functional unit. Using the least possible force and speed, move the drawtube on the machine to its front limit stop [see »Pre- paring the machine for installation«...
MANDO G211 Installation 7.6 Installation of the clamping element Ejector ring Segmented clamping bushing [clamping element] Tension bolt INFORMATION Before installing the clamping element, install the changing part if necessary, otherwise it can no longer be installed. As described in the »Preparation of the machine for in- stallation«...
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MANDO G211 Installation Fit the segmented clamping bushing to the product. For this, the slots in the segmented clamping bushing must engage in the lugs in the ejector ring. WARNING Serious injuries caused by tension bolt being ejected centrifugally if tightening torque is incor-...
MANDO G211 Installation 7.7.1 Installation of the variant x-times with axial screw connection Place the changing part onto the product. Screw in the changing part fixing screws on the chang- ing part and tighten to the specified tightening torque [see »Screw tightening torques« chapter].
MANDO G211 Installation 7.7.2 Installation of the variant x-times with bayonet axial screw connection INFORMATION Initial installation of the changing part with bayonet is in accordance with the variant with an x-times axial screw connection, see »Installation of x-times variant with axial screw connection«.
MANDO G211 Installation Screw in the changing part fixing screws and tighten to the specified tightening torque [see »Screw tightening torques« chapter]. 7.8 Aligning the clamping device with the test specimen To achieve the greatest possible accuracy, the clamping de- vice must be aligned on the workpiece.
MANDO G211 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 DANGER Serious injuries caused by workpieces being...
MANDO G211 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 ...
MANDO G211 Commissioning Prior to commissioning, check the complete stroke to ensure that there is sufficient reserve stroke and opening stroke. For this, the same measurement of the moving part must be performed at fixed points in front and rear limit positions.
MANDO G211 Commissioning Conduct a clamping force measurement. 8.4 Workpiece DANGER Serious injuries caused by parts being ejected centrifugally if level of workpiece clamping is in- sufficient! Never utilize the full clamping reserve. Do not exceed the permitted maximum clamping ...
MANDO G211 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. WARNING...
MANDO G211 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...
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MANDO G211 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 ...
MANDO G211 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.
MANDO G211 Removal As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps. Move the clamping device into release position. 10.3.1 Removal of the variant x-times with axial screw connection Unfasten and remove the fixing screws on the changing part.
MANDO G211 Removal 10.3.2 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. Turn the changing part until the screw head on the changing part fixing screw fits through the bayonet opening.
MANDO G211 Removal Take the changing part off the product. 10.4 Removal of the clamping element Ejector ring Segmented clamping bushing [clamping element] Tension bolt As described in the »Preparing the machine for re- moval« chapter, prepare for the following steps.
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MANDO G211 Removal Unfasten and remove the tension bolt. To do this, secure the ejector ring and the segmented clamping bushing to prevent them from falling out. Take the segmented clamping bushing off the product. Order hotline +49 7144.907-333...
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MANDO G211 Removal WARNING Serious injuries caused by tension bolt being ejected centrifugally if tightening torque is incor- rect! Always tighten the tension bolt down into the product and tighten to the specified tightening torque [see nomenclature]. Screw the tension bolt into the product and tighten to the specified tightening torque [see nomenclature].
MANDO G211 Removal 10.5 Removal of the product Drawtube adapter Spindle flange Fixing screws on spindle flange Transport thread on spindle flange Adapter kit ring C1 Adapter kit fixing screws Adapter for adapter kit Screw plug Functional unit Fixing screws on functional unit...
MANDO G211 Removal 10.5.2 Removal of the functional unit 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 its rear limit stop. Unfasten and remove the fixing screws on the functional unit.
MANDO G211 Removal 10.5.3 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. Take down the spindle flange from the machine spindle.
MANDO G211 Removal 10.5.4 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...
MANDO G211 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 ...
MANDO G211 Maintenance Interval Maintenance work 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« chapter depending upon which stipulation is achieved first Table 7: Maintenance table 11.3 Cleaning...
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MANDO G211 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- tive equipment, in addition to the basic equip-...
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MANDO G211 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. NOTE Damage to materials caused by incorrect Removal...
MANDO G211 Maintenance 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.
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. For this, the following lubricants are recommended: GP 355 universal grease [see the HAINBUCH product catalogue] Alternatively: Product designa- Lubricants Manufacturer...
MANDO G211 Disposal 12 Disposal If no agreement exists for return or disposal, send disman- tled components off for recycling. NOTE Substantial damage to the environment can result from incorrect disposal of environmentally haz- ardous substances! Lubricants, auxiliary materials and operating flu- ...
MANDO G211 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«...
MANDO G211 Faults 13.2 Fault table Fault Possible cause Remedial action Remedied by Remove and clean the clamping Dirt in the parts in element and, if necessary, re- Skilled special- the power flow move, dismantle and clean the clamping device...
MANDO G211 Faults Fault Possible cause Remedial action Remedied by Reduce the clamping force to the level applicable for the clamping device and the workpiece Elastic distortion Check the workpiece material Reduce the clamping force to the Clamping force is...
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.
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MANDO G211 Annex Order hotline +49 7144.907-333...
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MANDO G211 Annex Order hotline +49 7144.907-333...
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MANDO G211 Index directory Accessories needed Key to symbols ........7 mandoteX adapter kit ....27 Accessories, adapter kit needed Layout ..........25 Adapter kit for standard spindle Liability ..........9 flange / hs dock / ms dock ..27 Limits of use ........
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MANDO G211 Scope of delivery ........ 9 Tests ..........62 Screw tightening torques Transport inspection ......32 Aluminum components ....38 Transportation, internal ..... 33 Metric control threads ....37 Type designation ....... 24 Spare parts ........10 Speed ..........24 Unpacking .........
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