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Hainbuch HYDROK 32 Operating Instructions Manual

Hydraulic stationary chuck
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Operating instructions
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HYDROK
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Summary of Contents for Hainbuch HYDROK 32

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

  • Page 3: Table Of Contents

    HYDROK 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 ................... 10 1.5 Copyright ....................
  • Page 4 HYDROK 4.1 Overview and brief description ..............31 4.2 Accessories required................. 31 4.2.1 Clamping head ................31 4.3 Optional accessories ................. 31 4.3.1 Jaw module ................. 32 4.3.2 Magnet module ................32 4.3.3 MANDO Adapt ................32 4.3.4 Morse taper adaptation ..............32 4.3.5 Face driver adaptation ..............
  • Page 5 HYDROK 7.5.2 Preparation of the hydraulic port variant of the product on the underside of the product .............. 66 7.5.3 Preparation of the hydraulic port variant on the side of the product ..................66 7.5.4 Installation of the hydraulic port variant of the product to the underside of the product ..............
  • Page 6 HYDROK 13.1 Procedure with faults................105 13.2 Fault table ....................106 13.3 Commissioning after a fault has been remedied ........107 Annex ......................108 14.1 Contact ....................108 14.2 Manufacturer certification ................ 108 Order hotline +49 7144.907-333...
  • Page 7 HYDROK Directory of tables Table 1: Technical data ................23 Nomenclature conversion supply pressure – actuating force ..29 Table 2: Table 3: Operating conditions ..............30 Table 4: Nomenclature application limits ............ 36 Table 5: Maximum workpiece mass ............37 Table 6: Scatter widths of clamping force ...........

  • Page 8: General

    HYDROK 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

    HYDROK 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

    HYDROK 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 from any of the following: Non-compliance with this manual ...

  • Page 11: Spare Parts And Accessories

    HYDROK 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! Always use genuine clamping elements made by ...

  • 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 HYDROK 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. Interrupt work until unauthorized people have left ...

  • Page 14: Intended Use

    HYDROK 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 15 HYDROK 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 16: Personal Protective Equipment

    HYDROK 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]. Only skilled staff from the appropriate specialist ...

  • Page 17: Particular Hazards

    HYDROK 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.
  • Page 18 HYDROK 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 ...

  • Page 19: Other Safety Instructions

    HYDROK 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 HYDROK 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. WARNING Serious injuries caused by reaching into slots and bores!

  • Page 21: Screws

    HYDROK Safety CAUTION Injuries caused by slipping on escaping media!  Ensure that media are not able to escape. Drain the rest of the product.  NOTE Serious damage to materials / the machine tool / the product caused by workpieces being ejected centrifugally if clamping is released while they are still rotating! Never release the clamping of the workpiece...

  • Page 22: Functionality

    HYDROK 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- posal of environmentally hazardous substances! If environmentally hazardous substances enter ...

  • Page 23: Technical Data

    HYDROK Technical data 3 Technical data 3.1 General information 4-32 0.6 1.0 119 x 119 x 105 1000 30/1 4-42 0.6 1.0 154 x 154 x 120 1000 30/1 3-52 0.6 1.0 174 x 174 x 130 1000 30/1 3-65 0.6 1.0 174 x 174 x 130 1000 105 30/1...

  • Page 24: Balancing Quality

    HYDROK 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: Clamping Force Diagram

    HYDROK Technical data DANGER Serious injuries caused by projectile parts ejected when the product is used improperly!  Always pay attention to media feed lines when ro- tating the product. When using the side ports, the product must not  ever rotate.

  • Page 26: Size 32

    HYDROK Technical data 3.5.1 Size 32 Scan sample: At a supply pressure �� of 25 bar, radial clamping force �� is in the range ������ of 15.3 kN to 64 kN. lower limit value upper limit value 3.5.2 Size 42 / 52 Scan sample: At a supply pressure ��...

  • Page 27: Size 65

    HYDROK Technical data 3.5.3 Size 65 Scan sample: At a supply pressure �� of 25 bar radial clamping force �� is in the range ������ of 34 kN to 76 kN. lower limit value upper limit value 3.5.4 Size 80 Scan sample: At a supply pressure ��...

  • Page 28: Size 100

    HYDROK Technical data 3.5.5 Size 100 Scan sample: At a supply pressure �� of 25 bar, radial clamping force �� is in the range ������ of 64 kN to 104 kN. lower limit value upper limit value 3.5.6 Size 100 aluminum variant Scan sample: At a supply pressure ��...

  • Page 29: Conversion Of Supply Pressure - Actuating Force

    HYDROK Technical data 3.6 Conversion of supply pressure – actuating force To find the right machine settings, you need to convert from supply pressure to actuating force or vice versa. 3.6.1 Nomenclature Brief des- Unit Explanation ignation �� ���� Axial actuating force ����...

  • Page 30: Supply Pressure Diagram - Actuating Force

    HYDROK Technical data 3.6.4 Supply pressure diagram - actuating force Sample scan 1: At a supply pressure of 25 bar, the axial actuating force for size 65 is 27.5 kN and for size 100 it is 40 Sample scan 2: At a required axial actuat- ing force of 30 kN, a sup- ply pressure of 27 bar...

  • Page 31: Layout And Function

    HYDROK Layout and function 4 Layout and function 4.1 Overview and brief description Clamping head [clamping element] Coupling Clamping device The clamping device is screwed to the machine table. The media guides are connected to the clamping device. The clamping element was installed in the clamping device with an appropriate changing fixture and it clamps the work- piece being machined.

  • Page 32: Jaw Module

    HYDROK Layout and function 4.3.1 Jaw module The jaw module is an adaptation clamping device for the use with jaws. It enables the diameter of the jaw clamping range to be expanded. 4.3.2 Magnet module The magnet module is an adaptation clamping device for ferromagnetic materials for grinding or turning.

  • Page 33: Face Driver Adaptation

    HYDROK Layout and function 4.3.5 Face driver adaptation Adaptation of the face driver makes it possible to machine the entire length of the workpiece. 4.3.6 Multiple clamping plate The multiple clamping plate is used to install up to four hy- draulic clamping devices in a linear or square configuration.

  • Page 34: Use And Limits Of Use

    HYDROK 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 workpiece to enable it to be machined. Only ever operate the product with a suitable fluid. As well as for its general field of application, this product was designed and developed for use, when necessary, in a specific and documented application [see clamping situa-...
  • Page 35 HYDROK Use and limits of use Brief des- Unit Explanation ignation Clamping force supplement for rotational �� �� ���� compensation �� �� Density of workpiece �� Feed / rotational movement of drilling op- �� ���� �� eration �� �� Transverse force ��...

  • Page 36: First Limit [Workpiece Length]

    HYDROK Use and limits of use Brief des- Unit Explanation ignation Torque due to lateral force on the chuck �� ���� �� axis Maximum torque due to lateral force on �� ���� �� ������ the chuck axis �� ���� Workpiece mass ��...

  • Page 37: Second Limit [Workpiece Mass]

    HYDROK Use and limits of use 5.2.3 Second limit [workpiece mass] The maximum workpiece mass depends on the size of the clamping head chuck [see Table 5]. [These values apply to individual workpieces. Special values apply to the machining of bar stock] Maximum workpiece mass ��...

  • Page 38: Fourth Limit [Forces]

    [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 39 HYDROK Use and limits of use Pay attention to the following principles: �� ≥ �� 1. Principle ������ ������ ������ �� ≤ �� 2. Principle �� �� ������ �� ≤ �� 3. Principle �� �� ������ [Relevant to turning and/or to axial drilling operations.] ��...
  • Page 40 HYDROK Use and limits of use However, it is rare for axial drilling and turning operations to be superimposed because their opposing directions of rota- tion usually preclude them from running simultaneously. For computational purposes, the calculation should be based upon the point with the highest forces, that is the least favorable machining moment.
  • Page 41 HYDROK Use and limits of use Contact factor Consult the following tables for the contact factor, depending on the form of contact or the contact scenario. Interference fit Saddle fit Edge fit The clamping diameter of the The clamping diameter of the The clamping diameter of the clamping head matches the clamping head is greater than...
  • Page 42 HYDROK Use and limits of use Specific cutting forces These are approximate values, reflecting the relatively arbi- trary sub-categorization of materials. As a result, relatively large deviations from real values can be present. For deviating workpiece materials and/or for machining tasks in the boundary area of the clamping device, the respective ��...
  • Page 43 HYDROK Use and limits of use Specific cut- Specific cut- Specific cut- Workpiece materials ting forces ting forces ting forces �� �� �� �� ] at �� = �� ] at �� = �� ] at �� = �� �� ��...
  • Page 44 HYDROK Use and limits of use Clamping surface Workpiece surface Clamping head with longitudi- Clamping head Clamping head Smooth nal and trans- with Z serra- with F serra- clamping head verse serra- tions tions tions �� = 0.06 �� = 0.07 ��...
  • Page 45 HYDROK Use and limits of use Distance to mass Size of clamping center of gravity Clamping head [ �� ] in smallest mass �� [ ���� ] �� head �� position 9.10 0.062 0.075 12.20 Table 11: Clamping head mass and distance of mass center of gravity of clamping head segments to the rotational axis Determining the required clamping force INFORMATION...
  • Page 46 HYDROK Use and limits of use �� �� +0.63)∗ √ (�� + ( �� ∗�� ) (0.27∗ ∗�� +�� ∗�� �� �� �� �� �� �� ���� �� ���� 0.5∗(0.67∗(1.9∗�� −4.5����)+�� ∗�� ���� �� ���� �� �� �� = Longitudinal turning Surface turning / plunge-ma- ��...
  • Page 47 HYDROK Use and limits of use 5.2.5.2 Further to Principle 2: �� ≤ �� �� �� ������ When using a tailstock, due to the additional expanding force exerted on the clamping head chuck, the permitted maxi- mum tailstock force is limited to the following values in ac- cordance with the size of the clamping head chuck: Size of the clamping head [ ����...
  • Page 48 HYDROK Use and limits of use Size of the clamp- Up to total chuck [ �� ] �� �� ������ length �� [ ���� ] ing head chuck < 125 3600 < 140 5000 < 140 6000 < 160 8000 <...
  • Page 49 HYDROK Use and limits of use Size of the clamp- Up to total chuck �� [ �� ] �� ������ length �� [ ���� ] ing head chuck < 160 9000 < 200 13000 < 200 13800 < 200 15000 Table 14: Maximum permitted transverse force On extended chuck versions, the ratio of maximum permitted transverse force to chuck lengths needs to be reduced.

  • Page 50: Sample Calculation

    HYDROK 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 32 with �� = 150���� 120���� ∗ 120���� = 96���� 150���� 5.2.6 Sample calculation Applied to a specific example Longitudinal turning of an offset shaft made of 16MnCr5 [blank clamping diameter] unsupported in a horizontal posi-...
  • Page 51 HYDROK Use and limits of use INFORMATION �� from Table 6 �� from Table 8 �� from Table 9 [interpolated for �� = 0.25����] �� �� , �� from Table 10 �� �� �� , �� from Table 11 �� ��...
  • Page 52 HYDROK Use and limits of use �� �� +0.63)∗ √ (�� + ( �� ∗�� ) (0.27∗ ∗�� +�� ∗�� �� �� �� �� �� �� ���� �� ���� 0.5∗(0.67∗(1.9∗�� −4.5����)+�� ∗�� ���� �� ���� �� = �� = 133����, since the shaft should be ��...

  • Page 53: Aid To Selection Of The Hydraulic Unit

    HYDROK 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 105���� forces are being ���� ������ applied to the workpiece. In the example calculated here, an axial force of at least ��...

  • Page 54: Clamping And Release Volume

    HYDROK Use and limits of use 5.3.2 Clamping and release volume Refer to the following table for details of the clamping and release volume. Release volume ��/ Clamping volume Size of the clamp- ��/ 1 clamping de- 1 clamping device ing device vice [��] [��]...
  • Page 55 HYDROK Use and limits of use Clamping / release time �� [��] Size of the clamping de- vice Clamping de- Clamping de- Clamping de- vice vice vice 0.563 1.125 2.250 0.656 1.313 2.625 0.656 1.313 2.625 0.844 1.688 3.375 0.938 1.875 3.750 2.438...
  • Page 56 HYDROK Use and limits of use Clamping / release time �� [��] Size of the clamping de- vice Clamping de- Clamping de- Clamping de- vice vice vice 0.141 0.281 0.563 0.164 0.328 0.656 0.164 0.328 0.656 0.211 0.422 0.844 0.234 0.469 0.938 0.609...

  • Page 57: Transport, Packaging, Storage

    HYDROK 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 58: Symbols On The Packaging

    HYDROK 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-  bearing equipment and lifting tackle. NOTE Damage to materials caused by escaping medium and / or the ingress of dirt!

  • Page 59: Unpacking And Internal Transportation

    HYDROK 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. 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-...

  • Page 60: Storage

    HYDROK 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 61: Installation

    HYDROK 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 62: Preliminary Remarks

    HYDROK 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. Never move body parts under parts in the working ...

  • Page 63: 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 64: Preparation Of The Machine For Installation

    HYDROK Installation Tightening torque at screw quality [Nm] Thread designa- tion 10.9 12.9 Table 21: 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 Minimum screw tion [Nm]...

  • Page 65: Installation Of The Product

    HYDROK Installation 7.5 Installation of the product Expander Cap plug Cap plug seals Swivel joints Screw plugs D1 Screw plug seals Product Product fixing screws Test surface, product face run-out Test surface, position product The product can be connected to the hydraulic supply line on the machine in two different ways.

  • Page 66: Preparation Of The Hydraulic Port Variant Of The Product On The Underside Of The Product

    HYDROK 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 seals during installation/removal of the cap plugs! During installation/removal of the cap plugs, the ...
  • Page 67 HYDROK 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 68 HYDROK 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 69: Installation Of The Hydraulic Port Variant Of The Product To The Underside Of The Product

    HYDROK Installation 7.5.4 Installation of the hydraulic port variant of the product to the underside of the product Depressurize the hydraulic unit. DANGER Serious injuries caused by projectile workpieces, ejected by incorrectly connected hydraulic ports! The hydraulic connections on the machine and ...
  • Page 70 HYDROK 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 71 HYDROK 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 72: Installation Of The Hydraulic Port Variant Of The Product To The Side Of The Product

    HYDROK Installation 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 73 HYDROK 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 74 HYDROK 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 75: Installation Of The Clamping Element

    HYDROK 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 76 HYDROK 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 77: Installation Of The Changing Parts

    HYDROK Installation 7.7 Installation of the changing parts 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 Fixing screws changing part variant x-times axial screw connec- tion bayonet The changing parts, such as the workpiece end-stop, can be installed in different ways.

  • Page 78: Installation Of The Variant X-Times With Axial Screw Connection

    HYDROK 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]. Order hotline +49 7144.907-333...

  • Page 79: Installation Of The Variant X-Times With Bayonet Axial Screw Connection

    HYDROK 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«. After initial installation, the changing part fixing screws remain in the clamping device.
  • Page 80 HYDROK Installation 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 81: Commissioning

    HYDROK 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 ejected centrifugally or dropping out if clamping force is insufficient! Workpiece blanks must not be outside the clamp-...
  • Page 82 HYDROK 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  levels of corrosion inhibitor.

  • Page 83: Suitable Fluid

    HYDROK Commissioning 8.2 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 84: Tests

    HYDROK Commissioning For the axial nominal total stroke, the values of axial clamp- ing reserve and axial release stroke must be added together [see »General information« chapter]. 8.4 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 ...

  • Page 85: Workpiece

    HYDROK Commissioning 8.5 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  reserve stroke. The remaining clamping reserve must always be ...

  • Page 86: Activities After End Of Production

    HYDROK 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 Eye injuries and cuts caused by failure to wear protective clothing during cleaning operation! Never use compressed air to clean the product.

  • Page 87: Removal

    HYDROK 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 WARNING Serious injuries caused by unskilled staff during installation / removal! Installation and removal must be performed by...
  • Page 88 HYDROK 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 89: Preparing The Machine For Removal

    HYDROK Removal 10.2 Preparing the machine for removal Set the machine into set-up mode. Reduce the operating pressure to a minimum. Remove cutting tools and/or sharp objects from the working area of the machine, or cover them. Remove operating and auxiliary materials as well as re- maining processing materials and dispose of them in an environmentally responsible manner.

  • Page 90: Removal Of The Variant X-Times With Axial Screw Connection

    HYDROK Removal 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. Take the changing part off the product. Order hotline +49 7144.907-333...

  • Page 91: Removal Of The Variant X-Times With Axial Screw Connection Bayonet

    HYDROK 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.

  • Page 92: Removal Of The Clamping Element

    HYDROK Removal Take the changing part off the product. 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 93 HYDROK 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 94: Removal Of The Product

    HYDROK Removal 10.5 Removal of the product Expander Cap plug Cap plug seals Swivel joints Screw plugs D1 Screw plug seals Product Product fixing screws Test surface, product face run-out Test surface, position product The product can be connected to the hydraulic supply on the machine in two different ways.
  • Page 95 HYDROK 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 96: Removal Of The Hydraulic Port Variant Of The Product To The Side Of The Product

    HYDROK 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. 10.5.2 Removal of the hydraulic port variant of the product to the side of the product Depressurize the hydraulic unit.
  • Page 97 HYDROK 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 98: Maintenance

    HYDROK 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 99: Scheduled Maintenance

    HYDROK Maintenance Interval Maintenance work Maintain the complete product [see »Scheduled maintenance« chapter] Every two years or after 5000 operating hours* Lubricate the product [see »Lubricating the product« chapter] with storage See »Storage« chapter depending upon which stipulation is achieved first Table 23: Maintenance table 11.3 Scheduled maintenance Housing...
  • Page 100 HYDROK 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- ment: NOTE Damage to seals caused by the wrong solvent!
  • Page 101 HYDROK 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 of the product! More extensive disassembly than shown on the ...

  • Page 102: Cleaning

    HYDROK 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- ment: NOTE Damage to seals caused by the wrong solvent!

  • Page 103: 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! ...

  • Page 104: Disposal

    HYDROK 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. Dispose of media properly.

  • Page 105: Faults

    HYDROK 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 106: Fault Table

    HYDROK Faults 13.2 Fault table Fault Possible cause Remedial action Remedied by Remove and clean the clamping Dirt in the parts in Skilled special- element and clean the clamping the power flow device if necessary Defective axial Mistakenly Check fluid port and correct if nec- Hydraulic/pneu- strokes in the swapped fluid port...

  • Page 107: Commissioning After A Fault Has Been Remedied

    HYDROK Faults Fault Possible cause Remedial action Remedied by Remove clamping element / func- Dirty clamping ta- tional unit and clean the clamping taper Geometry error on the workpiece due Use a suitable clamping element to incorrect type of clamping element Reduce the clamping force to the level applicable for the clamping device and the workpiece...

  • Page 108: 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 109 HYDROK Annex Order hotline +49 7144.907-333...
  • Page 110 HYDROK Index directory Product.......... 65 Accessories, optional Installation safety ......61 Face driver adaptation ....33 Intended use ........14 Jaw module ........32 Magnet module ......32 Key to symbols ........8 MANDO Adapt ......32 Morse taper adaptation ....32 Layout ..........
  • Page 111 HYDROK Removal ........87 Transport, packaging, storage ..57 Technical data ........23 Scheduled maintenance ....99 Tests ..........84 Scope of delivery ......10 Transport inspection ......58 Screw tightening torques Transportation, internal ..... 59 Aluminum components ....64 Type designation .......
  • Page 112 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...

This manual is also suitable for:

Hydrok 42Hydrok 52Hydrok 65Hydrok 80Hydrok 100

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