Hainbuch HYDROK User manual

Installation manual
HYDROK
HYDROK 40 SE
HYDROK 32 RD
Hydraulic stationary chuck SPANNTOP
orce operated

HYDROK
Table of contents
1 General....................................................................................................................5
1.1 In ormation about this manual........................................................................5
1.2 Explanation o symbols..................................................................................5
1.3 Limitations o liability.......................................................................................6
1.4 Max. RPM.......................................................................................................7
1.5 Copyright........................................................................................................7
1.6 Scope o delivery............................................................................................7
1.7 Spare parts.....................................................................................................8
1.8 Warranty terms...............................................................................................8
2 Sa ety......................................................................................................................9
2.1 Responsibility o the customer.......................................................................9
2.2 Personnel requirements...............................................................................10
2.3 Intended use.................................................................................................11
2.4 Personal protective equipment.....................................................................12
2.5 Special dangers............................................................................................13
2.6 Further warnings...........................................................................................16
2.7 Clamping orce.............................................................................................17
2.8 Screws..........................................................................................................18
2.9 Functionality.................................................................................................18
2.10 Implementation limits....................................................................................19
2.10.1Nomenclature.....................................................................................19
2.10.2First limit [workpiece length]...............................................................21
2.10.3Second limit [workpiece mass]...........................................................21
2.10.4Third limit [clamping length]...............................................................22
2.10.5Fourth limit [ orces].............................................................................23
2.10.6Sample calculation.............................................................................34
2.11 Selection o aggregate.................................................................................37
2.11.1Clamping and release low at HYDROK............................................37
2.11.2Clamping and release times at 2-liter hydraulic aggregate...............37
2.11.3Clamping and release times at 4-liter hydraulic aggregate...............37
2.11.4Clamping and release times at 8-liter hydraulic aggregate...............38
2.12 Environmental protection..............................................................................38
3 Technical data.......................................................................................................39
3.1 General in ormation HYDROK.....................................................................39
3.2 General in ormation stationary chuck...........................................................40
3.3 Clamping orces HYDROK and hydraulic stationary chuck SPANNTOP....41
3.3.1 Clamping orce diagram – HYDROK – size 32 RD............................43
3.3.2 Clamping orce diagram – hydraulic stationary chuck – size. 32 RD 44
3.3.3 Clamping orce diagram – HYDROK – size 40 SE............................45
3.3.4 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 42/52 RD/SE...............................................................................46
3.3.5 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 65 RD/SE....................................................................................47
3.3.6 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 80 RD..........................................................................................48
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3.3.7 Clamping orce diagram – HYDROK and hydraulic stationary chuck –
size 100 RD/SE..................................................................................49
3.4 Operating conditions.....................................................................................50
3.5 Power speci ications.....................................................................................50
3.6 Type designation..........................................................................................50
4 Structure and unction...........................................................................................51
4.1 Overview HYDROK......................................................................................51
4.2 Overview HYDROK 32 RD / HYDROK 40 SE.............................................52
4.3 Brie description HYDROK / HYDROK32.....................................................53
4.4 Overview and brie description.....................................................................54
4.5 Brie description hydraulic stationary chuck SPANNTOP............................55
4.6 Designs hydraulic stationary chuck SPANNTOP.........................................56
4.6.1 Type 100x...........................................................................................56
4.6.2 Type 200x...........................................................................................56
4.7 Optional Accessories....................................................................................56
4.7.1 Changing ixture.................................................................................57
4.7.2 Clamping head...................................................................................57
4.7.3 Clamping head...................................................................................57
4.7.4 Grease................................................................................................58
4.7.5 Grease gun.........................................................................................58
4.7.6 Tandem cylinder.................................................................................58
4.7.7 Hydraulic base plate...........................................................................58
4.7.8 Multiple clamping pallet......................................................................59
5 Transporting, packaging and storing....................................................................60
5.1 Sa ety instructions or transporting...............................................................60
5.2 Symbols on the packaging...........................................................................60
5.3 Transport inspection.....................................................................................61
5.4 Unpacking and inner-company transportation.............................................61
5.5 Packaging.....................................................................................................62
5.6 Storing..........................................................................................................63
6 Assembly...............................................................................................................64
6.1 Pre-consideration.........................................................................................64
6.2 Preparations.................................................................................................65
6.3 Installation....................................................................................................66
6.3.1 Installation o the HYDROK and the hydraulic stationary chuck
SPANNTOP........................................................................................68
6.3.2 Installation o the HYDROK 32 RD and the HYDROK 40 SE............69
6.3.3 Installation o the clamping head.......................................................71
6.4 Workpiece.....................................................................................................72
6.5 Inspections...................................................................................................73
6.6 Control o the stroke position........................................................................74
6.7 Activities a ter production is concluded........................................................74
7 Disassembly..........................................................................................................75
7.1 Sa ety............................................................................................................75
7.2 Disassembling the clamping device.............................................................77
7.2.1 Disassembly o the clamping head....................................................77
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7.2.2 Disassembly o the HYDROK............................................................77
7.2.3 Disassembly o the HYDROK 32 RD / HYDROK 40 SE...................78
7.2.4 Disassembly o the hydraulic stationary chuck SPANNTOP.............79
7.3 Subsequent storage o the clamping device................................................79
7.4 Disposal........................................................................................................80
8 Maintenance..........................................................................................................81
8.1 General.........................................................................................................81
8.2 Cleaning........................................................................................................83
8.2.1 Cleaning HYDROK 32 RD and HYDROK 40 SE...............................84
8.3 Preservation.................................................................................................85
8.4 Use o lubricant.............................................................................................85
8.5 Maintenance schedule.................................................................................86
8.6 Bolt torque....................................................................................................87
9 Trouble shooting...................................................................................................88
9.1 Sa ety............................................................................................................88
9.2 Trouble shooting table..................................................................................89
9.3 Start-up a ter corrected ault.........................................................................90
10 Appendix...............................................................................................................91
10.1 Service Hotline.............................................................................................91
10.2 Representatives............................................................................................91
10.2.1Europe................................................................................................91
10.2.2North america.....................................................................................94
10.2.3South america....................................................................................94
10.2.4Asia....................................................................................................94
10.2.5Australia.............................................................................................95
10.2.6A rica..................................................................................................95
Index..............................................................................................................................96
EC Declaration o con ormity.........................................................................................99
»Translation of original installation manual«
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HYDROK – General
1 General
1.1 Information about this manual
This manual enables sa e and e icient handling o the
clamping device.
The manual is a component o the clamping device and
must be kept in the immediate vicinity o the clamping
device where it is accessible or personnel at all times.
Personnel must have care ully read and understood
this manual prior to starting all tasks. The basic prereq-
uisite or sa e work is compliance with all the sa ety in-
structions and handling instructions in this manual.
Illustrations in this manual are provided or a basic un-
derstanding and may deviate rom the actual model o
the clamping device.
It is assumed that the reader is amiliar with standard
procedures, such as cleaning the mounting sur aces.
1. Explanation of symbols
Safety instructions Sa ety instructions are indicated by symbols in this
operating manual. The sa ety instructions are intro-
duced by signal words that express the scope o the
hazard.
The sa ety instructions must be strictly adhered to.
You must act prudently to prevent accidents, personal
injury, and material damage.
DANGER
… indicates an imminent dangerous situation
than can result in death or serious injury i it is
not avoided.
WARNING
… indicates a possible dangerous situation
that can result in death or serious injury i it is
not avoided.
CAUTION
… indicates a possible dangerous situation
that can result in minor or light injury i it es not
avoided.
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NOTE
… indicates a possible dangerous situation
that can result in material damage i it is not
avoided.
Tips and recommen-
dations
… indicates use ul tips and recommendations,
as well as in ormation or e icient and trou-
ble- ree operation.
1.3 Limitations of liability
All in ormation and instructions in this operating manual
have been provided under due consideration o appli-
cable standards and regulations, the current state o
technology, as well as our many years o experience.
The manu acturer assumes no liability or damage due
to:
Failure to ollow the instructions in the manual
Non-intended use
Deployment o untrained personnel
Unauthorized conversions
Technical changes
Use o non-approved spare parts
The actual scope o delivery can vary rom the expla-
nations and graphic representations provided in this
manual in the case o special versions, i supplemental
order options are desired, or on the basis o the latest
technical changes.
The agreed obligations in the delivery contract, the
general terms and conditions, as well as delivery condi-
tions o the manu acturer, and the statutory regulations
valid at the time the contract was concluded, apply.
CAUTION!
Our clamping devices are balanced with bal-
ance quality G = 4, in one level n = 1.
The data on the rotation balance re ers to rota-
tionally symmetrical workpieces.
The clamping o not rotationally symmetrical
workpieces may not be clamped and/or only be
clamped a ter consultation with the manu ac-
turer.
Balancing bolts and balancing weights at the
clamping devices may not be removed / disas-
sembled!
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1.4 Max. RPM
CAUTION!
The maximum permissible speed is marked on
the product.
By the combination o a clamping device and
an add on clamping device a reduction o the
maximum permissible speed may be neces-
sary.
O all RPMs o the groups speci ied, the low-
est given RPM must always be used.
Note that the clamping orce is in luenced by
the centri ugal orce o the clamping elements.
I necessary, adjust the machining orce!
1.5 Copyright
This manual is protected by copyright and is provided
exclusively or internal purposes.
Delivery o the operating manual to third parties, dupli-
cation in any orm – including excerpts – as well as ex-
ploitation and/or communication o the content, are not
permitted [except or internal use] without written ap-
proval rom the manu acturer.
Actions to the contrary make damage compensation
mandatory. We reserve the right to en orce additional
claims.
1.6 Scope of delivery
All tools and accessories that are not included
in the scope o delivery are marked as option-
al.
In scope o delivery o the clamping device:
1 HYDROK
Optionally the scope o delivery o the clamping de-
vice HYDROK includes:
2 Koenig expander
Clamping head
Multiple clamping pallet [only or size 65]
Optionally the scope o delivery o the clamping de-
vice HYDROK 32 includes:
Clamping head
Tandem cylinder
Hydraulic base plate
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1.7 Spare parts
WARNING!
Safety risk if the wrong spare parts are
used!
Incorrect or de ective spare parts can cause
damage, mal unction, or total ailure; they can
also impair sa ety.
Only use manu acturer's original spare parts.
Only purchase spare parts rom authorized dealers or
direct rom the manu acturer. Addresses are in the ap-
pendix.
1.8 Warranty terms
The warranty terms are included in the manu acturer's
terms and conditions.
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HYDROK – Safety
Safety
This section provides an overview o all the important
sa ety aspects or optimal protection o personnel, as
well as or sa e and trouble- ree operation.
.1 Responsibility of the customer
The product is used in industrial applications. Conse-
quently the owner o the product is subject to legal in-
dustrial sa ety obligations.
In addition to the sa ety instruction in this manual,
generally valid sa ety and accident protection guide-
lines, and environmental protection guidelines as well
as the machines' manual must be adhered to and
complied with or the area o implementation o the
device.
Note in particular that the status scans o the machine
must be adjusted to the respective product.
DANGER!
Risk of injury due to thrown out parts!
Incorrect machine settings may lead to the
throwing out o parts.
The status scans the machine must be set to
the respective clamping device.
Regularly check the status scans o the ma-
chine, see chapter »Maintenance Schedule«.
I the end position can not be reached the
product may no longer be used.
Observe the operating instructions o the ma-
chine.
WARNING!
Risk of injury!
Declining operating orce, or example by de-
clining energy supply, may cause serious per-
sonal injury.
The product may be used only on machines
where it is ensured, that during use, the oper-
ating orce does not drop.
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WARNING!
Risk of injury!
An incorrect media supply [hydraulic, pneumat-
ic], e.g. by damaged or missing seals or pipes,
can cause serious personal injury.
Hydraulic and / or pneumatic tubes must be
secured by the machine by check valves and
a permanent pressure monitoring!
. Personnel requirements
WARNING!
Danger of injury due to insufficient qualifi-
cation!
Improper handling o the clamping device can
cause serious injury or material damage.
Only have activities per ormed by personnel
who are quali ied to per orm these activities.
The ollowing quali ications are cited in the operating
manual or the various activity areas.
Specialized personnel
are personnel who due to their specialized training,
skills, and experience, as well as knowledge o the
applicable regulations, are capable o executing the
tasks assigned to them and o recognizing and
avoiding possible hazards on their own.
Hydraulic specialist
The hydraulic specialist has been trained or the
particular task area in which he is active and is a-
miliar with the relevant standards and regulations.
Due to his specialized training and experience the
hydraulic specialist can per orm tasks on hydraulic
equipment and recognize and avoid possible dan-
gers on his own.
Electric specialist
The electric specialist has been trained or the par-
ticular task area in which he is active and is amiliar
with the relevant standards and regulations.
Due to his specialized training and experience the
electric specialist can per orm tasks on electric
equipment and recognize and avoid possible dan-
gers on his own.
Only persons rom whom it can be expected that they
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