Hainbuch MANOK User manual

Installation manual
MANOK / MANOK plus

MANOK / MANOK plus
Table of contents
1 General....................................................................................................................5
1.1 Information about this manual........................................................................5
1.2 Explanation of symbols..................................................................................5
1. Limitations of liability.......................................................................................6
1.4 Max. RPM.......................................................................................................6
1.5 Copyright........................................................................................................7
1.6 Scope of delivery............................................................................................7
1.7 Spare parts.....................................................................................................7
1.8 Warranty terms...............................................................................................7
2 Safety......................................................................................................................8
2.1 Responsibility of the customer.......................................................................8
2.2 Personnel requirements.................................................................................8
2. Intended use...................................................................................................9
2.4 Personal protective equipment.....................................................................10
2.5 Special dangers............................................................................................11
2.6 Further warnings...........................................................................................14
2.7 Clamping force.............................................................................................14
2.8 Screws..........................................................................................................15
2.9 Functionality.................................................................................................16
2.10 Environmental protection..............................................................................16
Technical data.......................................................................................................17
.1 General Information......................................................................................17
.2 Clamping force MANOK / MANOK plus.......................................................18
.2.1 Clamping force diagram – MANOK size 42.....................................19
.2.2 Clamping force diagram – MANOK size 52/65................................20
.2. Clamping force diagram – MANOK plus size 65 RD/SE..................21
.2.4 Clamping force diagram – MANOK size 80/100..............................22
. Draw forces MANOK plus............................................................................2
.4 Clamping forces – add on clamping device on MANOK plus......................24
.4.1 MANOK plus – size 65 SE...............................................................24
.4.2 MANOK plus – size 65 RD...............................................................24
.5 Operating conditions.....................................................................................25
.6 Power specifications.....................................................................................25
.7 Type designation..........................................................................................25
4 Structure and function...........................................................................................26
4.1 Overview and brief description MANOK.......................................................26
4.2 Overview and brief description MANOK plus...............................................28
4. Optional Accessories.................................................................................... 0
4. .1 Changing fixture............................................................................... 0
4. .2 Clamping head RD........................................................................... 0
4. . Clamping head................................................................................. 1
4. .4 Workpiece end-stop......................................................................... 1
4. .5 MANDO Adapt T211........................................................................ 1
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4. .6 MANDO Adapt T211 SE................................................................... 2
4. .7 Jaw module...................................................................................... 2
4. .8 Key....................................................................................................
4. .9 Grease..............................................................................................
4. .10 Grease gun.......................................................................................
5 Transporting, packaging and storing.................................................................... 4
5.1 Safety instructions for transporting............................................................... 4
5.2 Symbols on the packaging........................................................................... 4
5. Transport inspection..................................................................................... 5
5.4 Unpacking and inner-company transportation............................................. 5
5.5 Packaging..................................................................................................... 6
5.6 Storing.......................................................................................................... 7
6 Assembly............................................................................................................... 8
6.1 Pre-consideration......................................................................................... 8
6.2 Installation.................................................................................................... 9
6.2.1 Assembly of the MANOK..................................................................40
6.2.2 Assembly of the MANOK plus..........................................................40
6.2. Installing the base end-stop.............................................................41
6.2.4 Assembly of the clamping head.......................................................42
6. Workpiece.....................................................................................................4
6.4 Inspections...................................................................................................44
6.5 Control of the stroke position........................................................................45
6.6 Activities after production is concluded........................................................45
7 Disassembly..........................................................................................................46
7.1 Safety............................................................................................................46
7.2 Disassembling the clamping device.............................................................47
7.2.1 Disassembly of the clamping head..................................................47
7. Disassembling the base end-stop................................................................47
7. .1 Disassembly of the MANOK.............................................................48
7. .2 Disassembly of the MANOK plus.....................................................48
7.4 Subsequent storage of the clamping device................................................49
7.5 Disposal........................................................................................................49
8 Maintenance..........................................................................................................50
8.1 General.........................................................................................................50
8.2 Cleaning........................................................................................................51
8. Preservation.................................................................................................52
8.4 Use of lubricant.............................................................................................52
8.5 Maintenance schedule.................................................................................5
8.6 Bolt torque....................................................................................................54
9 Trouble shooting...................................................................................................55
9.1 Safety............................................................................................................55
9.2 Trouble shooting table..................................................................................56
9. Start-up after corrected fault.........................................................................57
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10 Appendix...............................................................................................................58
10.1 Service Hotline.............................................................................................58
10.2 Representatives............................................................................................58
10.2.1 Europe..............................................................................................58
10.2.2 North america...................................................................................61
10.2. South america..................................................................................61
10.2.4 Asia...................................................................................................61
10.2.5 Australia............................................................................................62
10.2.6 Africa.................................................................................................6
Index..............................................................................................................................65
EC Declaration of conformity.........................................................................................67
»Translation of original installation manual«
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MANOK / MANOK plus – General
1 General
1.1 Information about t is manual
This manual enables safe and efficient handling of the
clamping device.
The manual is a component of the clamping device and
must be kept in the immediate vicinity of the clamping
device where it is accessible for personnel at all times.
Personnel must have carefully read and understood
this manual prior to starting all tasks. The basic prere-
quisite for safe work is compliance with all the safety
instructions and handling instructions in this manual.
Illustrations in this manual are provided for a basic un-
derstanding and may deviate from the actual model of
the clamping device.
It is assumed that the reader is familiar with standard
procedures, such as cleaning the mounting surfaces.
1.2 Explanation of symbols
Safety instructions Safety instructions are indicated by symbols in this
operating manual. The safety instructions are introdu-
ced by signal words that express the scope of the ha-
zard.
The safety 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 if it is
not avoided.
WARNING
… indicates a possible dangerous situation
that can result in death or serious injury if it is
not avoided.
CAUTION
… indicates a possible dangerous situation
that can result in minor or light injury if it es not
avoided.
NOTE
… indicates a possible dangerous situation
that can result in material damage if it is not
avoided.
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Tips and recommen-
dations
… indicates useful tips and recommendations,
as well as information for efficient and trouble-
free operation.
1.3 Limitations of liability
All information and instructions in this operating manual
have been provided under due consideration of appli-
cable standards and regulations, the current state of
technology, as well as our many years of experience.
The manufacturer assumes no liability for damage due
to:
Failure to follow the instructions in the manual
Non-intended use
Deployment of untrained personnel
Unauthorized conversions
Technical changes
Use of non-approved spare parts
Use of non-approved accessories
The actual scope of delivery can vary from the expla-
nations and graphic representations provided in this
manual in the case of special versions, if supplemental
order options are desired, or on the basis of the latest
technical changes.
The agreed obligations in the delivery contract, the
general terms and conditions, as well as delivery condi-
tions of the manufacturer, and the statutory regulations
valid at the time the contract was concluded, apply.
1.4 Max. RPM
CAUTION!
The product is designed for stationary use and
may not be used for rotating machining!
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1.5 Copyrig t
This manual is protected by copyright and is provided
exclusively for internal purposes.
Delivery of the operating manual to third parties, dupli-
cation in any form – including excerpts – as well as ex-
ploitation and/or communication of the content, are not
permitted [except for internal use] without written ap-
proval from the manufacturer.
Actions to the contrary make damage compensation
mandatory. We reserve the right to enforce additional
claims.
1.6 Scope of delivery
All tools and accessories that are not included
in the scope of delivery are marked as optio-
nal.
The scope of delivery of the clamping device:
1 MANOK / MANOK Plus
1 Key
Optionally the scope of delivery of the clamping devi-
ce includes:
Clamping head
Chuck jaw
MANDO Adapt
1.7 Spare parts
WARNING!
Safety risk if t e wrong spare parts are
used!
Incorrect or defective spare parts can cause
damage, malfunction, or total failure; they can
also impair safety.
Only use manufacturer's original spare parts.
Only purchase spare parts from authorized dealers or
direct from the manufacturer. Addresses are in the ap-
pendix.
1.8 Warranty terms
The warranty terms are included in the manufacturer's
terms and conditions.
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MANOK / MANOK plus – Safety
2 Safety
This section provides an overview o fall the important
safety aspects for optimal protection of personnel, as
well as for safe and trouble-free operation.
2.1 Responsibility of t e customer
The product is used in industrial applications. Conse-
quently the owner of the product is subject to legal in-
dustrial safety obligations.
In addition to the safety instruction in this manual, ge-
nerally valid safety and accident protection guidelines,
and environmental protection guidelines as well as
the machines' manual must be adhered to and com-
plied with for the area of implementation of the devi-
ce.
Note in particular that the status scans of the machine
must be adjusted to the respective product.
DANGER!
Risk of injury due to t rown out parts!
Incorrect machine settings may lead to the
throwing out of parts.
The status scans the machine must be set to
the respective clamping device.
Regularly check the status scans of the ma-
chine, see chapter »Maintenance Schedule«.
If the end position can not be reached the
product may no longer be used.
Observe the operating instructions of the ma-
chine.
2.2 Personnel requirements
WARNING!
Danger of injury due to insufficient qualifi-
cation!
Improper handling of the clamping device can
cause serious injury or material damage.
Only have activities performed by personnel
who are qualified to perform these activities.
The following qualifications are cited in the operating
manual for the various activity areas.
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Specialized personnel
are personnel who due to their specialized training,
skills, and experience, as well as knowledge of the
applicable regulations, are capable of executing the
tasks assigned to them and of recognizing and avoi-
ding possible hazards on their own.
Hydraulic specialist
The hydraulic specialist has been trained for the
particular task area in which he is active and is fami-
liar with the relevant standards and regulations. Due
to his specialized training and experience the hy-
draulic specialist can perform tasks on hydraulic
equipment and recognize and avoid possible dan-
gers on his own.
Electric specialist
The electric specialist has been trained for the parti-
cular task area in which he is active and is familiar
with the relevant standards and regulations.
Due to his specialized training and experience the
electric specialist can perform tasks on electric
equipment and recognize and avoid possible dan-
gers on his own.
Only persons from whom it can be expected that they
reliably execute their work are considered as person-
nel. Persons whose capability to react is impaired, for
instance through drugs, alcohol, or medication, are
not approved.
Comply with age-specific and job-specific regulati-
ons that are applicable at the installation site when
selecting personnel.
2.3 Intended use
The clamping device is designed for installation on a
machine table.
The clamping device should only be mounted, opera-
ted, maintained, and cleaned by instructed, speciali-
zed personnel.
Intended use also includes compliance with all the in-
structions in this manual.
Any use that extends beyond the intended use, or any
other use of the clamping device is considered to be
misuse and can cause dangerous situations.
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WARNING!
Danger due to misuse!
Misuse of the clamping device can cause dan-
gerous situations.
Particularly refrain from the following uses of
the clamping device:
Use in turning machining.
Use with technical data other than that speci-
fied on the clamping device.
Claims of any type due to damage arising from non-
intended use are excluded.
2.4 Personal protective equipment
Wearing of personal protective equipment is required
to minimize health hazards when working with the de-
vice.
Always wear the protective equipment necessary for
the respective task when working with the device.
Follow the instructions that have been posted in the
work area.
Always wear For all tasks always wear:
Protective work clot ing
is tight-fitting work clothing with low resistance to tea-
ring, with tight sleeves, and without projecting parts. It
is primarily used to protect against entanglement by
moving machine parts.
Do not wear rings, chains, or other jewelry.
Safety footwear
for protection against heavy falling parts and slipping
on slippery substrates.
For special tasks
wear
Special protective equipment is required when execu-
ting special tasks. Separate reference is made to this
equipment in the specific sections of this manual. This
special protective equipment is explained below:
Hard at
to protect against falling and flying parts and materi-
als.
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Protective goggles
to protect eyes from flying parts and liquid splashes.
Protective gloves
to protect hands from friction, abrasion, puncture
wounds, or deeper injuries, as well as from contact
with hot surfaces.
2.5 Special dangers
In the following section residual risks are cited that
occur due to installation of the clamping device in a
machine tool. In each case the residual risks that
have been determined based on a risk analysis of the
machine must be specified by the customer.
Follow the safety instructions listed here and the
warnings in the other sections of this manual to re-
duce health hazards and to avoid dangerous situati-
ons.
Horizontal / lying
parts
WARNING!
Danger of injury due to orizontal parts!
Before transporting the clamping device in ho-
rizontal condition:
Put the clamping device on a non-slip pad
Screw in the eye bolts
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MANOK / MANOK plus – Safety
Suspended loads WARNING!
Life-t reatening danger due to suspended
loads!
Clamping device with weight more than 15 kg
must be lifted with a crane. When lifting the
clamping device there is a life-threatening ha-
zard due to falling parts or parts swinging out
of control.
Never step under suspended loads.
Never lift suspended loads over persons.
Comply with the instructions concerning the
intended attachment points. Ensure that the
sling gear is securely seated!
Do not attach lifting gear in projecting com-
ponents.
Only use approved hoists and sling gear with
sufficient bearing capacity.
Do not use rope and belts that are torn or
frayed.
Moving parts WARNING!
Danger of injury due to moving parts!
Rotating parts of the clamping device can cau-
se serious injuries.
Do not reach into moving parts or handle mo-
ving parts during operation.
Note the gap dimensions of moving parts.
Do not open covers when the device is in
operation.
Be aware of afterrun time:
Prior to opening the covers ensure that all
parts have come to a standstill.
Wear tight-fitting protective work clothing in
the danger zone.
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Wrong clamping of
t e workpiece
WARNING!
Danger of injury due to incorrect clamping
of t e work piece!
Incorrect workpiece clamping may lead to the
ejection of the workpiece and result in serious
injuries.
Under dimensioned parts can lead to incorrect
clamping!
Check the unmachined workpieces at ran-
dom on dimensional accuracy.
Too low axial clamping force can lead to the
reduction of radial clamping force!
Too high axial clamping force can lead to da-
mage of the components of the clamping devi-
ce!
Check and adjust, if necessary, the axial
clamping force regularly.
Do random checks of the unmachined work-
pieces on dimensional accuracy.
Missing c anging
parts
WARNING!
Danger of injury due to missing c anging
parts!
When operating the clamping device without
changing parts [segmented clamping bushing,
clamping heads, work piece end-stops] there is
a higher danger of crushing injuries due to the
stroke of movable components of the clamping
device.
The clamping process may not be initiated
without assembled segmented clamping bus-
hing and/or work piece end-stop.
Parts wit s arp
edges
WARNING!
Risk of injury!
When screwing in individual components such
as for example work piece end-stops, threaded
adapters and similar devices that are equipped
with an external thread or wear caused by
burrs, there is risk of cutting.
The operation must be done only by qualified
personnel.
Wearing of gloves / [PSA / personal protecti-
ve equipment] is required!
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CAUTION!
Risk of injury!
A special use-dependent or job-based design
can result in variations in the clamping strokes
and thus the clamping force.
The notes on the associated clamping situati-
ons or product drawing must always be ob-
served
2.6 Furt er warnings
WARNING!
Risk of injury!
Never reach for the clamping device while the
spindle is rotating. Before starting to work on
the mandrel, make sure the machine spindle
cannot be put in motion.
WARNING!
Risk of injury!
Falling down of the clamping device or its parts
can cause severe bruises and fractures.
The dead weight of the clamping device or its
parts can lead to high physical stress.
WARNING!
Risk of injury!
By repeated reworking or wear and tear of the
clamping surfaces sharp edges and burrs may
appear and lead to severe cutting damages.
2.7 Clamping force
The achieved clamping force can vary due to the main-
tenance condition of the clamping device [state of lubri-
cation and degree of contamination] [see chapter
»Maintenance«].
The clamping force must be checked at regular inter-
vals. This requires the use of static clamping force
measuring devices.
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CAUTION!
Damages due to excessive draw and com-
pressive force!
An excessive draw force and/or compressive
force may damage the clamping device and/or
the drawtube adapter.
The max. draw force and compressive force
may not be exceeded.
2.8 Screws
Moving parts WARNING!
Danger of injury due to screws and stud
screws being accelerated out of t e device!!
Screws and stud screws radially attached to
the product can be accelerated out of the devi-
ce and cause severe injuries.
At the product radially mounted screws and
stud screws which were loosened for assem-
bly and maintenance must be re-tightened
with the correct tightening torque!
The tightening torque is given at the product
itself, near the screw or threaded pin, and/or
given in chapter »Bolt torque«.
All screws or stud screws that are not mar-
ked with a tightening torque specification are
tightened with the prescribed tightening tor-
que and locked [medium-strength bonding] in
the factory and should only be unscrewed af-
ter consultation with the manufacturer. If in
doubt you must contact the manufacturer im-
mediately do determine the subsequent pro-
cedure.
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2.9 Functionality
NOTICE!
With high contamination of the clamping device
the functionality is no longer guaranteed.
The cleaning and maintenance intervals must
be observed.
2.10 Environmental protection
NOTE!
Environmental azard due to incorrect
andling!
Incorrect handling of environmentally hazar-
dous substances, particularly improper dispo-
sal, can cause significant environmental dama-
ge.
Always comply with the instructions cited be-
low
If environmentally harmful substances should
inadvertently get into the environment, initiate
suitable measures immediately. If in doubt
notify the responsible municipal authority
about the damage.
The following environmentally harmful substances are
used:
Lubricants Lubricants like greases and oils can contain toxic sub-
stances. Ensure that they do not get into the environ-
ment.
The device must be disposed of by a specialized dis-
posal company.
To achieve trouble-free operational performance of
the clamping device only use HAINBUCH lubricants.
See the appendix for reference addresses.
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MANOK / MANOK plus – Tec nical data
3 Tec nical data
3.1 General Information
Variant Size Weig t
[kg]
Dimensions
[l x w x in mm]
Clamping force
F rad. max.
[kN]
Draw force
F max.
[kN]
Torque
max.
[Nm]
MANOK
42 15 214 x 159 x 124 80 5 50
52 15 214 x 159 x 124 90 40 60
65 1 214 x 159 x 124 105 45 70
80 26 264 x 210 x 140 115 50 62
100 22 264 x 210 x 140 150 65 80
MANOK Plus
65 22 257 x 175 x 1 6 105 45 100
65 SE 22 257 x 175 x 1 6 120 [105] 45 100
Frad max. can only be reached in lubricated condition.
In unlubricated condition Frad max. is much lower.
WARNING!
Risk of injury!
Using false technical data can lead to serious
personal injury and property damage.
The technical data [label on the product, as-
sembly drawing] must be observed and may
not be modified by the operator!
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MANOK / MANOK plus – Tec nical data
3.2 Clamping force MANOK / MANOK plus
In the diagrams, the effects of friction and the clam-
ping diameter are included.
NOTE!
The measured values for the radial clamping
force Frad may not leave the permitted area. Un-
der optimal conditions, the values for Frad are
below the top, in bad conditions above the
lower limit.
If the measured clamping forces are outside
the allowed range, the maintenance is man-
datory to perform. After servicing, the clam-
ping forces have to be re-examined.
If the clamping force even after the mainte-
nance is not in the permitted area please
contact the manufacturer.
Example for size 42/52:
With an axial torque of 5 kN the radial clamping for-
ce Frad is, depending on the maintenance state of the
clamping device, in the range between 29,5 kN and
62,5 kN; it must not be smaller than 29,5 kN or higher
than 62,5 kN.
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MANOK / MANOK plus – Tec nical data
3.2.1 Clamping force diagram – MANOK size 42
Fig. 1
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MANOK / MANOK plus – Tec nical data
3.2.2 Clamping force diagram – MANOK size 52/65
Fig. 2
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