FLOATING HEAD MANUAL

Introduction
Thank you for choosing a high quality auxiliary unit with a high level of productivity for
your production system.

This manual will help you get to know your floating head and how to use it correctly.

The safety and danger warnings will let you use your aggregate safely and with no
inconveniences.

Please read this manual carefully before starting the production.

This manual – or parts of it - can be reprinted or reproduced only with HITECO’s written authorisation.
Any type of reproduction, distribution or saving on storage mediums in any form not authorised by
HITECO represents a violation of the applicable copyright and will be prosecuted.

We reserve the right to make any technical changes to improve the products described in this manual.

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Contents
1 Definitions and Conventions ............................................................................ 3

2 Safety warnings ................................................................................................. 5

2.1 INTENDED USE......................................................................................................................... 5
2.2 Meaning of the symbols........................................................................................................... 6
2.3 Unauthorised changes............................................................................................................. 6
2.4 Observations about the product............................................................................................. 6
2.5 Qualification of the personnel................................................................................................. 7
2.6 User’s obligations .................................................................................................................... 7
2.7 Personal Protective Equipment .............................................................................................. 7
2.8 Specific sources of danger...................................................................................................... 7
2.8.1 Mechanical dangers ................................................................................................................7
2.8.2 Heating of the floating head ....................................................................................................8
2.9 Using the floating heads.......................................................................................................... 8
2.10 Warranty .................................................................................................................................... 8

3 Transport and storage....................................................................................... 9

3.1 Transport ................................................................................................................................... 9
3.2 Surfaces to protect................................................................................................................... 9
3.3 Storage ...................................................................................................................................... 9

4 Structure and function of the aggregate ....................................................... 10

4.1 Spring pressure adjustment...................................................................................................11
4.2 Floating bell adjustment ........................................................................................................ 12
4.3 Floating bell interface discs .................................................................................................. 13
4.4 Adjustment of the sprung anti-rotation pin ......................................................................... 14

5 Tools specifications ........................................................................................ 15

6 Tool change-over ............................................................................................. 18

7 Start up and use............................................................................................... 20

8 Maintenance, repairs and cleaning ................................................................ 23

8.1 Maintenance and cleaning..................................................................................................... 24
8.2 Lubricants specifications ...................................................................................................... 25
8.3 Repairs..................................................................................................................................... 25
8.4 Troubleshooting ..................................................................................................................... 26
Appendix………………………………………………………………………………………………26

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1 Definitions and Conventions
Certain specific product terms, that may be useful to understand the content of this manual, are
explained in the drawing below.

Always refer to the drawings attached to the aggregate.

Pos. Description
1 Transmission cone (option with table support)
2 Body
3 Feeler hood
4 Tool holder spindle
5 Anti-rotation plate

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The rotation direction indicated in the figure is defined as right

Always check the rotation direction of the aggregate in order to assemble the
correct tool.

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2 Safety warnings
The manual must always be stored where the floating heads are used.
As well as the manual the applicable general and local accident prevention and environment
protection standards must be made available and complied with.

2.1 INTENDED USE

The only intended use of the floating heads is on machine tools with shavings extraction used to
machine work pieces in the following materials:

• chipboard panels
• solid wood
• other wooden materials
• plastic materials
• aluminium

In particular, the following types of machining operations:

• drilling
• routing
• cutting
• planing

Any other or different use is not intended and therefore non-complying. The manufacturer is not
responsible for any resulting damages.

Intended use includes:

• compliance with the indications of this manual

• compliance with the installation and maintenance instructions
• compliance with the power limits
• compliance with the maximum RPM
• compliance with the limits on the accessories fitted.

The following are included in unintended or non-complying uses

• grinding
• all applications that differ from the above

Further information on the performance of your floating head can be found in the technical
specifications sheet attached to the aggregate.

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2.2 Meaning of the symbols
The following symbols are used in the manual:

DANGER
This symbol indicates an immediate danger to the life and health of
people.
DANGER The non-observance of this warning has serious health
repercussions and can lead to fatal injuries.

WARNING
This symbol indicates a potential danger to the life and health of
people.
WARNING The non-observance of this warning has serious health
repercussions and can lead to fatal injuries.

ATTENTION
This symbol signals a potentially dangerous situation.
The non-observance of this warning can lead to light injuries or
ATTENTION damage to property.

NOTE
This symbol indicates notes, use advice and useful information that
can help the operator to use the machine functions in the best
possible way.

2.3 Unauthorised changes

Do not perform changes, expansions or modifications to the floating heads without HITECO’s
authorisation.

HITECO is not responsible for any resulting damages. The user is responsible for all risks.

The spare parts and parts subject to wear must comply with the technical requirements set out by
HITECO. This can be guaranteed only by using original spare parts.

2.4 Observations about the product

Excessive noise or overheating of the floating head can be due, amongst other things, to damage to
the bearings or the transmission parts resulting from the incorrect insertion of the floating head.

Check the floating head based on the indications set out in Chap. 8 and contact HITECO immediately.
If the problem persists after the check set out in Chap. 8., stop using the floating head.

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2.5 Qualification of the personnel
Only trained personnel can operate with/on the floating heads. The personnel skills must be
thoroughly defined for all the start-up, use, maintenance and repair operations. Apprentice operators
can operate on/with the floating heads only if supervised by expert personnel. The same applies to
personnel in training.

2.6 User’s obligations

The user will check at regular intervals that the personnel operate in compliance with the safety
standards. The user will also:

• guarantee that the operators know the safety in the workplace and accident prevention
regulations and are trained in the use of the floating heads.
• use the floating heads only on machines that comply with the applicable safety regulations.

2.7 Personal Protective Equipment

ATTENTION – Protective Equipment
Prevent cuts with tools. Always wear protective gloves when handling
tools. Prevent physical injuries. Always wear safety shoes, goggles and
ATTENTION ear defenders. Use suitable lifting devices and tested transport
equipment.

2.8 Specific sources of danger

2.8.1 Mechanical dangers

WARNING
When machining with the floating head check that the machine protection
devices are enabled and operational.
WARNING Check that the tool is locked correctly. Refer to the documents attached to
the floating head.
ATTENTION
Use adequate measures to transport and insert in the machine tool. Use
only suitable lifting equipment. Make sure that the maintenance and repair
operations on the floating heads are performed on an adequate support.
ATTENTION
Secure the floating head so that it cannot fall. Use adequate protection
and safety devices.

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2.8.2 Heating of the floating head

ATTENTION
During the operation of the floating head, the temperature
ATTENTION can reach 85°C. Therefore always wear protective gloves
when the tool is replaced manually or when it is removed
from the tool changer magazine.
DANGER
Always keep the floating head far from combustible or
DANGER
explosive materials.

2.9 Using the floating heads

The floating heads are constructed in compliance with recognized good manufacturing and safety
practices. The floating heads must be used only:

• for the intended use, [Chap. 2.1]

• in correct safety conditions.

ATTENTION
An incorrect use can cause fatal danger for the user or third parties or
ATTENTION damage to the floating heads or other property. Faults that could
compromise safety must be promptly eliminated.

2.10 Warranty
The warranty and responsibility rights in case of damages to people or property are voided whenever
the damages can be ascribed to one or more of the following causes:

• unintended use of the floating heads.

• incorrect set up, use and maintenance of the floating heads.
• using the floating heads with the safety or protection devices faulty and/or non-operational.
• non-compliance with the warnings set out in the manual in terms of the storage, start-up,
operation, maintenance and set-up of the floating heads.
• unauthorised construction changes to the floating heads.
• unauthorised changes to the transmission ratios (power, etc.).
• inadequate checks of the machine parts.
• repairs carried out incorrectly.
• catastrophic failure due to foreign bodies and force majeure.

• use of inadequate, worn (blunt) or faulty tools.

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3 Transport and storage
During transport and storage pay particular attention to the operational surfaces indicated in the
drawings of the floating heads. Any damages could irreparably compromise the floating head and limit
safety. All products leave our plant intact and perfectly operational. If the goods arrive damaged due to
transport, inform HITECO immediately.

3.1 Transport
All logistical activities connected with the transport are performed exclusively by HITECO: The
transport data are therefore not indicated. The weight of the floating head is indicated in the technical
specifications sheet in appendix to this manual.

3.2 Surfaces to protect

Protect the functional surfaces of the floating head from dirt, corrosion and any damages (Chap. 1).

Transmission cone (with table support if

present)

Support points and surfaces with precision

grinding on the torque pin (if present)

Tool holder spindle

3.3 Storage
If the floating heads are not used for a long time, pay attention to the following.

• Store the floating heads only packaged and in a dry area.

• Lubricate well and cover all components with an adequate protection film.
• Protect the functional surfaces of the floating heads from any
damage.[Chap. 3.2]
• After the storage period and before starting, clean the floating heads.
• Before restarting the floating heads check that the blockage device slides
freely and that there are not blockages to the transmission parts.

ATTENTION – Danger of collision

The non-observance of these instructions can cause serious
damages to the machine and the floating head. Proceed as follows:
ATTENTION before inserting or restarting the floating head always perform a
complete and precise collision test with a tool inserted.

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4 Structure and function of the aggregate
The basic structure of the floating head is described in this manual [Chap. 1].

For all machining operations with the floating head refer to the technical specifications data of the
drawing/s in appendix to this manual.

The spindle/s used for machining is/are fitted on first rate bearings. The transmission parts in floating
heads with high RPMs are designed for high speed machining.

Our floating heads can be fitted with various tool holder spindles. The tool holder spindle data can be
found in the drawings attached to the floating head.

ATTENTION – Danger of collision

The non-observance of these instructions can cause serious damages to the
machine and the floating head. Proceed as follows:
ATTENTION
Usually there are limitations on the use of the floating heads on other
machines, even if the machines are from the same manufacturer, are of the
same type or the same construction typology.

Before every start up or restart up and after every machine change, perform
a complete and precise collision test.

ATTENTION – Indication
The indications of the tools on the drawings are recommendations and can
ATTENTION be changed by complying with the material, feed speed and operation.
The blades must be used only by complying with valid instructions.

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4.1 Spring pressure adjustment
The head is supplied with a spring pressure of 10 daN.

To increase the pressure rotate the 3 screws (1) clockwise with the wrench (2),
Every 360° turn of the screw =0.35 daN

ATTENTION – complex operation

This operation must be performed only by adequately trained
personnel.
ATTENTION
Danger of burns.
Do not perform any type of intervention on an aggregate that has
just performed machining operations.
Wait for the aggregate to cool down before handling it.

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4.2 Floating bell adjustment

1. Loosen the ring nut (1), with the wrench (2)

2. Rotate the bell (3) and adjust it in relation to the tool (4) to achieve the desired machining
depth (H)
Position it to the desired value with the graduated indicator (2)
3. Once you have found the correct quota tighten the ring nut (1), with the wrench (2).

ATTENTION
When there is the danger of burns
Do not perform any type of intervention on an aggregate that
has just performed machining operations.
ATTENTION Wait for the aggregate to cool down before handling it.

NOTE
All the operations described must be carried out by adequately
prepared personnel.

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4.3 Floating bell interface discs

The aggregate is fitted with a floating bell flange, secured to the hood (1), with holes
out of which air is released to clean the panel.
Based on the tool dimensions and the precision necessary there are 3 types of flanges to choose
from.
(2) = Ø 85 mm
(3) = Ø 116 mm
(4) = Ø 40 mm
The standard aggregate is supplied with a Ø 85 mm flange.

If the hood (1) adjustment is not sufficient to achieve the machining depth
use the shimming rings (2)
Each ring has a height of 10 mm.
Use the screws supplied based on the number of rings used.

The feeler flange opening diameter affects the sensitivity with which the
panel thickness is read.
The smaller the diameter and the closer to the tool the greater the feeler sensitivity.
When choosing the feeler flange take into account the dimensions of the shavings produced during
machining. There must be sufficient space for the shaving passage between the tool and the flange.
Make sure that the flanges are assembled paying attention that the Ø 6 air outlet hole used for
cleaning match.
Check that air comes out of the flange once assembled.

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4.4 Adjustment of the spring of anti-rotation pin
(if present)

• Loosen the cylindrical screw (1).

• Press the anti-rotation pin downwards (2).
• Tighten the cylindrical screw (1).
• Change the aggregate by hand in the electro spindle of your machine.
• Turn the aggregate with the pin under the groove of the spindle or of axis C.
• Loosen the cylindrical screw (1).
• The pin must click in the groove without any play.
• Tighten the cylindrical screw (1).
• Check that there is no play.

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5 Tools specifications
When selecting the tools to fit to the aggregate, follow the recommendations below

• Never use deformed or damaged tools.

• Make sure that the rotating tools are perfectly balanced, sharp and suitable for machining.
• Never use tools beyond the speed limit stamped on them or indicated by the manufacturer.
• Before installing a tool in its seating make sure that the guide and centring surfaces are free of
dents and are perfectly clean.
• Tighten screws, bolts, nuts and ring nuts of each tool to the recommended torque.
• Always check that the rotation direction of the tool is the same as the rotation direction of the
spindle that it is installed on.
• Do not exceed the rotation speed limits indicated and set out in this manual or supplied
otherwise.

NOTE
Use only the locking screws supplied.

WARNING
The descriptions can also be found on the aggregate drawing in attachment.

Recommended tool geometry

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Locking collet taper compliant with DIN 6499 model B; Hi-Q/ER and ER-UP type
(REGOFIX© system).
The collet taper is a universal tool taper for boring, routing, reaming and threading. For
general applications use the ER type collet. For maximum precision use the ER-UP collet.
Take into account any differences of the dimensions or specifications of the collet taper
indicated for collets adapted to specific client requirements.
Legend:
1 Hole or surface wrench for spindle lock
2 Collet
3 Locking nut
4 Stop screw for the axial adjustment of the tool

Fit the locking nit on the spindle only when the collet is correctly engaged in position.
Never tighten the stems with interferences → spindle failure.
Tighten only cylindrical stems.
When tightening the locking nut always hold the spindle with the wrench → transmission
failure.

Assembly:
Fit the collet in the ring until you feel the collet locking in the ring nut.
After the assembly we recommend tightening the system with the torque shown in the graph.

Disassembly:
Press the front of the collet and remove it from the ring nut.

Tightening diameter Measurement point

Tightening diameter Centring tolerance
on (mm) up to (mm) ER type ER-UP type

Tolerance table

TOOL HOLDER SPINDLE TECHNICAL SPECIFICATIONS

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6 Tool change-over

ATTENTION – Collet spindles

The non-compliance with these instructions can cause serious damage to the
transmission parts of the floating head. To change the tool always use the
ATTENTION transport protection of the bit-holder head (if present) or keep the tool holder
spindle blocked with a suitable wrench.

ATTENTION
The non-compliance with these instructions can cause rejects and damage the
ATTENTION material. Refer to the technical specifications data sheet for the tool holder spindle
in appendix to this manual.

ATTENTION – Protective Equipment

Prevent cuts with tools. Always wear protective gloves when handling tools.
ATTENTION Prevent physical injuries. Always wear safety shoes, goggles and ear defenders.

DANGER
Only use tools and locking devices tested for the maximum number of RPM of the
floating head.
DANGER

Unscrew the hood (SEE SECTION 4.2) and position the opening so that there is good access for the wrenches.

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1. Block the shaft (2) with the wrench (1)

2. Unscrew the ring nut (4) with the wrench (5)
3. Insert the collet (3) in the seating of the ring nut (4) (see figure)

4. Screw the ring nut on the shaft, but without tightening it fully
5. Insert the tool (6) in the collet
6. Tighten the ring nut (4) fully with the wrench (5) with a tightening torque set out in the table

Collet Tightening torque (max value)

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7 Start up and use

Safety
The operator must have all the requirements required to use this type of machine

The protection devices used to protect the operator must always be installed and efficient.

Do not wear bracelets, rings, necklaces, etc. as they can cause serious injuries; before
starting to work, remove everything that could cause this type of risk.

Before starting the machining examine the work area for any dangerous conditions; check
that no foreign bodies have been left in or on the machine.

Perform the operating cycle start up sequence only as shown.

Do not insert hands or anything else close to or inside the moving parts or the live
parts of the machine or in the electrical cabinet.

Do not change the program parameters to try to achieve performance levels greater than
the ones set and programmed during planning and testing.

Do not operate in poor lighting; use all lights available and make sure that they are efficient.

Do not leave the machine unattended when it is operational.

Always keep a clear unobstructed view of the whole work area.

Before inserting the floating head check that it has not been damaged during transport. If there are
clear damages, the floating head must not be used.
Inform us promptly of any faults due to transport.
The head is fitted with the feeler surface cleaning system.
The feeler flange has holes. Check that air comes out of the holes.

NOTE
Use the drawings and technical sheets in attachment to check that
the machine tool requirements are correct in the following points:

• Machine adaptation
• Total dimensions and interferences
• Encumbrance in the tools magazine
• Total weight allowed and tool changer weight allowed

HITECO allows the head to be used continuously without considering the cycle times. The
rotation speed values and the maximum torque (maximum torque) (see diagram) must not be
exceeded. Other parameters to bear in mind are the feed speed, the tool conditions and the
material being machined. The user is responsible for checking these factors.

Ignoring these aspects could lead to the aggregate overheating.

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An adhesive on the head shows the instant temperature of the aggregate. The current
temperature is shown in green and it returns to the initial condition if cold. Do not exceed 75 °C
during continuous operation. If this temperature is reached, immediately stop machining and
allow the head to cool down. The temperature indicator will return to the initial conditions
You must follow an acceleration ramp based on the tool weight. See diagram.

Tempi di accelerazione

4 Velocità
Mandrino
Peso utensile [kg]

3 nmax.=7690min-1
nmax.=10000min-1
nmax.=12000min-1
2 nmax.=15000min-1

0
0 1 2 3 4 5 6 7 8
Tempi di accelerazione [s]

Acceleration times
Tool weight (kg)
Spindle speed
Acceleration times (s)

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The following operations MUST be performed:

• Collision test on the tool changer magazine.

• Collision test on the automatic tool changer.
• Collision test on devices and parts used.
• Accurate check of all the adaptation quotas.
• Perform all tests with the tool inserted.

When using floating heads always take into account the following:

• Rotation direction of the tool holder spindle.

• Suitable extraction specifications.

• Precisions achievable based on the system.

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8 Maintenance, repairs and cleaning
WARNINGS
Before performing any maintenance and/or cleaning intervention on the aggregate,
disassemble
it from the machine that it is installed on.

The maintenance must be performed by qualified personnel.

Before performing any maintenance or lubrication intervention, stop the machine

with the procedures listed in the manual and wait for the aggregate to cool down.

Each time that an aggregate must be disassembled or installed, make sure that it is supported
correctly.

Transfer the load immediately on adequate transport devices or stands.

Never use petrol, solvents or flammable liquids to clean parts. Use only commercial
non-flammable and non-toxic type-approved detergents.

Perform all the maintenance and repair operations carefully and in compliance with the
indications set out in this manual.

Always use personal protective equipment.

Use electrical tools that comply with the applicable safety standards.

Before starting the machine, make sure that nobody is performing maintenance
operations.

Do not work under or close to a kinematic mechanism if not adequately supported and
blocked.

Before performing cleaning or repair operations or various interventions on the machine

always block the start-up switch.

Wear protective goggles with side screens.

Before removing any protection, stop the machine completely by cutting the main
power supply, checking that there are no moving parts.

The machine must be used as intended.

The machine must always be used in compliance with the applicable safety standards in
every country.

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8.1 Maintenance and cleaning

Regularly clean the floating heads with suitable materials. (Do not use compressed air for
cleaning!) In most applications simply use a cloth to clean the surfaces and a brush to clean areas
that are difficult to access.

Perform any anti-corrosion treatments required. Normally it is sufficient to regularly oil the floating
heads.
! Respect the environment!
! Perform the disposal to reduce the environmental impact!

NOTE
Opening the floating heads without HITECO’s express authorisation,
except to re-lubricate with the service lubricator, voids any warranty.

During use all the mobile parts of the floating head must be cleaned at least every 2 weeks. Their free
movement must also be checked.
When cleaning remove any shavings and dirt from the floating head to guarantee the correct operation
of all components.

ATTENTION
ATTENTION Do not use compressed air for cleaning; otherwise any impurities
can be pushed under the gaskets and in the bearings.

Further details on the maintenance intervals of the floating heads are listed in the table below.

Activity Intervals
Clean all mobile parts that can be accessed
2 weeks (if necessary earlier)
externally
After a year of operation in case of one shift
Complete check of the floating head
operation

These checks must be documented in a maintenance program by the user.

After a year of operation we recommend checking the floating head completely. For more information
contact the HITECO technical support service.

Clean the surfaces indicated (Ref. A) with a cloth soaked in denatured alcohol or trichloroethylene.
After cleaning, to ensure that the taper does not remain blocked in the electro spindle, spray
the contact surfaces (Ref. A) with KLÜBER LUSIN PROTECT G31.

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8.2 Lubricants specifications

Use lubricants indicated in the table Use equivalent lubricants only if the lubricants
indicated cannot be found. If the lubricant needs to be replaced with an equivalent one
clean the part concerned thoroughly to remove any residue of the previous product, to prevent
any chemical reactions that could damage the machine.

Lubricant
Name Specifications
KLÜBER LUSIN PROTECT G31 Category: PROTECTIVE

8.3 Repairs
The floating head support, transmission and sealing parts are subject to natural wear. The wear
depends on:

• operation time
• intensity of the mechanical stresses
• type of material being machined.

Regularly check the wear of the transmission parts of the floating head based on the stresses and
operation time.

ATTENTION
The repairs must be performed by trained personnel.
To guarantee that the repairs are performed correctly use only original HITECO
ATTENTION spare parts. Contact HITECO for the spare parts. Keep the manual in an
accessible place to order any spare parts required.

ATTENTION – Collision
After any work or changes to the floating head always perform a complete and
ATTENTION precise collision test with a tool inserted.

ATTENTION – Lubricants
Always wear gloves when working on the units.
In case of contact with skin: Wash with delicate detergents and rinse
ATTENTION thoroughly with plenty of water.
In case of contact with eyes: Use an eye bath - contact a doctor.
If swallowed: Do not induce vomiting – contact a doctor.

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8.4 Troubleshooting

NOTE
Any faults on the floating head can lead to indirect damages and
considerably reduce the life and precision of the floating head. Always
ask for the advice of an HITECO expert.

Fault Check Solution

Check the length of the stop pin and
of the support points
Excessive noise
Check the wear and concentricity of
the tools used
Check the length of the stop pin and
of the support points
Overheating
Check that there are no leaks from
the head and that there are no grease
leaks
Is the method used sufficient to
achieve the precision required?
Excessive tool wear
Work piece dimension and shape
errors Drift due to excessive shaving forces
The length of the pins must be adapted precisely by
HITECO.
Use only sharp tools in perfect condition Correct the
concentricity of the tools (balancing)
The length of the pins must be adapted precisely by
HITECO.
Complete maintenance and repairs by HITECO
Change the method
Replace the tool
Reduce the machining parameters

Concentricity error too large Check that the tool is locked

Angle error Measure the angular position of the head

Appendix
In attachment to the head you will find:

• Drawing with connection and programming quotas

• Test certificate

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