SCHUNK TANDEM KSF3-LH Assembly And Operating Manual
Clamping force block
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Summary of Contents for SCHUNK TANDEM KSF3-LH
- Page 1 Translation of Original Operating Manual TANDEM Clamping Force Block KSF3, KSF3-LH, KSF3-F Assembly and Operating Manual...
- Page 2 Imprint Imprint Copyright: This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: 1467140 Version: 05.00 | 14/12/2022 | en...
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Page 3: Table Of Contents
Table of Contents Table of Contents General........................ 5 About this manual.................... 5 1.1.1 Presentation of Warning Labels............... 5 1.1.2 Applicable documents ................ 6 1.1.3 Sizes ...................... 6 1.1.4 Variants.................... 6 Warranty ...................... 6 Scope of Delivery .................... 6 Basic safety notes .................... 7 Intended use ...................... - Page 4 Table of Contents Maintenance and care .................... 29 Notes........................ 29 Maintenance and lubrication intervals .............. 29 Greasing areas / lubricants ................ 30 Maintenance work ..................... 30 7.4.1 Lubrication ..................... 30 7.4.2 Basic cleaning.................. 32 7.4.3 Adjustment of the pneumatic jaw end position monitoring (PM).. 35 7.4.4 Leak test....................
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Page 5: General
General 1 General 1.1 About this manual This manual contains important information for a safe and appropriate use of the product. This manual is an integral part of the product and must be kept accessible for the personnel at all times. Before starting work, the personnel must have read and understood this operating manual. -
Page 6: Applicable Documents
• General terms of business * • Catalog data sheet of the purchased product * The documents labeled with an asterisk (*) can be downloaded from schunk.com. 1.1.3 Sizes This operating manual applies to the following sizes: • KSF3 64, 100, 140, 160, 200, 250, 315 •... -
Page 7: Basic Safety Notes
• Structural changes should only be made with the written approval of SCHUNK. 05.00 | KSF3, KSF3-LH, KSF3-F | TANDEM Clamping Force Block | en | 1467140... -
Page 8: Spare Parts
Use of unauthorized spare parts Using unauthorized spare parts can endanger personnel and damage the product or cause it to malfunction. • Use only original spare parts or spares authorized by SCHUNK. 2.5 Use of special chuck jaws Requirements of the chuck jaws When using special chuck jaws, please observe the following rules: •... -
Page 9: Personnel Qualification
Basic safety notes 2.7 Personnel qualification Inadequate qualifications of the personnel If the personnel working with the product is not sufficiently qualified, the result may be serious injuries and significant property damage. • All work may only be performed by qualified personnel. •... -
Page 10: Notes On Safe Operation
Basic safety notes 2.9 Notes on safe operation Incorrect handling of the personnel Incorrect handling and assembly may impair the product's safety and cause serious injuries and considerable material damage. • Avoid any manner of working that may interfere with the function and operational safety of the product. -
Page 11: Disposal
Basic safety notes 2.12 Disposal Handling of disposal The incorrect handling of disposal may impair the product's safety and cause serious injuries as well as considerable material and environmental harm. • Follow local regulations on dispatching product components for recycling or proper disposal. 2.13 Fundamental dangers •... -
Page 12: Protection During Commissioning And Operation
Basic safety notes 2.13.2 Protection during commissioning and operation Falling or violently ejected components Falling and violently ejected components can cause serious injuries and even death. • Take appropriate protective measures to secure the danger zone. • Never step into the danger zone during operation. 2.13.3 Protection against dangerous movements Unexpected movements Residual energy in the system may cause serious injuries while... - Page 13 Basic safety notes WARNING Risk of injury due to immediate closing of the product with high spring force in the event of pneumatic pressure failure. Ensure stable compressed air supply • Use pressure maintenance valves • WARNING Risk of injury in the event of workpiece loss due to failure or pressure reduction of the compressed air.
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Page 14: Technical Data
Technical data 3 Technical data Installation position Operating temperature +5°C to +60°C Noise emission [dB(A)] ≤70 Pressure medium Compressed air, compressed air quality according to ISO 8573-1: 7:4:4 Max. speed of rotation 100 RPM KSF3 Designation Stroke per jaw [mm] Clamping force range* 2 - 2.5 7 - 12... - Page 15 Technical data KSF3-F Designation Stroke per jaw [mm] Clamping force range* 2 - 2.5 7 -12 13 - 18 20 - 30 26 - 35 37 - 50 69 - 95 [kN] Opening pressure [bar] 6 - 9 6 - 9 6 - 9 6 - 9 6 - 9...
- Page 16 Technical data Dimensions of the product Optional Z variant ±0.01 mm to clamping center Clamping sleeve ±0.04 mm to clamping center Fitting screw ±0.02 mm to clamping center Only with variant "PM" 05.00 | KSF3, KSF3-LH, KSF3-F | TANDEM Clamping Force Block | en | 1467140...
- Page 17 Technical data KSF3 / KSF3-LH / KSF3-F Dimen sion Ø C 4H7 x 7.5 6H7 x 12 8H7 x 14 8H7 x 14 8H7 x 14 10H7 x 20 10H7 x 20 29.5 64.5 45.5 64.5 34.5 51.8 59.7 92.6 33.6 139.6 50.7...
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Page 18: Tightening Torques For Screws
Tightening torques for screws 4 Tightening torques for screws Tightening torques for mounting the clamping system on the machine table (screw quality 10.9) Screw size M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 Tightening 120 160 200 290 400 500 torque M (Nm) Tightening torques for mounting top jaws on the TANDEM... -
Page 19: Assembly And Connection
Assembly and connection 5 Assembly and connection The numbers shown for individual components refer to the illustrations for assembly or connections of the clamping force } 9 [ / 43] block and to the "Assembly Drawings" chapter. WARNING Danger of crushing due to the product approaching the machine table during assembly Do not reach between the product and machine table during •... -
Page 20: Assembly Of The Clamping Block On The Machine Table
Assembly and connection 5.1 Assembly of the Clamping Block on the machine table Cylindrical pins Ø m6} 8.3 [ / 39] Fitting screw Ø f7 } 8.3 [ / 39] Screw DIN EN ISO 4762 Clamping sleeve DIN EN ISO 13337 NOTE •... -
Page 21: Connecting The Clamping Force Block
Assembly and connection 5.2 Connecting the clamping force block OPEN (front) CLOSED (front) OPEN (bottom) CLOSED (bottom) Coolant drainage / connection for air purge (front) Dynamic pressure monitoring for jaw end position "open" Air coupling in top jaw 1 Air coupling in top jaw 2 Dynamic pressure monitoring for jaw end position "closed"... -
Page 22: Supply Lines And Lubrication Lines
Assembly and connection 5.2.1 Supply lines and lubrication lines The clamping force block has four air connections: I, II, III, IV. Two connections for OPEN (I and III) and two connections for CLOSE (II and IV). The application determines which of the two air connections must be opened for actuation: •... -
Page 23: Dynamic Pressure Monitoring Of The Jaw End Positions (Variant "Pm")
Assembly and connection NOTE: All four air connections come sealed on delivery of the clamping force block. On the base side with set-screws (item 60) and on the front with locking screws (item 23). • When using the air purge via connection 5, the two sound absorbers (V) must be removed and replaced by set-screws (item 93). - Page 24 Assembly and connection Circuit diagram for internal workpiece clamping: Circuit diagram Connection Signal output Jaw end position open Clamping position Jaw end position closed Connection Jaw end position open clamping force block closed Clamping position Jaw end position closed clamping force block open NOTES: •...
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Page 25: Air Coupling In Top Jaw (Variant "Pm")
Assembly and connection 5.2.3 Air coupling in top jaw (variant "PM") An air coupling in top jaw 1 is integrated via connection 2 on the bottom and an air coupling in top jaw 2 via connection 3. Size Dimension ØC [mm] D [mm] 37.5 E [mm]... -
Page 26: Pneumatic Circuit Diagram
Assembly and connection 5.2.4 Pneumatic circuit diagram Circuit symbols Actuation 5/3 directional control valve, center position ventilated 3/2 directional control valve Pressure switch Pressure gauge Flow control valve Compressed air supply <-- --> Jaw stroke "open" --> <-- Jaw stroke "close" Dynamic pressure monitoring for jaw end position "open"... -
Page 27: Troubleshooting
Check maintenance unit, perform maintenance work. Place the oiler closer to the clamping system; adjust the necessary oil quantity Chuck piston screw broken (overload) Send clamping system to SCHUNK for repair Piston rod or piston rod screw Send clamping system to SCHUNK for repair... - Page 28 Troubleshooting Clamping force block movement jerky Possible cause Solution(s) Steel guide rollers on sliding surfaces See chapter "Maintenance and Care" } 7 [ / 29] not greased The monitoring piece in a base jaw is Loosen the adjustment screws and readjust the pressed too tightly against the housing monitoring piece } 7 [ / 29]...
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Page 29: Maintenance And Care
Replacement of the housing and base jaws The base jaws and the guides in the housing are matched to each other. To replace these parts, send the entire product to SCHUNK with a repair order. 7.2 Maintenance and lubrication intervals... -
Page 30: Greasing Areas / Lubricants
LINOMAX plus can also be used as an alternative to microGLEIT LP 410. The specified clamping forces are however based exclusively on microGLEIT LP 410 as used by SCHUNK. When using LINOMAX plus, the clamping forces can be lower. 7.4 Maintenance work 7.4.1 Lubrication... - Page 31 Maintenance and care Manual lubrication • Press grease either into the grease nipples at the side or front of the respective supply line (6/7). • Only lubricate in the open position. • After greasing, run through the complete stroke several times. •...
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Page 32: Basic Cleaning
Any work requiring disassembly of the chuck piston, cover or • cylinder piston may only be performed by SCHUNK. For basic cleaning, only the base jaws with their attachments, • as well as the chuck piston and the cover strip may be dismantled. - Page 33 Maintenance and care • Remove screws (64) and take off the cover strip (8). • Remove screws (66) and take off the guide strip (6). • Variant "PM" also includes a compression spring (27), O-ring (43), sphere (24) and O- ring (42) •...
- Page 34 Maintenance and care Variant "PM" also includes O-ring (44), monitoring piece (7) and compression springs (26). The monitoring element is adjusted and secured with the set-screws (61, 63). Caution! The monitoring piece is under spring pre-load and is installed directionally oriented for each base jaw! See detail views for jaw 1 and jaw 2! Maintenance...
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Page 35: Adjustment Of The Pneumatic Jaw End Position Monitoring (Pm)
Maintenance and care 7.4.3 Adjustment of the pneumatic jaw end position monitoring (PM) Jaw 1: monitoring open jaw position • Move base jaws to OPEN position. • Screw the set-screw (61) into the bore hole "o" up to the stop and then unscrew it again by a few turns. -
Page 36: Leak Test
If the clamping system is leaking, check the fittings first (e.g. with Metaflux leak detection spray). Seal any leaking screws. If the cause of the leak is not the fittings, send the product to SCHUNK for repair. 05.00 | KSF3, KSF3-LH, KSF3-F | TANDEM Clamping Force Block | en | 1467140... -
Page 37: Sealing Kits, Accessory Kits And Parts Lists
8.1.1 Piston chamber sealing kit The piston chamber seals should only be replaced by SCHUNK! Danger to life in case of improper disassembly. The sealing kit for the piston chamber contains all seals and wearing parts for the parts installed inside (e.g. -
Page 38: Monitoring Sealing Kit / Connection
Sealing kits, accessory kits and parts lists 8.1.2 Monitoring sealing kit / connection The sealing kit for monitoring includes all seals and wearing parts for the pneumatic monitoring of the PM variants, as well as the O- rings of the bottom connections. The customer can carry out the basic cleaning themselves with this. -
Page 39: Parts Lists
Sealing kits, accessory kits and parts lists 8.3 Parts lists Parts list "Standard stroke" and "Long stroke" variants Item Designation Quantity Body >Housing< ● Base jaw ● Chuck piston ● Cylinder piston ● Cover ● Guide strip ● Monitoring piece ●... - Page 40 Sealing kits, accessory kits and parts lists Countersunk screw ● ● ● ● ● ● ISO 14581 ● Cylindrical screw ● ● ● ● ● ● ● Cylindrical screw ● Screw ● Set-screw ● Plug ● ● Fitting screw ● ●...
- Page 41 Sealing kits, accessory kits and parts lists Parts list "fixed jaw" variant Item Designation Quantity Body >Housing< ● Base jaw ● Chuck piston ● Cylinder piston ● Cover ● Guide strip ● Monitoring piece ● Covering strip ● Base jaw ●...
- Page 42 Sealing kits, accessory kits and parts lists Cylindrical screw ● ● ● ● ● ● ● Cylindrical screw ● Cylindrical screw ● Cylindrical screw ● Screw ● Set-screw ● ● Plug ● ● Fitting screw ● ● O-ring DIN ISO 3601 4 ●...
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Page 43: Assembly Drawings
Assembly drawings 9 Assembly drawings 9.1 KSF3, KSF3-LH with variant "PM" Centering with fitting screws Centering with clamping sleeves Centering with cylindrical pins (Z variant) 05.00 | KSF3, KSF3-LH, KSF3-F | TANDEM Clamping Force Block | en | 1467140... -
Page 44: Ksf3-F
Assembly drawings 9.2 KSF3-F with variant "PM" Centering with fitting screws Centering with clamping sleeves Centering with cylindrical pins (Z variant) 05.00 | KSF3, KSF3-LH, KSF3-F | TANDEM Clamping Force Block | en | 1467140... -
Page 45: Translation Of The Original Declaration Of Incorporation
Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of the Council on machinery. Manufacturer/ H.-D. SCHUNK GmbH & Co. Spanntechnik KG Distributor Lothringer Str. 23 D-88512 Mengen We hereby declare that on the date of the declaration the following partly completed machine complied with all basic safety and health regulations found in the directive 2006/42/EC of the European Parliament and of the Council on machinery. -
Page 46: Appendix On Declaration Of Incorporation, As Per 2006/42/Ec, Annex Ii, No. 1 B
Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B 11 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B 1. Description of the basic safety and health protection requirements, as per 2006/42/EC, annex I, that apply to and are fulfilled for the scope of the incomplete machine: Product designation TANDEM clamping force block, spring-loaded Type designation... - Page 47 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Protection against mechanical hazards 1.3.1 Risk of loss of stability 1.3.2 Risk of break-up during operation 1.3.3 Risks due to falling or ejected objects 1.3.4 Risks due to surfaces, edges or angles 1.3.5 Risks related to combined machinery 1.3.6...
- Page 48 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Maintenance 1.6.1 Machinery maintenance 1.6.2 Access to operating positions and servicing points 1.6.3 Isolation of energy sources 1.6.4 Operator intervention 1.6.5 Cleaning of internal parts Information 1.7.1 Information and warnings on the machinery 1.7.1.1 Information and information devices 1.7.1.2 Warning devices...
- Page 52 Translation of Original Operating Manual H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D-88512 Mengen Tel. +49–7572-7614-0 Fax +49-7572-7614-1099 info@de.schunk.com schunk.com Folgen Sie uns I Follow us...
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