SCHUNK TANDEM KSH3 Translation Of Original Operating Manual
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Summary of Contents for SCHUNK TANDEM KSH3
- Page 1 Translation of Original Operating Manual TANDEM Clamping Block KSH3, KSH3-LH, KSH3-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: 1477683 Version: 03.00 | 20/12/2022 | 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 .................... 26 Notes........................ 26 Maintenance and lubrication intervals .............. 26 Greasing areas / lubricants ................ 26 Maintenance work ..................... 27 7.4.1 Lubricate .................... 27 7.4.2 Basic cleaning.................. 28 7.4.3 Testing the leakage and tightness of the hydraulic system .... 32 7.4.4 Assembly devices piston seals ...............
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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: • KSH3 64, 100, 140, 160, 200 •... -
Page 7: Basic Safety Notes
• Structural changes should only be made with the written approval of SCHUNK. 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683... -
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 in the event of workpiece loss due to failure or pressure reduction of the oil pressure. Provide system pressure monitoring in the hydraulic system • Provide protection in the user program in case of pressure •...
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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 Hydraulic oil Requirement for the pressure filtered (10 μm), viscosity 46 mm/s at 40 °C in line medium with ISO VG Volumetric flow max. - Page 15 Technical data KSH3 / KSH3-LH / KSH3-F KSH3-LH Dime nsion Ø C 4H7 x 7.5 6H7 x 12 8H7 x 14 8H7 x 14 8H7 x 14 10H7 x 20 10H7 x 20 200 x 180 29.5 25 (2x) 64.5 45 (off- center) 64.5...
- Page 16 Technical data Optional Z variant ±0.01 mm to clamping center Clamping sleeve ±0.04 mm to clamping center Clamping sleeve fitting screw ±0.02 mm to clamping center Only with variant "PM" 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683...
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Page 17: 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 torque 120 160 200 290 400 500 (Nm) Tightening torques for mounting top jaws on the TANDEM clamping force block (screw quality 12.9) -
Page 18: 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 [ / 41] block and to the "Assembly Drawings" chapter. WARNING Danger of crushing due to the product approaching the machine table during assembly. - Page 19 Assembly and connection NOTE • For vertical installation, the openings of the coolant drain (V) must always face downwards • Surface »X« is parallel to the guideway of the base jaws (2) in order to be able to align the clamping force block on the machine table or check the positioning.
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Page 20: 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 21: Supply Lines
Assembly and connection 5.2.1 Supply lines The clamping force block has four hydraulic connections: I, II, III, Two connections for OPEN (I and III) and two connections for CLOSE (II and IV). Which of the two hydraulic connections has to be opened for actuation depends on the specific application: •... -
Page 22: Dynamic Pressure Monitoring Of The Jaw End Positions (Variant "Pm")
Assembly and connection 5.2.2 Dynamic pressure monitoring of the jaw end positions (variant "PM") Dynamic pressure monitoring for the jaw end positions is integrated via connections 1 and 4 on the bottom. Connection 1 → monitoring outer end jaw position. Connection 4 →... -
Page 23: 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. Dimension Size Ø C [mm] D [mm] 37.5 E [mm]... -
Page 24: Hydraulic Circuit Diagram
Assembly and connection 5.2.4 Hydraulic circuit diagram Electronic symbol 4/2 directional control valve 3/2 directional control valve Pressure switch Regulator Pressure gauge Flow control valve Compressed air supply Hydraulic supply ← → Jaw stroke "open" → ← Jaw stroke "close" Dynamic pressure monitoring for jaw end position "open"... -
Page 25: Troubleshooting
Troubleshooting 6 Troubleshooting Clamping force block chuck jaws will not move Possible cause Solution(s) Oil supply interrupted Check the hydraulic supply System pressure too low Increase system pressure according to clamping system technical specifications Connections mixed up Check connections and functions and connect properly Hydraulic connections that are in use Check connections and open... -
Page 26: 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 The following maintenance work should be carried out after the specified cycle numbers or at the latest after the monthly data. -
Page 27: Maintenance Work
Maintenance and care 7.4 Maintenance work 7.4.1 Lubricate CAUTION Allergic reactions or irritation due to skin or eye contact with lubricants on the product. Wear protective equipment (protective gloves, protective • goggles) in case of foreseeable contact with lubricants on the product (e.g. -
Page 28: Basic Cleaning
Maintenance and care Central lubrication • To use central lubrication, the set-screws of the factory sealed connections (6, 7) must be removed. • For proper lubrication, both supply lines must be connected. • The central lubrication system must be suitable for greases of NLGI 2 classification. •... - Page 29 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). Remove screws (65) and pull out cover (5) together with O-ring (45) and flat gaskets (48) out of the housing.
- Page 30 Maintenance and care Additionally for the KSH3-F variant: Remove screw (68). Pull out the positioning bolt (10) via its extraction thread with a screw as far as the stop. Pull the base jaw (9) out of the housing. Variant "PM" also includes the O-ring (44). Pull the base jaws (2) out of the housing.
- Page 31 Maintenance and care Maintenance • Clean all parts thoroughly and check for damage and wear. • Treat all greasing areas with lubricant } 7.3 [ / 26]. • Replace all wearing parts and seals if necessary } 8.1 [ / 35]. Assembly Assembly is done in the reverse order of disassembly.
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Page 32: Testing The Leakage And Tightness Of The Hydraulic System
Maintenance and care Jaw 2: monitoring closed jaw position • Move base jaws to CLOSED position. • Screw the set-screw (61) into the bore hole "oo" up to the stop and then unscrew it again by a few turns. • Slowly screw the set-screw (61) into the bore hole "o" until the differential pressure sensor emits a switching signal. -
Page 33: Assembly Devices Piston Seals
To assemble the seal (40), a multi-part assembly tool is required. If no assembly tool is available, repair work on the TANDEM clamping force block should be carried out by SCHUNK. 1. Assembly • Disassemble the two-part seal (40) and grease with Renolit HLT 2 or an equivalent grease. - Page 34 Maintenance and care A cone sleeve Material: steel +0.15 +0.3 KSH3 Piston Ø 22.5 36.5 51.5 59.5 76.5 250/315 105 106.5 B expansion sleeve Material: POM, NYLON® or similar +0.3 KSH3 Piston Ø 20.37 16.37 12.37 3 x 120° 34.64 30.64 26.64 3 x 120°...
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Page 35: Sealing Kits, Accessory Kits And Parts Lists
Sealing kits, accessory kits and parts lists 8 Sealing kits, accessory kits and parts lists When ordering spare parts, the type size and, if possible, the serial number of the lamping force block must always be stated to avoid delivery mistakes. Seals, sealing elements, fittings, springs, bearings, screws, wiper bars and parts that come into contact with the workpiece are not covered by the warranty. -
Page 36: 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 wear parts for the pneumatic monitoring of the PM variants, as well as the O-rings of the bottom connections. Sealing kit * Size 64 1470480... -
Page 37: Parts Lists
Sealing kits, accessory kits and parts lists 8.3 Parts lists Parts list "Standard stroke" and "Long stroke" variants Item Description Quanti Body >Housing< ● Base jaw ● Chuck piston ● Cylinder piston ● Cover ● Guide strip ● Monitoring piece ●... - Page 38 Sealing kits, accessory kits and parts lists Countersunk screw ● ● ● ● ● ● ISO 14581 ● Countersunk screw 9 ● Cylindrical screw ● ● ● ● ● Cylindrical screw ● Screw ● Sealing plug ● ● ● ● ●...
- Page 39 Sealing kits, accessory kits and parts lists Parts list "fixed jaw" variant Item Description Quanti Body >Housing< ● Base jaw ● Chuck piston ● Cylinder piston ● Cover ● Guide strip ● ● ● ● ● Monitoring piece ● Covering strip ●...
- Page 40 Sealing kits, accessory kits and parts lists Countersunk screw 9 ● Cylindrical screw ● ● ● ● Cylindrical screw ● Cylindrical screw ● Cylindrical screw ● Screw ● Sealing plug ● ● ● ● ● ● ● Plug ● ● Fitting screw ●...
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Page 41: Assembly Drawings
Assembly drawings 9 Assembly drawings 9.1 KSH3, KSH3-LH with variant "PM" Centering with fitting screws Centering with clamping sleeves Centering with cylindrical pins (Z variant) 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683... -
Page 42: Ksh3-F
Assembly drawings 9.2 KSH3-F with variant "PM" Centering with fitting screws Centering with clamping sleeves Centering with cylindrical pins (Z variant) 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683... -
Page 43: 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 44: 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, hydraulic Type designation... - Page 45 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Protection against mechanical hazards 1.3.4 Risks due to surfaces, edges or angles 1.3.5 Risks related to combined machinery 1.3.6 Risks related to variations in operating conditions 1.3.7 Risks related to moving parts 1.3.8 Choice of protection against risks arising from moving parts...
- Page 46 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B Maintenance 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 1.7.2 Warning of residual risks 1.7.3 Marking of machinery 1.7.4...
- Page 48 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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