SCHUNK TANDEM KSH plus Assembly And Operating Manual Download Page 4

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Table of contents

05.00|0489065 KSH plus, KSH-LH plus, KSH-F plus |en

8.2 Assembling the piston seal ..................................................................................... 30

8.3 Testing the leakage and tightness of the hydraulic system ................................... 31

9 Sealing kits, accessory packs and parts lists ............................................................. 33

9.1 Sealing kit lists ........................................................................................................ 33

9.2 Accessory packs ...................................................................................................... 35

9.3 Part lists .................................................................................................................. 36

10 Assembly drawings .................................................................................................. 46

10.1 KSH plus, KSH-LH plus ............................................................................................. 46

10.2 KSH-F plus ............................................................................................................... 47

11 Translation of the original declaration of incorporation ........................................... 48

Summary of Contents for TANDEM KSH plus

Page 1: ...Translation of the original operating manual TANDEM Clamping Force Block KSH plus KSH LH plus KSH F plus Assembly and Operating Manual Superior Clamping and Gripping ...

Page 2: ...alterations for the purpose of technical improvement Document number 0489065 Version 06 00 02 02 2021 en H D SCHUNK GmbH Co All rights reserved Dear Customer thank you for trusting our products and our family owned company the leading technology supplier of robots and production machines Our team is always available to answer any questions on this product and other solutions Ask us questions and c...

Page 3: ...8 Personal protective equipment 9 2 9 Notes on safe operation 10 2 10 Transport 10 2 11 Malfunctions 11 2 12 Disposal 11 2 13 Fundamental dangers 11 2 13 1 Protection during handling and assembly 12 2 13 2 Protection during commissioning and operation 12 2 13 3 Protection against dangerous movements 13 2 13 4 Notes on particular risks 13 3 Technical Data 16 4 Tightening torques for screws 18 5 Ass...

Page 4: ...esting the leakage and tightness of the hydraulic system 31 9 Sealing kits accessory packs and parts lists 33 9 1 Sealing kit lists 33 9 2 Accessory packs 35 9 3 Part lists 36 10 Assembly drawings 46 10 1 KSH plus KSH LH plus 46 10 2 KSH F plus 47 11 Translation of the original declaration of incorporation 48 ...

Page 5: ...manual Illustrations in this manual are provided for basic understanding and may differ from the actual product design In addition to these instructions the documents listed under 1 1 2 Page 6 are applicable Presentation of Warning Labels To make risks clear the following signal words and symbols are used for safety notes DANGER Danger for persons Non observance will inevitably cause irreversible ...

Page 6: ...hs after delivery date from factory or 500 000 cycles if it is used as intended under the following conditions Observe the applicable documents 1 1 2 Page 6 Observe the ambient conditions and operating conditions 2 6 Page 8 Observance of the specified care and maintenance instructions 8 Page 26 Parts touching the workpiece and wear parts are not included in the warranty A cycle consists of a compl...

Page 7: ...ting equipment as a press as a punching tool as a lathe chuck as a drill or as a cutting tool It is used in working environments that are not permissible Workpieces are not properly clamped Safety regulations are disregarded and persons are working at this product for example to machine clamped workpieces without additional protective equipment The technical data specified by the manufacturer are ...

Page 8: ...face pressures in the jaw guidance and can significantly reduce the clamping force Do not use welded jaws Reduce operating pressure for higher clamping points Environmental and operating conditions Required ambient conditions and operating conditions Incorrect ambient and operating conditions can make the product unsafe leading to the risk of serious injuries considerable material damage and or a ...

Page 9: ...aining knowledge and experience qualified personnel is able to perform the delegated tasks recognize and avoid possible dangers and knows the relevant standards and regulations Instructed persons were instructed by the operator about the delegated tasks and possible dangers due to improper behaviour Due to its technical training knowledge and experience service personnel of the manufacturer is abl...

Page 10: ...t to any corrosive media This does not apply to products that are designed for special environments Eliminate any malfunction immediately Observe the care and maintenance instructions Observe the current safety accident prevention and environmental protection regulations regarding the product s application field IMPORTANT Following a longer shutdown period more than approx 6 hours always re tensio...

Page 11: ... 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 Fundamental dangers General Observe safety distances Never deactivate safety devices Before commissioning the product take appropriate protective...

Page 12: ...rules Use suitable assembly and transport equipment and take precautions to prevent jamming and crushing Incorrect lifting of loads Falling loads may cause serious injuries and even death Stand clear of suspended loads and do not step into their swiveling range Never move loads without supervision Do not leave suspended loads unattended Protection during commissioning and operation Falling or viol...

Page 13: ...estricted Limit prevent accidental access for people in this area due through technical safety measures The protective cover and protective fence must be rigid enough to withstand the maximum possible movement energy EMERGENCY STOP switches must be easily and quickly accessible Before starting up the machine or automated system check that the EMERGENCY STOP system is working Prevent operation of t...

Page 14: ...lamping block on machines with the appropriate connection dimensions CAUTION Risk of crushing from chuck jaws opening and closing when manually loading and unloading Do not reach between the chuck jaws Wear personal protective equipment Prevent the clamping block from being actuated unintentionally Use automated loading CAUTION Risk of slipping or falling if the operational environment of the clam...

Page 15: ...afety notes 05 00 0489065 KSH plus KSH LH plus KSH F plus en 15 CAUTION Risk of burns due to workpieces with high temperatures Wear protective gloves when removing the workpieces Automatic loading is preferred ...

Page 16: ... 5 16 26 40 50 4 18 30 45 max pressure bar 60 60 60 60 120 120 120 120 45 60 60 60 60 Repeat accuracy mm 0 01 0 01 0 01 5 0 02 0 01 0 01 0 01 5 0 02 0 03 0 01 0 01 0 01 5 0 02 max jaw height mm 60 60 60 60 60 60 60 60 150 60 60 60 60 Weight kg 1 5 5 9 5 14 1 5 5 9 5 14 35 1 5 5 9 5 14 Clamping force is the arithmetic sum of the individual forces occurring at the chuck jaws at distance H see catalo...

Page 17: ...SH plus KSH LH plus KSH F plus 64 100 140 160 250 I 41 64 91 104 170 J 55 7 74 2 77 7 87 2 103 2 K 33 3 47 46 50 57 L 14 15 13 5 15 20 M 30 57 88 100 45 off center N M6 M8 M8 M10 M12 O 12 15 15 5 18 20 P 2 5 4 3 5 4 5 Ø Q 8f7 10f7 10f7 12f7 14f7 Ø R 8 11 11 13 16 S 4 4 5 5 5 6 6 ...

Page 18: ...le torque MA Nm 4 2 7 5 13 28 50 88 120 160 200 290 400 500 Tightening torques to mount top jaws on the TANDEM clamping block screw quality 12 9 Screw size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24 Tightening torques MA Nm 5 9 15 32 62 108 170 262 510 880 Tightening torques to mount the chuck piston onto the cylinder piston screw quality 12 9 Variante Screw size M5 M8 M10 M12 KSH KSH F Tightening torque...

Page 19: ...clamping block is off during assembly and connection Perform maintenance modifications or installations outside of the danger zone WARNING Risk of injury from clamping block or chuck jaws falling during transport installation or removal Make sure the clamping block and chuck jaws do not fall during transport installation or removal Use a crane and or a transport truck for transportation Only insta...

Page 20: ...en using fitting screws item 9 use them instead of the clamping sleeves item 27 and the two corresponding screws item 19 Connecting the clamping block Make sure the power supply is off when connecting the clamping block Observe the Basic safety notes and the hydraulic wiring diagram 5 3 Page 23 The hydraulic screw fittings must be assembled in accordance with the installation conditions recommende...

Page 21: ...I for operation with external hydraulic pipes or hose lines The thread for the hydraulic fitting on the front of the housing item 1 is G for all clamping force blocks Connection III and IV in the base for hose free direct connection in the machine table The threads for hose free direct connection are not designed for hydraulic screw fittings NOTE All four hydraulic connections come sealed on deliv...

Page 22: ...abletop are precisely aligned above one another and the O rings for sealing are inserted Screw the clamping force block to the machine table observing the tightening torques 4 Page 18 The assembly parts screws clamping sleeves O rings are included in the accessory pack The different mounting variations of the clamping force block are described in the chapter on Mounting the clamping force block on...

Page 23: ...erted in an O ring seat in the table top The dimensions for the production of the axial sealing O ring seat are Ø 9 0 1 x 1 1 0 05 The recommended O rings for sealing the supply lines Ø 5 28 x 1 78 FKM 75 are not included in the clamping force block s scope of delivery Hydraulic circuit diagram Hydraulic circuit diagram 5 3 ...

Page 24: ...o leaks in the line system If the clamping system is involved in a collision it must be tested to see if it is still functioning properly before using it again Only use original SCHUNK spare parts when replacing damaged parts Visually inspect the clamping block at least once per shift for visible damage and defects Renew the chuck jaw mounting bolts if there are signs of wear or damage Only use sc...

Page 25: ...ace damaged parts 8 1 Page 26 or send to SCHUNK for repair The clamping block does not make a complete stroke Possible cause Remedial measures Chips or dirt between the covering strip and base jaws Unscrew the covering strip item 7 and remove chips and dirt The clamping force is getting weaker Possible cause Remedial measures The clamping block is not tightly sealed Check connection and sealing sc...

Page 26: ...ousing base jaws and chuck piston and lubricate all the guides housing base jaws chuck piston with LINOMAX 200 Reassemble everything and relubricate the two front or two side lubricating nipples with LINOMAX 200 Product information for LINOMAX 200 can be requested from SCHUNK CAUTION Allergic reactions due to grease in contact with skin Wear gloves IMPORTANT Please regularly check the clamping dev...

Page 27: ...ved to position CLOSED To do this reconnect the clamping block to the hydraulic system and set the clamping block to position OPEN or CLOSED with the prescribed pressure and loosen the screw Do not remove the pressure line until the screw item 14 has been removed 5 Pull the plugs item 8 out of the housing item 1 6 Loosen the screws items 9 19 and disassemble the clamping system from the machine ta...

Page 28: ...mbly 14 Clean all the parts thoroughly and check for damage and wear Replace damaged and worn parts with original SCHUNK spare parts 15 Grease the new seal item 15 with Renolit HLT 2 or an equivalent grease Carefully install the seal it must not be damaged 16 Disassemble the two part seal item 20 and grease with Renolit HLT 2 or an equivalent grease Insert the O ring of the seal item 20 into the g...

Page 29: ...piston item 3 Be sure to observe the installation position for the base jaws and the chuck piston In addition for variant KSH F plus Mount base jaw item 31 in the housing item 1 Mount the positioning bolt item 29 between base jaw item 31 and housing item 1 Screw in the screw item 32 between the base jaw item 31 and the housing item 1 28 Connect the hydraulic clamping force block to the air supply ...

Page 30: ...rease with Renolit HLT 2 or an equivalent grease Pull the O ring of the seal item 12 over the cylinder piston item 4 and into the groove Do not stretch or tear the O ring Stretch the sealing ring with an expansion sleeve over the cone sleeve and slide over the cylinder piston and the O ring that was previously inserted into the groove 2 Calibration After sliding it over the Turcon ring snaps into ...

Page 31: ...90 160 58 55 22 51 22 47 22 28 91 86 78 4 x 90 250 120 115 54 111 54 107 54 58 106 101 93 6 x 60 C calibration sleeve Material steel KSH plus Piston Ø D d1 0 1 L I1 l2 1 64 21 29 05 21 05 30 1 10 100 35 43 05 35 05 30 1 10 140 50 58 05 50 05 30 1 10 160 58 66 05 58 05 30 1 10 250 120 128 05 120 05 30 1 10 Testing the leakage and tightness of the hydraulic system The TANDEM clamping block is hydrau...

Page 32: ...be closed When using a hose free direct connection the clamping system must stay firmly screwed to the machine table The leakage and tightness test is to be performed in the following order 1 Actuate the clamping block with reduced hydraulic pressure Check the clamping block for free movement by opening and closing the jaws several times 2 Check the clamping block with the maximum permissible hydr...

Page 33: ...ling kit lists KSH plus 64 KSH LH plus 64 KSH F plus 64 ID 0405139 Item Designation Quantity 12 Turcon Glyd Ring 1 15 Sealing ring 1 17 O ring 1 18 O ring 4 20 Turcon Glyd Ring 1 22 Flat seal 4 54 O ring 4 56 Locking screw DIN908 with copper sealing ring 2 KSH plus 100 KSH LH plus 100 KSH F plus 100 ID 0405239 Item Designation Quantity 12 Turcon Glyd Ring 1 15 Sealing ring 1 17 O ring 1 18 O ring ...

Page 34: ...ty 12 Turcon Glyd Ring 1 15 Sealing ring 1 17 O ring 1 18 O ring 4 20 Turcon Glyd Ring 1 22 Flat seal 2 41 O ring 2 54 O ring 4 56 Locking screw DIN908 with copper sealing ring 2 KSH plus 250 KSH LH plus 250 KSH F plus 250 ID 0405559 Item Designation Quantity 12 Turcon Glyd Ring 1 15 Sealing ring 1 17 O ring 1 18 O ring 4 20 Turcon Glyd Ring 1 54 O ring 4 56 Locking screw DIN908 with copper sealin...

Page 35: ...pper sealing ring 2 KSH plus 100 KSH LH plus 100 KSH F plus 100 ID 8507915 Item Designation Quantity 8 Plug 4 9 Fitting screw 2 18 O ring 4 19 Screw 4 27 Clamping sleeve 2 51 Screw 8 54 O ring 4 56 Locking screw DIN908 with copper sealing ring 2 KSH plus 140 KSH LH plus 140 KSH F plus 140 ID 1346788 Item Designation Quantity 8 Plug 4 9 Fitting screw 2 18 O ring 4 19 Screw 4 27 Clamping sleeve 2 51...

Page 36: ...plus 250 KSH LH plus 250 KSH F plus 250 ID 8507918 Item Designation Quantity 8 Plug 4 9 Fitting screw 2 18 O ring 4 19 Screw 4 27 Clamping sleeve 2 51 Screw 8 52 T handle for KSP 2 53 Set screw 2 54 O ring 4 56 Locking screw DIN908 with copper sealing ring 2 Part lists KSH plus 64 ID 0405130 KSH LH plus 64 ID 1313057 Item Designation Quantity 1 Body 1 2 Base jaw 2 3 Piston 1 4 Cylinder piston 1 5 ...

Page 37: ...4 19 Screw 4 20 Turcon Glyd Ring 1 21 Countersunk screw 8 22 Flat seal 4 23 Set screw 8 25 Countersunk screw 2 27 Clamping sleeve 2 56 Locking screw DIN908 with copper sealing ring 2 KSH F plus 64 ID 0405140 Item Designation Quantity 1 Body 1 2 Base jaw 1 3 Piston 1 4 Cylinder piston 1 5 Cover 1 6 Guide strip 1 7 Covering strip 1 8 Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking...

Page 38: ...9 Socket pin 1 30 Screw 1 31 Base jaw 1 32 Screw 1 33 Guide strip 1 56 Locking screw DIN908 with copper sealing ring 2 KSH plus 100 ID 0405230 KSH LH plus 100 ID 0405250 Item Designation Quantity 1 Body 1 2 Base jaw 2 3 Piston 1 4 Cylinder piston 1 5 Cover 1 6 Guide strip 2 7 Covering strip 1 8 Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Soun...

Page 39: ...eeve 2 56 Locking screw DIN908 with copper sealing ring 2 KSH F plus 100 ID 0405240 Item Designation Quantity 1 Body 1 2 Base jaw 1 3 Piston 1 4 Cylinder piston 1 5 Cover 1 6 Guide strip 2 7 Covering strip 1 8 Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 2 17 O ring 1 18 O ring 4 19 Screw ...

Page 40: ...2 Screw 1 56 Locking screw DIN908 with copper sealing ring 2 KSH plus 140 ID 1330214 KSH LH plus 140 ID 1330216 Item Designation Quantity 1 Body 1 2 Base jaw 2 3 Piston 1 4 Cylinder piston 1 5 Cover 1 6 Guide strip 2 7 Covering strip 1 8 Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 2 17 O ...

Page 41: ...1 2 Base jaw 1 3 Piston 1 4 Cylinder piston 1 5 Cover 1 6 Guide strip 1 7 Covering strip 1 8 Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 1 17 O ring 1 18 O ring 4 19 Screw 4 20 Turcon Glyd Ring 1 21 Countersunk screw 15 22 Flat seal 4 23 Set screw 8 24 Set screw 2 25 Countersunk screw 2 2...

Page 42: ...ing kits accessory packs and parts lists 42 05 00 0489065 KSH plus KSH LH plus KSH F plus en Item Designation Quantity 30 Screw 1 31 Base jaw 1 32 Screw 1 56 Locking screw DIN908 with copper sealing ring 2 ...

Page 43: ...Plug 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 2 17 O ring 1 18 O ring 4 19 Screw 4 20 Turcon Glyd Ring 1 21 Countersunk screw 15 22 Flat seal 2 23 Set screw 4 24 O ring 2 25 Countersunk screw 2 26 Set screw 4 27 Clamping sleeve 2 41 O ring 2 56 Locking screw DIN908 with copper sealing ring ...

Page 44: ...ubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 1 17 O ring 1 18 O ring 4 19 Screw 4 20 Turcon Glyd Ring 1 21 Countersunk screw 15 22 Flat seal 2 23 Set screw 4 24 O ring 2 25 Countersunk screw 2 26 Set screw 4 27 Clamping sleeve 2 28 Spherical washer 1 29 Socket pin 1 30 Screw 1 31 Base jaw 1 32 Screw 1 41 O ring 2 56 Locking ...

Page 45: ... 4 9 Fitting screw 2 10 Funnel lubrication nipple 4 11 Locking screw 2 12 Turcon Glyd Ring 1 13 Sound absorber 1 14 Screw 1 15 Sealing ring 1 16 Screw 2 17 O ring 1 18 O ring 4 19 Screw 4 20 Turcon Glyd Ring 1 23 Set screw 2 24 Set screw 2 25 Countersunk screw 2 27 Clamping sleeve 2 Individual components are precisely coordinated and cannot not be replaced by the customer See seal kit list parts c...

Page 46: ...ly drawings 46 05 00 0489065 KSH plus KSH LH plus KSH F plus en Assembly drawings KSH plus KSH LH plus for size 100 for sizes 140 160 250 Centering with clamping sleeves Centering with fitting screws 10 10 1 ...

Page 47: ...Assembly drawings 05 00 0489065 KSH plus KSH LH plus KSH F plus en 47 KSH F plus A for size 100 B for sizes 140 160 C Centering with clamping sleeves D Centering with fitting screws 10 2 ...

Page 48: ...plus 160 ID number 0405130 0405132 0405230 0405232 1330214 1330215 0405330 0405332 1313057 1313058 0405250 0405252 1330216 1330217 0405350 0405352 0405550 0405552 0405140 0405142 0405240 0405242 1330218 1330219 0405340 0405342 The partly completed machine may not be put into operation until conformity of the machine into which the partly completed machine is to be installed with the provisions of ...

Page 49: ...Translation of the original declaration of incorporation 05 00 0489065 KSH plus KSH LH plus KSH F plus en 49 ...

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