SCHUNK TANDEM KSF plus Series User instructions

Translation of Original Operating Manual

TANDEM Clamping Block

KSF plus, KSF-LH plus, KSF-F plus

Assembly and Operating Manual

Superior Clamping and Gripping

Imprint

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Imprint

This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights

reserved. Any reproduction, processing, distribution (making available to third parties),

translation or other usage - even excerpts - of the manual is especially prohibited and

requires our written approval.

Technical changes:

We reserve the right to make alterations for the purpose of technical improvement.

Document number: 1151456

Version: 03.00 |18/06/2019|en

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 challenge us. We will find a solution!

Best regards,

Your SCHUNK team

H.-D. SCHUNK GmbH & Co.

Spanntechnik KG

Lothringer Str. 23

D-88512 Mengen

Tel. +49–7572-7614-0

Fax +49-7572-7614-1099

[email protected]

schunk.com

Table of contents

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Table of contents

About this manual.................................................................................................... 4

1.1

Presentation of Warning Labels ............................................................................... 4

1.2

Applicable documents .............................................................................................. 4

Basic safety instructions ........................................................................................... 5

2.1

Intended use............................................................................................................. 5

2.2

Not intended use ...................................................................................................... 5

2.3

Notes on particular risks........................................................................................... 6

2.4

Notes on safe operation........................................................................................... 8

2.4.1

Constructional changes, attachments or modifications............................... 9

2.5

Personnel qualification............................................................................................. 9

2.6

Organizational measures.......................................................................................... 9

2.7

Personal protective equipment.............................................................................. 10

Warranty................................................................................................................. 11

Scope of delivery ..................................................................................................... 11

Technical data ......................................................................................................... 12

Tightening torques for screws.................................................................................. 15

Assembly................................................................................................................. 15

7.1

Assembly of the clamping block on the machine table ......................................... 15

7.2

Connections of the clamping block ........................................................................ 17

7.3

Mounting recommendations ................................................................................. 19

7.3.1

Installation recommendation for partial integration: ................................ 20

7.3.2

Installation recommendation for complete installation: ........................... 20

Trouble shooting ..................................................................................................... 22

Maintenance and care ............................................................................................. 23

9.1

Disassembly and assembly of the clamping block ................................................. 23

9.2

Control of thightness.............................................................................................. 27

Sealing kits, accessory packs and parts lists ............................................................. 28

10.1

Seal kit lists ............................................................................................................. 28

10.2

Accessory packs ...................................................................................................... 29

10.3

Lists of spare parts.................................................................................................. 30

Drawings ................................................................................................................. 43

Translation of original declaration of incorporation ................................................. 45

Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B ..... 46

About this manual

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

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. Prerequisite for safe working is

the observance of all safety instructions in this 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

(1.2, Page 4) 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 injury or death.

WARNING

Dangers for persons!

Non-observance can lead to irreversible injury and even death.

CAUTION

Dangers for persons!

Non-observance can cause minor injuries.

NOTICE

Material damage!

Information about avoiding material damage.

Applicable documents

•General terms of business *

•Catalog data sheet of the purchased product *

The documents marked with an asterisk (*) can be downloaded on

our homepage www.schunk.com.

1.1

1.2

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Basic safety instructions

Improper handling, assembly and maintenance of this product may

result in risk to persons and equipment if this operating manual is

not observed.

Report any failures and damage immediately and repair without

delay to keep the extent of the damage to a minimum and prevent

compromising the safety of the product.

Only original SCHUNK spare parts may be used.

Intended use

•This product is intended for clamping and holding workpieces

on machine tools and other suitable technical devices.

•It is designed to be set up on a machine table or machine

pallets.

•The product may only be used within the scope of its technical

data, (5, Page 12).

•The product is intended for industrial and industry-oriented

use.

•Appropriate use of the product includes compliance with all

instructions in this manual.

Not intended use

•The product is not being used as intended if, for example:

•It is used as lifting 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 exceeded

during usage.

•It is used with machines/systems or workpieces that are not

designed to be used with it.

2.1

2.2

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Notes on particular risks

The TANDEM clamping block can cause injury for persons and

material damage, for example:

•it is used other than as intended;

•it is not installed or maintained properly;

•the safety and installation instructions, the safety and accident

prevention regulations valid at the usage site or the EC

Machinery Directive are not observed.

WARNING

Risk of injury to operating personnel if the clamping block fails

because the technical data have been exceeded and a

workpiece is released or parts fly off!

•The technical data specified by the manufacturer for using the

clamping block must never be exceeded.

•The clamping block may only be used on machines and

facilities that fulfill the minimum requirements of the EC

Machinery Directive 2006/42/EC; specifically, they must have

effective technical measures to protect against possible

mechanical hazards.

WARNING

Risk of injury due to immediate closing of the clamping block

with a high spring pressure in case of failure of the pneumatic

pressure.

•Do not reach between the chuck jaws when manually loading

and unloading.

•Remove the power supplies of the clamping block for

maintenance work.

2.3

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

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 transport.

•Only install the clamping 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 clamping block's operational

environment is not clean (e.g. contaminated with cooling

lubricants or oil).

•Ensure that the working environment is clean before starting

assembly and installation work.

•Wear suitable safety boots.

•Follow the safety and accident-prevention regulations when

operating the clamping block, especially when working with

machine tools and other technical equipment.

CAUTION

Risk of burns due to workpieces with high temperatures.

•Wear protective gloves when removing the workpieces.

•Automatic loading is preferred.

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Notes on safe operation

Follow the care and maintenance instructions.

Assembling the TANDEM clamping block

During assembly and connection, the power supply for the

clamping block must be switched off. During connection,

adjustment, commissioning and testing, make sure that no

accidental operation of the TANDEM clamping block by the fitter

or other persons is possible.

Remove the power supplies for installation, modification,

maintenance, or adjustment work. Do maintenance work,

modifications, and add attachments outside of the danger zone.

Functional testing

•After installing the TANDEM clamping block, its proper function

must be checked before putting it into operation. There must

be no leaks in the piping system here.

•If the clamping block 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

items.

•Check the clamping block at least once per shift for externally

visible damage and malfunctions.

•If there are signs of wear or damage, the fixing screws for the

chuck jaws must be replaced. Only use screws with a quality of

12.9.

Maintenance instructions

The reliability of the clamping block can be guaranteed only if the

maintenance instructions are followed exactly.

Use of special chuck jaws

When using special chuck jaws, please observe the following rules:

•The chuck jaws should be designed to be as low as possible.

The clamping point must be as near as possible to the housing.

(clamping points at a greater distance cause higher surface

pressures in the jaw guides and can significantly reduce the

clamping force.)

•For higher clamping points, the operating pressure must be

reduced.

•Do not use welded jaws.

2.4

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Constructional changes, attachments or modifications

Modifications and rework (additional threads or bore holes) or

attaching fittings that are not offered as accessories by SCHUNK

may be performed only with permission of SCHUNK. This also

applies to the installation of safety devices.

Personnel qualification

The clamping block must only be installed, removed, started up,

operated and serviced by qualified specialist personnel with the

relevant safety training.

All persons charged with operating, maintaining and servicing the

clamping block must have access to the operating manual,

especially the chapter "Basic safety notes". We recommend that

the operator draw up in-house safety operating instructions.

Trainees may not work on machines and technical equipment in

which a clamping block is installed unless they are supervised at all

times by qualified specialist personnel.

Organizational measures

Obeying the rules

Via suitable organizational measures and instructions, the

operator must ensure that the relevant safety rules are obeyed by

the persons asked to operate, maintain and repair the clamping

block.

Checking the behavior of personnel

The operator must at least occasionally check that the personnel

are behaving in a safety conscious manner and are aware of the

potential hazards.

Danger signs

The operator must ensure that the signs concerning safety and

hazards mounted on the machine where the clamping block is

mounted are clearly legible and are observed.

Faults

If a fault occurs on the clamping block which endangers safety or if

a problem is suspected due to production characteristics, the

machine where the clamping block is mounted must be

immediately stopped and remain shut down until the fault has

been located and remedied. Only allow specialists to remedy

faults.

2.4.1

2.5

2.6

Basic safety instructions

03.00|KSF plus, KSF-LH plus, KSF-F plus |en

Spare parts

Only use original SCHUNK spare parts.

Environmental regulations

The applicable environmental regulations must be observed for all

maintenance and repair work.

The use of petroleum ether is prohibited. It is extremely

flammable, can build up an electrostatic charge and can form an

explosive gas air mixture. When selecting greases and lubricating

oils, pay attention to environmental compatibility, health risks,

disposal regulations and to local options for disposal according to

regulations.

Personal protective equipment

Using personal protective equipment

Not wearing personal protective equipment while working with

the product, may result in dangers that impact the personnel's

safety and health.

•While working with the product, observe the health and safety

regulations and wear the required personal safety equipment.

•Observe the valid safety and accident prevention regulations.

•In case of sharp edges and corners and rough surfaces, wear

protection gloves.

•In case of hot surfaces, wear heat-resistant protection gloves.

•When dealing with hazardous substances, wear protection

gloves and goggles.

•In case of moving parts, wear tight protection clothes.

2.7

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