SCHUNK TANDEM KSH3 Operation manual

Translation of Original Operating Manual
TANDEM Clamping Block
KSH3, KSH3-LH, KSH3-F
Assembly and Operating Manual

Imprint
2 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683
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
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
Customer Management
Tel. [phone]
Fax [phone]
[email protected]
Please read the operating manual in full and keep it close to the product.

Table of Contents
Table of Contents
1 General.....................................................................................................................5
1.1 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
1.2 Warranty.............................................................................................................. 6
1.3 Scope of Delivery ................................................................................................. 6
2 Basic safety notes ....................................................................................................7
2.1 Intended use ........................................................................................................ 7
2.2 Not intended use ................................................................................................. 7
2.3 Constructional changes........................................................................................ 7
2.4 Spare parts........................................................................................................... 8
2.5 Use of special chuck jaws..................................................................................... 8
2.6 Environmental and operating conditions ............................................................ 8
2.7 Personnel qualification ........................................................................................ 9
2.8 Personal protective equipment ........................................................................... 9
2.9 Notes on safe operation .................................................................................... 10
2.10 Transport............................................................................................................ 10
2.11 Malfunctions ...................................................................................................... 10
2.12 Disposal.............................................................................................................. 11
2.13 Fundamental dangers ........................................................................................ 11
2.13.1 Protection during handling and assembly ............................................. 11
2.13.2 Protection during commissioning and operation .................................. 12
2.13.3 Protection against dangerous movements............................................ 12
2.13.4 Notes on particular risks ........................................................................ 12
3 Technical data.........................................................................................................14
4 Tightening torques for screws.................................................................................17
5 Assembly and connection .......................................................................................18
5.1 Assembly of the Clamping Block on the machine table..................................... 18
5.2 Connecting the clamping force block................................................................. 20
5.2.1 Supply lines ............................................................................................ 21
5.2.2 Dynamic pressure monitoring of the jaw end positions (variant "PM")
............................................................................................................... 22
5.2.3 Air coupling in top jaw (variant "PM") ................................................... 23
5.2.4 Hydraulic circuit diagram ....................................................................... 24
6 Troubleshooting .....................................................................................................25
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Table of Contents
7 Maintenance and care ............................................................................................26
7.1 Notes.................................................................................................................. 26
7.2 Maintenance and lubrication intervals .............................................................. 26
7.3 Greasing areas / lubricants ................................................................................ 26
7.4 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 ............................................................... 33
8 Sealing kits, accessory kits and parts lists................................................................35
8.1 Sealing kit lists.................................................................................................... 35
8.1.1 Piston chamber sealing kit ..................................................................... 35
8.1.2 Monitoring sealing kit / connection....................................................... 36
8.2 Accessory kits..................................................................................................... 36
8.3 Parts lists............................................................................................................ 37
9 Assembly drawings .................................................................................................41
9.1 KSH3, KSH3-LH ................................................................................................... 41
9.2 KSH3-F................................................................................................................ 42
10 Translation of the original declaration of incorporation ..........................................43
11 Appendix on Declaration of Incorporation, as per 2006/42/EC, annex II, No. 1 B.....44
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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. Prerequisite for safe working is
the observance of all safety instructions in this manual.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
In addition to these instructions, the documents listed
under }1.1.2 [/6] are applicable.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Dangers 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.
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General
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1.1.2 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
• KSH3-LH 64, 100, 140, 160, 200, 250, 315
• KSH3-F 64, 100, 140, 160, 200
1.1.4 Variants
This manual applies to the following variants:
• Pneumatic monitoring (PM)
• Jig-machined positioning bores (Z)
1.2 Warranty
If the product is used as intended, the warranty is valid for
24 months from the date of delivery from the production facility or
500 000 cycles* under the following conditions:
• Observe the applicable documents, }1.1.2 [/6]
• Observe the ambient conditions and operating
conditions, }2.6 [/8]
• Observance of the specified care and maintenance
instructions }7 [/26]
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.3 Scope of Delivery
Clamping force block
KSH3 or KSH3-LH or KSH3-F
(without top jaws)
ACCESSORY KIT:
(for contents, see sealing kit list and parts list) }8.1 [/35]

Basic safety notes
2 Basic safety notes
2.1 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, }3 [/14].
• The product is intended for industrial and industry-oriented use.
• Appropriate use of the product includes compliance with all
instructions in this manual.
2.2 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.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of the
product or damage it.
• Structural changes should only be made with the written
approval of SCHUNK.
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Basic safety notes
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2.4 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:
• The chuck jaws should be designed to be as low as possible. The
clamping point must be as close as possible to the housing.
(clamping points at a greater distance cause higher surface
pressures in the jaw guidance and can significantly reduce the
clamping force.)
• Do not use welded jaws.
• Reduce operating pressure for higher clamping points.
2.6 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 significant reduction to the product's life span.
• Make sure that the product is used only in the context of its
defined application parameters, }3 [/14].
• Make sure that the product is a sufficient size for the
application.
• Ensure that maintenance and lubrication intervals are
observed, }7 [/26].
• Ensure that the environment is free from ferromagnetic
particles or chips.

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.
• Before working with the product, the personnel must have read
and understood the complete assembly and operating manual.
• Observe the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Trained electrician Due to their technical training, knowledge and experience, trained
electricians are able to work on electrical systems, recognize and
avoid possible dangers and know the relevant standards and
regulations.
Qualified personnel Due to its technical training, 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 person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.8 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
• When working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
• Observe the valid safety and accident prevention regulations.
• Wear protective gloves to guard against sharp edges and
corners or rough surfaces.
• Wear heat-resistant protective gloves when handling hot
surfaces.
• Wear protective gloves and safety goggles when handling
hazardous substances.
• Wear close-fitting protective clothing and also wear long hair in
a hairnet when dealing with moving components.
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Basic safety notes
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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.
• Use the product as intended.
• Observe the safety notes and assembly instructions.
• Do not expose the product 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-tension the clamping device in order to compensate for
the setting properties of the clamping situation or possible
pressure losses and the resulting loss of clamping force.
2.10 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
• When handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
• Secure the product against falling during transportation and
handling.
• Stand clear of suspended loads.
2.11 Malfunctions
Behavior in case of malfunctions
• Immediately remove the product from operation and report the
malfunction to the responsible departments/persons.
• Order appropriately trained personnel to rectify the
malfunction.
• Do not recommission the product until the malfunction has
been rectified.
• Test the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.

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
• Observe safety distances.
• Never deactivate safety installations.
• Before commissioning the product, take appropriate protective
measures to secure the danger zone.
• Disconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
• Do not reach into the open mechanism or movement area of
the product during operation.
2.13.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
• Have all work carried out by appropriately qualified personnel.
• For all work, secure the product against accidental operation.
• Observe the relevant accident prevention 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.
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Basic safety notes
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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
working with the product.
• Switch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
• Never rely merely on the response of the monitoring function
(dynamic pressure monitoring with pressure sensors) to avert
danger. Assume that the drive movement is faulty as long is the
installed monitors are not effective, since the effect depends on
the control and the current operating state of the drive.
Perform maintenance, modification and attachment work
outside of the danger zone defined by the movement range.
• To avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted.
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 the machine if this protective equipment
does not function correctly.
2.13.4 Notes on particular risks
WARNING
Risk of injury in the event of workpiece loss due to component
failure on the product as a result of exceeding the technical
data.
•The product may only be used within the scope of its technical
data

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
loss
WARNING
Risk of injury from falling parts during transport, assembly and
disassembly of the product and its accessories.
•Use suitable load handling equipment for transport
•Do not remain in the danger zone
•Wear protective equipment (protective shoes)
WARNING
Danger of crushing due to the chuck jaws approaching the
workpiece during the clamping procedure when loading and
unloading manually.
•Prioritize automated loading
•Do not reach between the workpiece and the chuck jaw
during the clamping procedure
WARNING
Risk of injury due to accidental actuation when working on the
product
•Disconnect the power supply when working on the product
CAUTION
Ergonomic risk to the musculoskeletal system when lifting and
transporting the product using manual force.
•Use load handling equipment for lifting and transporting
CAUTION
Allergic reactions or irritation due to skin or eye contact with
lubricants on the product.
•In case of foreseeable contact with lubricants on the product
(e.g. when lubricating or cleaning), wear protective equipment
(protective gloves, protective goggles)
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Technical data
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3 Technical data
Installation position any
Operating temperature +5 °C to +60 °C
Noise emission [dB(A)] ≤ 70
Pressure medium Hydraulic oil
Requirement for the pressure
medium
filtered (10 μm), viscosity 46 mm/s at 40 °C in line
with ISO VG
Volumetric flow max. 2 l/min
Oil loss by adhering oil removal max. 0.5 mg/cycle
Max. speed of rotation 100 RPM
Size Stroke/
jaw [mm]
Clamping
force at
max.
pressure*
[kN]
Max.
pressure
[bar]
Repeat
accuracy
** [mm]
max. jaw
height
[mm]
Weight
[kg]
KSH3 64 2 4.5 60 0.01 60 1.5
100 2 18 60 0.01 60 5
140 3 30 60 0.01 60 9.5
160 3 45 60 0.01 60 14
200 4 60 60 0.02 100 24
KSH3-LH 64 4 4.5 120 0.01 60 1.5
100 6 16 120 0.01 60 5
140 7 30 120 0.01 60 9.5
160 8 40 210 0.01 60 14
200 10 53 120 0.02 100 24
250 15 50 60 0.02 150 36.5
315 18 95 120 0.02 200 83
KSH3-F 64 4 4 60 0.01 60 1.5
100 4 18 60 0.01 60 5
140 6 30 60 0.01 60 9.5
160 6 45 60 0.01 60 14
200 8 60 60 0.02 100 24
* Clamping force is the arithmetic sum of the individual forces occurring at the
chuck jaws at distance "H" (see also catalog).
** Distribution of the clamping position with 100 consecutive clamping operations.

Technical data
Dime
nsion
KSH3 / KSH3-LH / KSH3-F KSH3-LH
64 100 140 160 200 250 315
A 36 90 126 146 184 180 290
B 56 64 92 106 146 160 230
Ø C 4H7 x 7.5 6H7 x 12 8H7 x 14 8H7 x 14 8H7 x 14 10H7 x 20 10H7 x 20
D 50 80 110 125 160 200 x 180 250
E 17 29.5 25 (2x) 50 64.5 45 (off-
center)
100
F 17 32 40 40 64.5 80 108
G 21 34.5 51.8 59.7 72 50 112
H 33.6 55 74 82 116 140 192
I 41 64 91 104 138 170 220
J 55.7 74.2 77.7 87.2 95.2 103.2 141
K 33.3 41 43 47 53 57 78
L 14 15 13.5 15 17.5 20 25
M 30 57 88 100 129 45 200
N M6 M8 M8 M10 M12 M12 M16
O 12 15 15.5 18 21 20 26
P 2.5 4 3.5 4 6 5 5
Ø Q 8f7 10f7 10f7 12f7 14f7 14f7 18f7
Ø R 8 11 11 13 16 16 21
S 4 4.5 5.5 6 6 6 6
T 32 54 74 82 116 140 192
U 0 18.7 26 29 41 54 65
V -27 40 58.5 67 83 104 132
W 6 9.5 12 12 17 18 25
X 26.5 43 63 72 91 115 146
Y 7.3 6 6 5 9 20 37.5
Z 2.5 4.5 0 0 0 0 0
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Technical data
16 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683
1 Optional Z variant ±0.01 mm to clamping center
2 Clamping sleeve ±0.04 mm to clamping center
3 Clamping sleeve fitting screw ±0.02 mm to clamping center
4 Only with variant "PM"

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
MA (Nm)
4.2 7.5 13 28 50 88 120 160 200 290 400 500
Tightening torques for mounting top jaws on the TANDEM
clamping force block (screw quality 12.9)
Screw size M4 M5 M6 M8 M10 M12 M14 M16 M20 M24
Tightening torque
MA (Nm)
5 9 15 32 62 108 170 262 510 880
Tightening torques for mounting the chuck piston onto the
cylinder piston (screw quality 12.9)
Description Screw size M5 M8 M10 M12 M20
KSH3 Tightening torque MA
(Nm)
9 32 62 108 510
KSH3-LH Tightening torque MA
(Nm)
9 32 75 140 510
KSH3-F Tightening torque MA
(Nm)
4 25 50 90 290
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Assembly and connection
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5 Assembly and connection
The numbers shown for individual components refer to the
illustrations for assembly or connections of the clamping force
block and to the "Assembly Drawings" chapter. }9 [/41]
WARNING
Danger of crushing due to the product approaching the machine
table during assembly.
•Do not reach between the product and machine table during
assembly
CAUTION
Danger of abrasions due to rough components of the product
and its accessories, which may slip out of your hands during
assembly.
•Wear protective equipment (protective gloves) when working
on the product and when handling its accessories
5.1 Assembly of the Clamping Block on the machine table
34 Cylindrical pins Ø m6 }8.3 [/37]
82 Fitting screw Ø f7 }8.3 [/37]
84 Screw DIN EN ISO 4762
85 Clamping sleeve DIN EN ISO 13337

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.
Assembly with clamping sleeves:
Mount the clamping force block on the machine table together
with clamping sleeves (85) and screws (84).
Assembly with fitting screws:
There are two fittings in the housing (1) that, along with the fitting
screws (82), are used to center the clamping force block on the
machine table with repeat accuracy. Do not realign the clamping
force block after removing it from the machine table (e.g. after
replacing the seals). When using fitting screws (82), these are used
instead of the clamping sleeves (85) and two of the four screws
(84).
Assembly with cylindrical pins (Z variant):
The clamping force block is fastened to the machine table with
4 screws (84). The two cylindrical pins (34) are used for alignment
with repeat accuracy. Do not realign the clamping force block after
removing it from the machine table (e.g. after replacing the seals).
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Assembly and connection
20 03.00 | KSH3, KSH3-LH, KSH3-F | TANDEM Clamping Block | en | 1477683
5.2 Connecting the clamping force block
I OPEN (front)
II CLOSED (front)
III OPEN (bottom)
IV CLOSED (bottom)
V Coolant drainage / connection for air purge (front)
1 Dynamic pressure monitoring for jaw end position "open"
2 Air coupling in top jaw 1
3 Air coupling in top jaw 2
4 Dynamic pressure monitoring for jaw end position "closed"
5 Bottom connection for coolant drain or use for air purge
6 Bottom connection for lubrication (one-sided supply, left)
7 Bottom connection for lubrication (one-sided supply, right)
8 No use
* For connection 1-7 with size 64