SCHUNK KSX-C2 User manual

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Montage- und Betriebsanleitung
Installation- and operating instruction
5-Achs-Spanner mit Schnellwechselbacken
5-axis-vice with Quick change jaws
KSX-C2
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Strasse 23
D-88512 Mengen

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Table of contents:
User information..................................................................................... 241
Purpose of document, validity.................................................................................... 241.1
Illustration of safety features ..................................................................................... 241.2
General safety instructions .................................................................... 252
Intended use ................................................................................................................ 252.1
Technical data ................................................................................................................ 252.1.1
Reasonably foreseeable misapplication..................................................................... 262.2
Alterations and modifications.......................................................................................... 262.2.1
Spare and wear parts and auxiliary material..................................................................... 262.2.2
Residual risk ................................................................................................................. 272.3
Jaw change .................................................................................................................... 272.3.1
Notes on clamping technology........................................................................................ 272.3.2
Duties of the organisation in charge.......................................................................... 27
2.4
Operator duties............................................................................................................ 282.5
Operator qualification................................................................................................. 282.6
Personal protective equipment................................................................................... 282.7
Warranty ...................................................................................................................... 282.8
Description of the clamping device ....................................................... 293
Function........................................................................................................................ 293.1
Operation (standard operation)............................................................. 304
Clamping / aligning ..................................................................................................... 304.1
Jaw range..................................................................................................................... 314.2
Fitting the system jaws ............................................................................................... 314.3
Clamping procedure ............................................................................... 325
Precision clamping (without lifting) ........................................................................... 325.1
Raw workpiece clamping (with lift-off) ..................................................................... 335.2
Troubleshooting, eliminating faults ...................................................... 346
General clearing / lubrication ..................................................................................... 346.1
Disasembly / assembly of the spindle ........................................................................ 356.2
Cleaning the spindle.................................................................................................... 356.3
Assembly drawing .................................................................................. 367
Parts list........................................................................................................................ 367.1
Pull rod extension ................................................................................... 378
Swivel and adapter plate ....................................................................... 389
Function........................................................................................................................ 389.1
Servicing, cleaning, maintenance ............................................................................... 389.2
Troubleshooting, eliminating faults........................................................................... 389.3
Removing and replacing parts .................................................................................... 39
9.4
Fitting the 6-fold reversible jaws................................................................................ 399.5
Steel jaws soft......................................................................................... 4010
Precision jaws set.................................................................................... 4011
KSX-C2 125 hydraulic.............................................................................. 4112
Function........................................................................................................................ 4112.1
Risks of hydraulic system ............................................................................................ 4212.2
Pull rod extension ................................................................................... 4213
Taking out of service .............................................................................. 4314
EC declaration of incorporation ............................................................. 4315

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User information1
Purpose of document, validity1.1
These instructions are an integral part of the product supplied and contain important
information for the safe installation, commissioning, operation, servicing and maintenance.
These instructions must be read before using the product and must be observed during
operation, in particular the "General safety instructions" section.
Illustration of safety features1.2
DANGER
Indicates imminent danger.
If the information is ignored, death or serious injury
(permanent disability) will result.
WARNING
Indicates a potentially dangerous situation.
If the information is ignored, it is possible that death or serious
injury (permanent disability) will result.
WARNING
Indicates a potentially dangerous situation.
If the information is ignored, it is possible that material damage
and light to medium injury will result.
Information on useful tips or for preventing material damage
NOTE
Indicates general information, useful tips for users and
work recommendations which do not impact on the health and
safety of operators.
… underscores useful tips and recommendations as well as infor-
mation for efficient and trouble-free operation.
Important for preventing more extensive material damage
CAUTION
Indicates a potentially dangerous situation.
If the information is ignored, material damage will result.
… points out a potentially dangerous situation that can lead to
material damage if it is not avoided.

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General safety instructions2
Intended use2.1
The clamping device may only be used in accordance with the technical data and has been
designed for stationary application on milling machines in an industrial environment.
Using the device in accordance with the intended purpose includes compliance with the
commissioning, installation and operating instructions, and with the environmental and
service conditions as provided by the manufacturer.
The manufacturer accepts no liability for damage resulting from non-intended use.
Technical data2.1.1
Version
max. torque
max. clamping force
KSX-C2 125 Raw part clamping
100 Nm
50 kN
KSX-C2 125 Precision clamping
120 Nm
40 kN
KSX-C2 125-L Raw part clamping
100 Nm
50 kN
KSX-C2 125-L Precision clamping
120 Nm
34 kN
Raw part clamping KSX-C2 125 and KSX-C2 125-L
Precision clamping KSX-C2 125 Precision clamping KSX-C2 125-L
Exposure to loads in excess of the max. pull-in torque results in damage to the spindle.

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Weight:
KSX-C2 125-330 without system jaws: 33.2 kg
KSX-C2 125-430 without system jaws: 36.1 kg
KSX-C2 125-500 without system jaws: 38.1 kg
KSX-C2 125-630 without system jaws: 41.8 kg
KSX-C2 125-800 without system jaws: 46.6 kg
KSX-C2 125-330-L without system jaws: 27.3 kg
KSX-C2 125-430-L without system jaws: 30.2 kg
KSX-C2 125-500-L without system jaws: 32.2 kg
KSX-C2 125-630-L without system jaws: 35.9 kg
KSX-C2 125-800-L without system jaws: 40.7 kg
For further data, please see the Homepage >> schunk.com <<
Reasonably foreseeable misapplication2.2
Any application that is not in accordance with the "Intended use" or exceeds such
intended use is considered not in accordance with the regulations, and is forbidden.
Any other use of the device is subject to confirmation from the manufacturer.
Examples of forseeable misapplication
Clamping device used on rotating systems.
Clamping widely protruding workpieces.
Clamping workpieces with a weight of over 20 kg in vertical position without an additional
protection for the operator against the workpiece falling out.
Alterations and modifications2.2.1
In the case of unauthorised alterations and modifications of the clamping device,
the manufacturer's liability ceases and any warranty is voided.
Spare and wear parts and auxiliary material2.2.2
Only use original parts or parts approved by the manufacturer.
Using spare and wear parts by third party manufacturers may lead to risk.

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Residual risk2.3
The user is responsible for applying the correct workpiece tension.
New clampings have to be carefully checked by qualified personnel with relevant training.
One always needs to allow for the risk that the workpiece may slip or be dislodged, even when
the clamping device is functioning correctly. This is due to the different geometries to be
clamped, contact surfaces, clamping friction values, processing force, wrong manipulation of the
milling machine etc.
Protective devices are to be attached to the processing machine that will protect the operator
from any tool or workpiece parts that may be ejected.
It is mandatory that operators and others in the proximity of the processing machine wear
protective goggles.
Do not use methods of operation that impair the function and operational safety.
Jaw change2.3.1
Damage may result if system jaws are insufficiently fastened.
Notes on clamping technology2.3.2
The operator is responsible for ensuring that the clamping geometry and clamping forces are
suitable for the intended processing.
The clamping forces can only be achieved if the clamping device functions correctly and the
workpiece is correctly held in the device.
Regular servicing and cleaning in accordance with the operating instructions is mandatory in
order to ensure correct function.
When clamping thin-walled elastic workpieces, e.g. tubes or packages, it is possible
that the clamping force is significantly reduced due to yielding of the workpiece.
Duties of the organisation in charge2.4
The organisation in charge of the device undertakes to only allow operatives to work on the device:
who are familiar with the basic health and safety regulations and regulations for the
prevention of accidents.
who have completed appropriate induction for working with the machine.
who have read and understood these operating instructions.
The requirements of the EC Directive 2007/30/EC on the use of work machinery must be
complied with.

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Operator duties2.5
All persons who have been instructed to work with the machine undertake to:
observe the basic regulations for health and safety and for the prevention of accidents.
read and understand the section on safety and the safety instructions in these operating
instructions prior to working with the machine, and to observe these instructions.
Operator qualification2.6
The installation, initial setup, fault analysis and periodic monitoring have to be carried out by
competent personnel with the relevant qualifications.
Personal protective equipment2.7
WARNING
Risk of eye injury through ejected, hot fragments!
Ejected hot fragments can lead to serious eye injury.
The regulations for safety at work and the prevention of
accidents always have to be observed when working
with the machine.
Personal protection equipment must be worn at all times,
in particular safety boots, gloves and safety goggles.
Warranty2.8
The warranty period is 24 months from the date of delivery ex-works, provided the machine is
used as intended and subject to the following conditions:
Compliance with the concurrent documents.
Observance of environmental and work conditions.
Observance of the specified servicing and lubrication intervals.
Observance of the maximum service life.
Parts in contact with the workpiece are not covered by the warranty.
Warranty –Maximum service life
Period of warranty
24 months
Maximum service life [clamping cycles]
50,000

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Description of the clamping device3
The KSX-C2 has been designed for clamping unprocessed and processed workpieces.
The force is generated mechanically and the spindle is protected against dirt thanks to complete
encapsulation.
Raw parts clamping with jaw lift-off
At 100 Nm torque is the clamping force 50 kN.
Precision clamping without jaw lifting
At 120 Nm torque, the clamping force is 34 kN for the S version and 40 kN for the standard
version.
Improper use and clamping with too high torques will cause damage to the spindle and jaws.
Function3.1
The clamping range can be quickly adjusted by turning the spindle with a hand crank.
The KSX-C2 can be extended for an even larger clamping range with additional pull rod extensions.

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Operation (standard operation)4
Clamping / aligning4.1
The basic version has countersunk holes for screwing the
KSX-C2 from the top with cylinder screw M12 on the T-
slot tables with a pitch of 100 mm.
The KSX-C2 can also be clamped with clamping claws.
Important:
Up to a base plate length of 500 mm, ensure a symmetrical
distance of the two clamping claws is 100 to 150 mm.
For a base plate length of 630 and 800 mm use at least six
clamping claws with a distance of 150 mm for the length
630 mm or 200 mm for the length 800 mm to the center of
the vice.
Alignment with alignment pins (1), precision sliding blocks (2) or fitting screws (4).
The base plate is fitted with an interface to attaching the clamping pin for the VERO-S quick-change
palleting system.
The KSX-C2 can also be produced at the factory with customer-specific positioning and fixing
holes as well as with location recesses for various commonly available quick-change palleting
systems.

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Jaw range4.2
The reliable function of the clamping device is significantly affected by the selection of the
correct system jaws.
Fitting the system jaws4.3
Basically, no tools are necessary for assembly.
The system jaws are clicked in from above via a quick-change system 1 and can be
rotated 180°.
To remove the system jaws, we recommend turning a screwdriver in the opening under the system
jaw to the jaw clicks out.

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Clamping procedure5
Precision clamping (without lifting)5.1
Position fixed support jaw and tighten the cylinder screw 1 with a torque of 140 Nm.
The clamping range is adjustet with the movable support jaw by placing the system jaw
1-2 mm in front of the workpiec.
Tighten the cylinder screw 1 at the movable support jaw with a torque of 140 Nm.
Clamp the workpiece on the spindle with the desired clamping force.
Important:
The cylinder screw must be tightened to 140 Nm and it must not clamped without the
workpiece, as otherwise the carrier jaws could shift and could damage the base plate.
Precision clamping KSX-C2 125 Precision clamping KSX-C2 125-L

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Raw workpiece clamping (with lift-off)5.2
With the raw part clamping it is possible to clamp with simpler set-up and greater clamping forces.
Position fixed support jaw and tighten the cylinder screw 1 with a torque of 140 Nm.
Cylinder screw 1 at the movable support jaw remains loose and workpiece is clamped with the
desired clamping force.
Important:
Significantly higher clamping forces are achieved with the raw workpiece clamping.
Make sure that the torque of 100 Nm is not exceeded to overload the clamping system in
the long run.
Raw part clamping KSX-C2 125 and KSX-C2 125-L

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Troubleshooting, eliminating faults6
Lubricate the running and contact surfaces of the system and support jaws with highpressure
grease every two weeks.
Remove the support jaw out of the working position and grease the guides of the moving
support jaw at regular intervals or every two weeks.
When changing pull rod extensions, ensure sufficient lubrication.
If creaking noises occur during operation, lubricate the spindle dry-running guides immediately.
General clearing / lubrication6.1
Remove the system jaws (1).
Release the lock (2) and remove the spindle. (3)
Loosen the carrier jaws (5) (4) and extend.
Clean and oil the base plate guide surfaces.
Refit the carrier jaws. (5)
Clean and grease the thread (3) and reinstall.
Clean and grease the contact surfaces of the system jaws and click in the system jaws. (1)

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Disasembly / assembly of the spindle6.2
Both carrier jaws (1) must be clamped and the rear lock (5) released.
Both support jaws (1) must be clamped.
Turn the spindle (2) until the pull rod extension (3) is pressed out of the support jaw.
Remove the pull rod extension (3).
Place screwdriver in groove (4) and pull the spindle (2) out of the support jaw.
The procedure can also performed by released the lock (5) of the spindle (2) and pushing the
spindle (2) out first.
Cleaning the spindle6.3
Unscrew the spindle completely.
Clean and lubricate with high pressure grease.
When assembling, make sure that the seal is seated correctly.
Stroke limitation
The spindle is completely encapsulated and the maximum stroke is marked (3).
Important:
The thread must not be turned above the limit line marking (3), as a spindle that is opened
too far can break out during clamping.

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Assembly drawing7
Parts list7.1
Position
Designation
Quantity
10
Support jaw mobile
1
20
Support jaw fix
1
30
Clamping lever
1
40
Position holder
1
50
Internal hexagon threaded pin M16x30
2
60
Pressure piece
2
70
Damper
1
80
Damper
1
90
Pull-down hook
1
100
Bracket left with thread M16
1
110
Bracket right with thread M16
1
120
Bracket left with counterbore M16
1
130
Bracket right with counterbore M16
1
140
Base plate
1
150
Mechanical spindle
1
160
Spindle lock
2
170
Internal hexagon cylinder screw M16x120 12.9
2
180
Spiral spring 1.40x5.70x22.00
2
190
Lens head screw M.2.5x5
2
200
Internal hexagon cylinder screw M6x14
2
210
Internal hexagon threaded pin M6x6
1
220
O-ring NBR/70 53.00x5.00
2
230
Spiral spring 1.00x5.0x17.3
8
240
Internal hexagon cylinder screw M12x120 12.9
2
250
Internal hexagon cylinder screw M6x10
2
260
Spiral spring 0.90x3.60x9.70
2
270
Internal hexagon threaded pin ZA M5x10
2
280
Spring pin Ø2.5x6
2

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Pull rod extension8
Removing / Installation
Both carrier jaws (1) must be clamped and the rear locks (5) released.
Turn the spindle (2) until the pull rod extension (3) is pressed out of the support jaw.
Remove the pull rod extension. (3)
Release clamping claws. (1)
Insert the pull rod extension (5, 6 or 7), screw on and close the lock. (5)
Position carrier jaws and tension the clamping claws (1) with 140 Nm.

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Swivel and adapter plate9
Function9.1
Slanted and curved items can be securely clamped with 4-point clamping using the swivel plate
system.
The swivel plate is pulled downwards during the clamping process due to its conical swivel plate
bearings; this means that the swivel plate is not likely to lift off.
With the 6-fold reversible jaw it is possible to cover numerous clamping solutions in a straight-
forward way. A total of six different clamping sides are available, at the four sides of the jaw as
well as at two places with a convex "grip" profile.
It is also possible to carry out two-sided processing using the tungsten carbide coated side of the
6-fold reversible jaw.
Processing the first side
For raw part clamping using the 6-fold reversible jaw, five different "grip" clamping sides are
available with a clamping depth of 3, 8 and 18 mm.
Processing the second side
Clamping with the tungsten carbide coated side of the 6-fold reversible jaw.
It is important to take into account that during the first clamping process, the 6-fold reversible
jaws can yield slightly until the play in the peg seating is eliminated.
The workpiece position must be measured; the zero point should not be determined until after
3 to 5 power clampings.
Important:
Max. 3° rotating.
Handling the demounted swivel plate
When handling the swivel plate, it should not be turned upside down as the peg fall out.
Servicing, cleaning, maintenance9.2
The upper shoulder of the swivel peg must be greased regularly.
Troubleshooting, eliminating faults9.3
Swivel plate is difficult to turn
Disconnect the swivel plate and push the swivel peg from below out of the swivel plate.
Check the jaw fixing and swivel plate surface for indentations or deformations. If necessary,
re-grind the plate and the jaw fixing.
Check the peg for soiling.
Lubricate the entire system with grease and reassemble.
Swivel plate wobbles
Check whether marking (R) on the swivel peg and the swivel plate points outside.
If not, turn swivel plate / swivel peg.

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Removing and replacing parts9.4
Release the two cylinder screws. (2)
Remove the adapter and swivel plate.
Clean and oil the contact surfaces, e.g. with MOTOREX Supergliss 68 K to ISO VG 68.
Place the adapter plate (1) on the fixed jaw.
Tighten the two cylinder screws (2) with 40 Nm.
Engage the swivel plate (4) and the swivel peg (5) in the clamping lever and check whether marking
(R) on swivel peg and swivel plate points outside.
Fit the cover plate.
Fitting the 6-fold reversible jaws9.5
Determine the mounting positions of the 6-fold reversible jaws.
The best clamping results are achieved when clamping parts as far out as possible.
Move the cover screws so that the selected clamping position is available.
Position the 6-fold reversible jaws and loosely insert the cylinder screws.
Turn the 6-fold reversible jaws on to the required clamping faces and slightly pre-clamp the
workpiece with the clamping jaws so that the clamping faces are parallel to, and touch,
the workpiece.
Use a torque of 80 Nm to tighten the cylinder screws of the 6-fold reversible jaws.
Important:
When the clamping faces of the 6-fold reversible jaws are not aligned parallel to the
workpiece surface it is possible that the 6-fold reversible jaw becomes loose through the
clamping force.

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Steel jaws soft10
Important:
Max. milling depth 15 mm.
Precision jaws set11
The precision jaws must be hard-milled in the precision clamping with 60 Nm clamping force
according to the views.
For machining in the standard position must the supplied reference tip and for the VS position a
gauge block used.
Important:
Max. milling depth 0.15mm (+/-0.1mm)

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KSX-C2 125 hydraulic12
Function12.1
Instead of the and spindle assembly is a hydraulic spindle with spring reset fitted and the power
supply of the cylinder via a hydraulic unit with pressure regulator by the customer.
The force is set via an external pressure controller in accordance with the diagram.
Depending on the clamping range must the short or long hydraulic cylinder be installed.
Raw part clamping KSX-C2 125 and KSX-C2 125-L
Precision clamping KSX-C2 125 Precision KSX-C2 125-L
Exposure to loads in excess of the max. hydraulic pressure of 250 bar results in damage to
the spindle.
Recommended operating medium: hydraulic oil HLP 15 –HLP 46
Important:
The hydraulic supply hose must be vented before connecting it to the vice.
Once the hose is connected, carry out some clamping actions without workpieces.
Version
max.
clamping force
max.
clamping stroke
Oil-volume
(by max. stroke)
KSX-C2 125-H Raw part clamping
50 kN
4 mm
10 cm³
KSX-C2 125-H Precision clamping
40 kN
4 mm
10
cm³
KSX-C2 125-H-L Raw part clamping
30 kN
4 mm
10
cm³
KSX-C2 125-H-L Precision clamping
25 kN
4 mm
10
cm³