Chuck quick-change ROTA FSW

Transcription

1 Translation of Original Operating Manual Chuck quick-change ROTA FSW Assembly and Operating Manual Superior Clamping and Gripping

2 Imprint Imprint Copyright: This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely supplied to our customers and operators of our products and forms part of the product. This documentation may not be duplicated or made accessible to third parties, in particular competitive companies, without our prior permission. Technical changes: We reserve the right to make alterations for the purpose of technical improvement. Document number: Edition: /11/2015 en SCHUNK GmbH & Co. KG All rights reserved. Dear customer, congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for the highest precision, top quality and best service. You are going to increase the process reliability of your production and achieve best machining results to the customer's complete satisfaction. SCHUNK products are inspiring. Our detailed assembly and operation manual will support you. Do you have further questions? You may contact us at any time even after purchase. Kindest Regards Your H.-D. SCHUNK GmbH & Co. Spanntechnik KG Lothringer Str. 23 D Mengen Tel Fax info@de.schunk.com ROTA FSW en

3 Table of Contents Table of Contents 1 General Warnings Applicable documents Basic safety notes Intended use Not intended use Notes on particular risks Notes on safe operation Substantial modifications Personnel qualification Organizational measures Using personal protective equipment Warranty Torques per screw Scope of delivery Technical data Precision classes Permissible imbalance Attachment and disassembly of the ROTA FSW Chuck quick-change Pre-assembly measures Assembly of the ROTA FSW Chuck quick-change Assembly of the ROTA FSW Chuck quick-changes with a reducing or extension flange Assembly of the ROTA FSW Chuck quick-change with a direct mount Attachment of the flexible adapter to the draw tube/draw bar Attaching the retainer ring and draw tube adapter to the clamping device Attachment of the clamping device and the ROTA FSW Chuck quick-change Disassembling and assembling the ROTA FSW Chuck quick-change Function and handling Function of the ROTA FSW Chuck quick-change Handling the ROTA FSW Chuck quick-change ROTA FSW en 3

4 Table of Contents 9 Maintenance Lubrication Maintenance instructions Period of maintenance Storing the ROTA FSW Chuck quick-change Disposal Spare parts Assembly drawing Translation of original EC declaration of incorporation ROTA FSW en

5 General General This operating manual is an integral component of the product and contains important information on safe and proper assembly, commissioning, operation, care, maintenance and disposal. This manual must be stored in the immediate vicinity of the product where it is accessible to all users at all times. Before using the product, read and comply with this manual, especially the chapter Basic safety notes.( 2, Page 7) If the product is passed on to a third party, these instructions must also be passed on. Illustrations in this manual are provided for basic understanding of the product and may differ from the actual product design. We accept no liability for damage resulting from the failure to observe and comply with this operating manual. Warnings To make risks clear, the following signal words and symbols are used for safety notes. DANGER Danger for persons. Non-compliance will inevitably cause irreversible injury or death. WARNING Dangers for persons. Ignoring a safety note like this can lead to irreversible injury and even death. CAUTION Dangers for persons. Non-observance can cause minor injuries ROTA FSW en 5

6 General NOTICE Material damage Information about avoiding material damage. WARNING Warning about hand injuries WARNING Warning about hot surfaces 1.2 Applicable documents General terms of business Catalog data sheet of the purchased product Calculation of the jaw centrifugal forces ("Technology" chapter in the lathe chuck catalog) The above mentioned documents can be downloaded at ROTA FSW en

7 Basic safety notes Basic safety notes 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 use original SCHUNK spare parts. Intended use The ROTA FSW Chuck quick-change acts exclusively as an interface between the spindle and clamping device in the machine tool. The technical data specified by the manufacturer must never be exceeded! The product is intended for industrial use. Intended use also means that the user has read and understood this operating manual in its entirety, especially the chapter Basic safety notes. The maximum speed of the design and the maximum actuating force of the clamped clamping device must be determined by the operator for each clamping task in accordance with the valid standards or technical specifications of the manufacturer. Not intended use The ROTA FSW Chuck quick-change is not being used as intended if, for example, the clamping device is not positioned and clamped properly in the Chuck quick-change. the intended use of the clamping device is ignored. (See the Assembly and Operating Manual of the respective clamping device.) it is used under working environment conditions that are not permissible. people work on machines or technical equipment that do not comply with the EC Machinery Directive 2006/42/EC, disregarding the applicable safety regulations. the technical data specified by the manufacturer for using the ROTA FSW Chuck quick-change or the clamping device are exceeded. the ROTA FSW Chuck quick-change is used for machines or clamping devices for which it is not designed ROTA FSW en 7

8 Basic safety notes 2.3 Notes on particular risks This product may pose a danger to persons and property if, for example: It is not used as intended; It is not installed or maintained properly; The safety and installation instructions, local applicable safety and accident prevention regulations or the EC Machinery Directive are not observed. DANGER Possible risk of fatal injury to operating personnel if a jaw breaks or if the ROTA FSW Chuck quick-change or the clamping device fails because the technical data has been exceeded and a workpiece is released or parts fly off! The technical data specified by the manufacturer for using the ROTA FSW Chuck quick-change must never be exceeded. The ROTA FSW quick-change clamping system may only be used on machines and equipment that fulfill the minimum requirements of the Machine Directive 2006/42/EC; specifically, they must have effective technical measures to protect against possible mechanical hazards. DANGER Possible risk of fatal injury to operating personnel from clothing or hair being caught on the ROTA FSW Chuck quick-change and/or clamping device and being dragged into the machine. Loose clothing or long hair may become caught on projecting parts of the ROTA FSW Chuck quick-change or clamping device and be drawn into the machine. The machines and facilities must 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. Always wear tight-fitting clothing and a hairnet when working on the machine and the ROTA FSW Chuck quick-change or clamping device ROTA FSW en

9 WARNING Basic safety notes Risk of injury due to dropping the ROTA FSW Chuck quickchange during transport, installation or removal Take special care in the danger zone when transporting, installing or removing the ROTA FSW Chuck quick-change or clamping device. Note the relevant load securing regulations for working safely with cranes, ground conveyors, lifting gear and load-handling equipment. CAUTION Risk of slipping or falling if the ROTA FSW Chuck quick-change'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 ROTA FSW Chuck quick-change, especially when working with machine tools and other technical equipment. CAUTION Danger of limbs being crushed when manually attaching the ROTA FSW Chuck quick-change and assembling and dismantling the clamping device. Use a crane to install the ROTA FSW Chuck quick-change and clamping device. Wear personal protective equipment. Do not reach between the spindle nose and the ROTA FSW Chuck quick-change. Do not reach between the ROTA FSW Chuck quick-change and clamping device. Follow the safety and accident-prevention regulations when operating the ROTA FSW Chuck quick-change, especially when working with machine tools and other technical equipment ROTA FSW en 9

10 Basic safety notes CAUTION Risk of burns due to workpieces with high temperatures. Wear protective gloves when removing the workpieces and the clamping device. Automatic loading of workpieces and clamping devices is to be preferred. CAUTION Danger of damage due to incorrectly set clamping positions of the clamping slides when changing the clamping devices. If an incorrect clamping position is chosen for the clamping slides relative to the clamping device, the ROTA FSW Chuck quickchange and clamping device may be damaged. Ensure that the clamping slides are locked/unlocked securely before or after changing the clamping devices with the ROTA FSW Chuck quick-change. CAUTION Hazard from vibration due to imbalanced rotating parts and noise generation. Physical and mental strains due to imbalanced workpieces and noise during the machining process on the clamped and rotating workpiece. Ensure that the ROTA FSW Chuck quick-change and the clamped clamping device run true, both radially and axially. Check options for remedying imbalances on special top jaws on the clamping device and workpieces. Reduce the speed. Wear hearing protection. 2.4 Notes on safe operation Do not start the spindle until the clamping device is clamped securely and the optional draw tube is locked into place. Do not start the spindle until the clamping pressure is built up in the clamping cylinder with power clamping and the clamping position display of the ROTA FSW Chuck quick-change is lowered ROTA FSW en

11 Basic safety notes Unclamping must not be possible until the spindle is shut down. If the clamping energy fails, the workpiece must remain firmly clamped until the spindle is shut down and the workpiece is secured. The safety specifications from the relevant operating manual must be followed precisely. Functional test After installation of the ROTA FSW Chuck quick-change, its function must be checked prior to start-up. Important points are: Smooth running The actuating screw must turn smoothly and the clamping slides must move smoothly as a result. Stroke control The clamping slides must have a margin of safety at the inner and outer end positions. The spindle must only start up once the lever has passed through the safety margin. Indicator pins are fitted to the circumference of the ROTA FSW Chuck quick-change to monitor the margin of safety. They may only be monitored with safety limit sensors compliant with DIN EN Position 1: Position 2: Position 3: Change position, clamping slide inside - machine is not enabled. Lock position, chuck is locked, not clamped yet - machine is not enabled. Clamping position, chuck clamped - machine enabled ROTA FSW en 11

12 Basic safety notes When determining the necessary clamping force to machine a workpiece, take the centrifugal force acting on the chuck jaws into account (according to VDI 3106). If the power clamping device is changed, adjust the machine-side stroke control of the clamping cylinder to the new situation. RPM DANGER Possible risk of fatal injury to operating personnel if the ROTA FSW Chuck quick-change's or clamping device's top speed is exceeded and a workpiece is released or clamping device and parts fly off. If the machine tool or technical equipment can reach a higher speed than the ROTA FSW Chuck quick-change or clamping device top speed, a reliable speed limiter must be installed and proof must be provided that the speed limiter is effective. The maximum recommended speed may only be run in conjunction with maximum actuating force and prescribed tightening torque and only with the ROTA FSW Chuck quickchange with clamping device in optimal, fully functioning condition. The clamped clamping device must function fully for this. Maintenance instructions The ROTA FSW Chuck quick-change's reliability and safety can only be guaranteed if the operator complies with the manufacturer's maintenance instructions. For lubrication, we recommend our tried and tested special grease, LINO MAX 200. Unsuitable lubricants can have a negative impact on the functioning of the Chuck quick-change (clamping force, coefficient of friction, wear characteristics). (For product information about LINO MAX 200, see the "Accessories" chapter of the SCHUNK lathe chuck catalog or contact SCHUNK). The flexible adapter and draw tube adapter must be replaced every 250,000 clamping cycles or 5,000 clamping device changes at the latest, whichever occurs first. For this purpose, the O.D or I.D. clamping on the fitted clamping device and changes thereof must be documented, monitored reliably and proof must be available. Corresponding counters must be set up on the machine on initial assembly and when changing the flexible adapter, or the counter readings must be noted ROTA FSW en

13 Basic safety notes To replace the flexible adapter and the draw tube adapter, the parts must be ordered from SCHUNK and can be changed by the SCHUNK Service Team on request. NOTICE Loss of function in the event of heavy soiling. It is essential that the cleaning intervals are observed. Safety notes for servicing Follow all the applicable legal standards for health and safety during servicing. Use suitable personal protective equipment, especially protective gloves, goggles and safety boots, paying particular attention to the operating system and hazard assessment. DANGER Possible risk of fatal injury to operating personnel due to ROTA FSW Chuck quick-change failure if the maintenance and servicing instructions for the ROTA FSW Chuck quick-change and the chuck are disregarded The servicing instructions specified by the manufacturer must be complied with to ensure safe operation of the ROTA FSW Chuck quick-change. Work must be carried out by qualified specialist personnel with the relevant safety training. Avoiding material damage NOTICE Damage of clamping devices and the ROTA FSW Chuck quickchange! The clamping device may only be disassembled when at a standstill! NOTICE Damage due to excess tensile force and pressure! Excessive clamping force or actuating force can cause damage to the clamping device or adapter. The maximum tensile force and pressure must not be exceeded ROTA FSW en 13

14 Basic safety notes NOTICE Property damage due to damaged products! Damaged, incomplete or unbalanced clamping devices or adapters could damage or even destroy the machine and the workpiece severely. Only mount undamaged, complete and fine-balanced products. If the ROTA FSW Chuck quick-change and the clamping device are involved in a collision, they must be tested for cracks before using them again. Damaged parts must be replaced with original SCHUNK spare parts. Replace the mounting screws if there are signs of wear or damage. Use screws of the same quality only. Tighten the screws to the torque specified (see chapter "Screw torques" ( 4, Page 16)) Substantial modifications No substantial modifications may be made to the ROTA FSW Chuck quick-change. Modifications, conversions and attachments or attaching fittings that are not offered as accessories by SCHUNK may be performed only with permission of SCHUNK. If the operator carries out a substantial modification to the ROTA FSW Chuck quick-change, the product no longer complies with the EC Machinery Directive 2006/42/EC. 2.5 Personnel qualification The ROTA FSW Chuck quick-change 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 our ROTA FSW Chuck quick-change must have access to the operating manual, especially the chapter "Basic safety notes". We recommend that the operator creates in-house safety operating instructions. Trainees may work on machines and technical equipment in which a ROTA FSW Chuck quick-change is installed, provided that they are supervised at all times by qualified specialist personnel ROTA FSW en

15 Basic safety notes 2.6 Organizational measures Obeying the rules The operator must put suitable organizational measures and instructions into place to ensure that the relevant safety rules are obeyed by the persons asked to operate, maintain and repair the ROTA FSW Chuck quick-change. Monitoring 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 ROTA FSW Chuck quick-change is mounted are clearly legible and are observed. Malfunctions If a malfunction occurs on the ROTA FSW Chuck quick-change and this malfunction endangers safety or if a problem is suspected due to production characteristics, the machine tool where the Chuck quick-change is mounted must be immediately stopped and remain shut down until the malfunction has been located and remedied. Only allow specialists to remedy malfunctions. 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. 2.7 Using personal protective equipment When using this product, you must comply with the relevant health and safety at work rules and you must use the required personal safety equipment (minimum: category 2) ROTA FSW en 15

16 Warranty / Torques per screw / Scope of delivery 3 Warranty If the product is used as intended, the warranty is valid for 24 months from the date of delivery from the production facility under the following conditions: Observe the applicable documents( 1.2, Page 6) Observe the environmental and operating conditions. Observation of the maximum clamping cycles( 6, Page 17) Observe the mandatory maintenance and lubrication intervals.( 9, Page 28) Parts touching the work piece and wearing parts are not part of the warranty. Torques per screw Tightening torques for mounting screws used to clamp the ROTA FSW Chuck quick-change on lathes or other suitable technical equipment (screw quality 10.9) Screw size M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 Admissible torque M A (Nm) Scope of delivery 1 ROTA FSW Chuck quick-change 1 clamping device and machine-specific attachment 1 actuating key 1 eye bolt 1 Assembly and Operating Manual 1 Short Operating Manual ROTA FSW en

17 Technical data 6 Technical data Type ROTA FSW 220-A8 290-A A15 ID no Tightening torque [Nm] Max. actuating force [kn] Max. r.p.m. [min -1 ] Weight without adapter [kg] Ambient temperature [ C] The maximum permissible actuating force and the maximum permissible RPM for special machining must be calculated by the user based on the permitted data of the ROTA FSW Chuck quick-change and the mounted clamping device or toolholder. Warranty and maximum clamping cycles Length of warranty Maximum number of clamping cycles of the flexible adapter and the draw tube adapter Maximum number of clamping device changesof the flexible adapter and the draw tube adapter 24 months 250,000 5, Precision classes Tolerances for axial and radial run-out accuracy correspond to the Technical Supply Terms per DIN ISO Permissible imbalance The permissible imbalance for ROTA FSW Chuck quick-change is quality class G 6.3 as per DIN ISO ROTA FSW en 17

18 Attachment and disassembly of the ROTA FSW Chuck quick-change Attachment and disassembly of the ROTA FSW Chuck quick-change The item numbers specified for the corresponding individual components relate to chapter drawings.( 12, Page 33) Pre-assembly measures Carefully lift the product (e.g. using suitable lifting gear) from the packaging. CAUTION Danger of injury due to sharp edges and rough or slippery surfaces Use personal protective gear, especially safety gloves. Check the delivery for completeness and for transport damage. WARNING Risk of injury due to dropping the ROTA FSW Chuck quickchange and the clamping device during transport, installation or removal During transport, installation and removal, secure the Chuck quick-change and the clamping device to prevent them falling. Only mount the ROTA FSW Chuck quick-change on machines with suitable connection dimensions. Use a crane to mount the Chuck quick-change and the clamping device. For high true running accuracy of the ROTA FSW Chuck quickchange or the inserted clamping device, the machine side must be aligned before assembly of the ROTA FSW Chuck quick-change or the intermediate flange. To do this, check the contact surfaces on the spindle for axial and radial run-out accuracy using a dial indicator (see Fig. Assembly of the Chuck quick-change or intermediate flange - A). There should be a maximum concentricity error in the centering of the mount of mm and a maximum axial run-out error in the contact surfaces of mm. The flat surface of the spindle must also be checked for flatness using a straight edge. Make sure that the surface area of the flat surface is chamfered at the bore holes and is clean ROTA FSW en

19 Attachment and disassembly of the ROTA FSW Chuck quick-change Checking the spindle nose for mounting the ROTA FSW Chuck quick-change or intermediate flange Assembly of the Chuck quick-change or intermediate flange Assembly of the ROTA FSW Chuck quick-change Assembly of the ROTA FSW Chuck quick-changes with a reducing or extension flange If the ROTA FSW Chuck quick-change is screwed on with an intermediate flange, the following points must be observed: To mount the ROTA FSW Chuck quick-change with a reducing or extension flange on the spindle with a short taper, a corresponding intermediate flange is fastened to the spindle nose. Before assembly of the intermediate flange, remove any dirt or chips from the spindle and from the centering mount and contact surface of the flange. An intermediate flange produced by the user must be fully machines on the spindle and balanced and aligned before assembly of the ROTA FSW Chuck quick-change ROTA FSW en 19

20 Attachment and disassembly of the ROTA FSW Chuck quick-change After assembly, ensure that the flange is in contact with the entire surface. Then check the run-out accuracy and true running as described in "Measures before starting assembly" ( 7.1, Page 18) (see Fig. Assembly of the Chuck quick-change or intermediate flange B) After aligning the intermediate flange, the ROTA FSW Chuck quickchange is assembled. Remove any impurities on the intermediate flange and the contact surfaces of the ROTA FSW Chuck quickchange. WARNING Risk of injury if the ROTA FSW Chuck quick-change falls during transport or assembly! Use a crane to assemble the ROTA FSW Chuck quick-change. This can be fastened on the eye bolt provided (see Fig. Assembly of the Chuck quick-change or intermediate flange - C). The eye bolt is included in the scope of delivery. Before starting up the ROTA FSW Chuck quick-change, the eye bolt must be removed on the circumference. (See chapter "Disassembling and assembling the ROTA FSW Chuck quickchange" ( 7.5, Page 24)). Push the ROTA FSW Chuck quick-change onto the intermediate flange. Ensure that the through-bores for fastening the Chuck quick-change line up with the threaded holes of the intermediate flange (see Fig. Assembly of the Chuck quick-change or intermediate flange D). Insert and slightly tighten the mounting screws. Afterwards check the ROTA FSW Chuck quick-change for run-out accuracy at the fix cone and true running accuracy on the clamping bearing surface (see Fig. Assembly of the Chuck quick-change or intermediate flange E) and align at the outer diameter with gentle taps using a plastic hammer. Then tighten the mounting screws on the ROTA FSW Chuck quick-change to the specified torque (see chapter "Screw torques" ( 4, Page 16)). Then check the axial and radial run-out accuracy again (see Fig. Assembly of the Chuck quick-change or intermediate flange E) ROTA FSW en

21 Attachment and disassembly of the ROTA FSW Chuck quick-change Assembly of the ROTA FSW Chuck quick-change with a direct mount If the ROTA FSW Chuck quick-change is mounted directly on the spindle without a reducing or an extension flange, the following points must be observed: Before assembly of the ROTA FSW Chuck quick-change, remove any dirt or chips from the spindle and from the centering mount and contact surface of the ROTA FSW Chuck quickchange. WARNING Risk of injury if the ROTA FSW Chuck quick-change falls during transport or assembly! Use a crane to install the ROTA FSW Chuck quick-change. This can be fastened on the eye bolt provided (see Fig. Assembly of the Chuck quick-change or intermediate flange - C). The eye bolt is included in the scope of delivery. Push the ROTA FSW Chuck quick-change onto the spindle. Ensure that the through-bores for fastening the Chuck quickchange line up with the threaded holes of the spindle nose (see Fig. Assembly of the Chuck quick-change or intermediate flange D). Insert and slightly tighten the included mounting screws. Afterwards check the ROTA FSW Chuck quick-change for run-out accuracy at the fix cone and true running accuracy on the clampling bearing surface (see Fig. Assembly of the Chuck quick-change or intermediate flange E) and align at the outer diameter with gentle taps using a plastic hammer. Then tighten the mounting screws on the ROTA FSW Chuck quick-change to the specified torque (see chapter "Screw torques" ( 4, Page 16)). Then check the axial and radial run-out accuracy again (see Fig. Assembly of the Chuck quick-change or intermediate flange E). The run-out accuracy and true running accuracy to be achieved depend on the external chuck diameter. The run-out and true running tolerances correspond to the technical delivery conditions for lathe chucks per DIN ISO ROTA FSW en 21

22 Attachment and disassembly of the ROTA FSW Chuck quick-change 7.3 Attachment of the flexible adapter to the draw tube/draw bar The flexible adapter must be designed to suit the machine and the changing clamping devices. Only original SCHUNK attachments may be used. Remove the flexible adapter (Item 9) from the packaging and check it for damage/completeness. Ensure that there is either a guide ring for the draw tube/draw bar in the spindle, and that it is in perfect condition, so that a maximum axial run-out error of the draw tube/draw bar contact surface of 0.2 mm is observed; or the axial run-out of max. 0.2 mm is already complied with (see Fig. Assembly of the Chuck quick-change or intermediate flange E). Turn the actuating screw (Item 5) carefully clockwise as far as the back stop. The golden indicator pins (Item 6) are then level with the housing (Item 1). Actuate the clamping cylinder to move the draw tube/draw bar to the foremost position and screw the flexible adapter included (Item 9) to the draw tube/draw bar on the block. Piston in foremost position R1 = Push the clamping device piston to its foremost position and measure with a depth gage R2 = R1 0.5 mm (max. 2 mm) Ensure that the clamping device piston can be moved to the foremost (jaw change) position. To do this, ensure that the dimensions for the attachment are complied with ROTA FSW en

23 Attachment and disassembly of the ROTA FSW Chuck quick-change EXCEPTION: the ROTA NCR power chuck series. Contact SCHUNK before using this power chuck type with the ROTA FSW Chuck quick-change Attaching the retainer ring and draw tube adapter to the clamping device The clamping devices to be changed are generally already fitted with a retainer ring (Item 7) and a draw tube adapter (Item 10) and do not require any further assembly steps. If necessary, a clamping device can also be mounted on-site to the corresponding retainer ring and the corresponding draw tube adapter. The following steps must also be performed after releasing the retainer ring from a clamping device delivered in an assembled state. Remove the clamping device from the packaging box and check for damage/completeness. Before assembling the retainer ring and the draw tube adapter to the clamping device, clean dirt and chips from every contact surface. Lay the retainer ring on the locating surface of the chuck so that the bore hole of the positioning block faces the installer, and then tighten slightly using the screws. Then check the axial and radial run-out accuracy again (see Fig. Assembly of the Chuck quick-change or intermediate flange E). Tighten the screws to the specified torque (see chapter "Screw torques" ( 4, Page 16)). Then check the axial and radial run-out accuracy again (see Fig. Assembly of the Chuck quick-change or intermediate flange E). 7.4 Attachment of the clamping device and the ROTA FSW Chuck quick-change Move the draw tube/draw bar to its foremost position by actuating the clamping cylinder. Turn the actuating screw (Item 5) carefully counter-clockwise as far as the back stop. The golden indicator pin on the clamping device side (Item 6) is then level with the housing (Item 1) ROTA FSW en 23

24 Attachment and disassembly of the ROTA FSW Chuck quick-change Move the draw tube/draw bar to its rearmost position by actuating the clamping cylinder. This warps the flexible adapter radially inwards via the already retracted clamping slides. Align the clamping device to be fitted (Item 23) in the rotary position relative to the ROTA FSW Chuck quick-change taking the position of the positioning block into account. A mark in form of a notch helps in the housing as well as in the retainer ring. Push the clamping device onto the ROTA FSW Chuck quickchange. The flat surface of the clamping device may not be more than 0.5 mm from the flat contact surface of the Chuck quick-change housing. Tighten the actuating screw clockwise to the torque specified (see chapter "Technical data " ( 6, Page 17) and Chuck quickchange housing). Ensure that the two golden indicator pins are level with the Chuck quick-change housing and the clamping device was tightened against the ROTA FSW Chuck quick-change. Actuate the clamping cylinder to move the draw tube/draw bar to the foremost position; the flexible adapter then locks into the draw tube adapter of the clamping device. This is indicated by an audible snap. 7.5 Disassembling and assembling the ROTA FSW Chuck quick-change The FSW Chuck quick-change can only be disassembled when not installed. Remove the two set-screws (Item 8) and remove the compression springs (Item 26) and the indicator pins (Item 6). Remove the cylindrical pin (Item 22) from the housing (Item 1) via the pulling off thread with a sliding hammer. Rotate the actuating screw (Item 5) counter-clockwise from the lever (Item 4) and remove it. Remove the key (Item 25) from the housing via the pulling off thread with a sliding hammer. Remove the lever (Item 4). Remove the five shoulder screws (Item 13) with an hexagonal socket with screw-pins according to DIN 6212 and remove the drive ring (Item 2) ROTA FSW en

25 Attachment and disassembly of the ROTA FSW Chuck quick-change Remove the six clamping slides (Item 3) from the housing. Remove the screw (Item 24) and remove the positioning block (Item 23). Clean all individual components and check them for damage and wear. Only original SCHUNK spare parts may be used. Reverse the procedure to assemble the ROTA FSW Chuck quickchange. Tightening torque for the shoulder screws (Item 13): ROTA FSW 220-A8 290-A A15 Tightening torque for the shoulder screws [Nm] Before assembly, lubricate all parts well with LINO MAX 200 special grease. CAUTION Allergic reactions due to grease in contact with skin! Wear gloves ROTA FSW en 25

26 Function and handling Function and handling The item numbers specified for the corresponding individual components relate to chapter drawings.( 12, Page 33) Function of the ROTA FSW Chuck quick-change The Chuck quick-change has a clamping and release mechanism with manual actuation. The side of the housing (Item 1) offers access to the actuating screw (Item 5), which is actuated using the enclosed hexagon socket for torque wrenches. If another socket is used to operate the actuating screw with the torque wrench, it must comply with DIN EN 1550 Par A lever (Item 4) transfers the rotary movement of the actuating screw to the drive ring (Item 2). The control curves in the drive ring guide the clamping slides (Item 3) into the clamping position. The clamping and release function of the ROTA FSW Chuck quickchange is purely manual; no additional medium is required for actuation. 8.2 Handling the ROTA FSW Chuck quick-change Unlocking and removing the changed clamping devices Move the clamping cylinder into the front position without a workpiece. Turn the actuating screw (Item 5) at the side counter-clockwise as far as the back stop using the included hexagon socket. In this case, the clamping device is pushed up from the ROTA FSW Chuck quick-change min. 0.3 to a few mm (see chapter 7.3). The clamping slides (Item 3) move radially inwards. Support the clamping device with a crane or other suitable lifting equipment. Move the clamping cylinder into the rearmost position. The flexible adapter (Item 9) is unlocked via the clamping slides which were previously moved inwards. The clamping device is now exposed and hangs in the lifting equipment ROTA FSW en

27 Function and handling Locking and inserting a clamping device Move the clamping cylinder into the foremost position. Turn the actuating screw (Item 5) at the side counter-clockwise as far as the back stop using a hexagon socket. Move the clamping cylinder into the rearmost position. The flexible adapter (Item 9) is unlocked via the clamping slides which were previously moved inwards. The clamping device to be inserted must be prepared in accordance with chapter 7.2. Align the clamping device to be fitted (Item 23) in the rotary position relative to the ROTA FSW Chuck quick-change taking the position of the positioning block into account. A mark in a form of a notch helps in the housing as well as in the retainer ring. Push the clamping device onto the ROTA FSW Chuck quickchange. The flat surface of the clamping device may not be more than 0.5 mm from the flat contact surface of the Chuck quick-change housing. Tighten the actuating screw clockwise to the torque specified (see chapter "Technical data " ( 6, Page 17) and the marking on the Chuck quick-change housing). Ensure that the two golden indicator pins are level with the Chuck quick-change housing and the clamping device was tightened against the ROTA FSW Chuck quick-change. Actuate the clamping cylinder to move the draw tube/draw bar to the foremost position; the flexible adapter then locks into the draw tube adapter of the clamping device. This is indicated by an audible snap. After inserting a new clamping device, the end position monitoring of the machine clamping cylinder must be checked and adjusted! ROTA FSW en 27

28 Maintenance 9 Maintenance To comply with the radial and axial run-out tolerances, the corresponding back stop and guide diameter must be clean. Compliance with the maintenance, cleaning and replacement intervals of the flexible adapter is essential. NOTICE Risk of damage to the adapter due to cleaning with compressed air. When cleaning the adapter with compressed air, metal chips can become trapped in the threads and grooves. That can damage or even destroy the adapter. 9.1 Lubrication To maintain the safe function and high quality of the chuck quickchange ROTA FSW, it has to be regularly lubricated. A Lubrication nipples on the circumference Turn the chuck quick-change into the open position. Lubricate the chuck at the lubrication nipples (A) using a high-pressure grease gun with 2-4 strokes (depending on the chuck side) of SCHUNK LINO MAX special grease. For optimum grease distribution, the chuck quick-change must be closed and opened several times after lubrication. Chuck ROTA FSW 220-A8 290-A A15 Number of strokes ROTA FSW en

29 Maintenance (For product information about LINO MAX, see the "Accessories" chapter of the SCHUNK lathe chuck catalog or contact SCHUNK). CAUTION Allergic reactions due to grease in contact with skin! Wear gloves Maintenance instructions After disassembling the ROTA FSW Chuck quick-change (see chapter "Disassembling and assembling the ROTA FSW Chuck quickchange" ( 7.5, Page 24)), all parts must be degreased, cleaned and checked for damage. Use original SCHUNK spare parts only when exchanging damaged parts. During assembly, all moving parts must be lightly lubricated with grease (LINE MAX 200). The screws must be tightened in accordance with the usual torques with a torque wrench (see chapter "Screw torques" ( 4, Page 16)). When tightening the screws, ensure they are tightened evenly to avoid warping parallel to the axis under load and to maintain the rigidity. In order to avoid accuracy errors, the screw and fitting surfaces must be cleaned. The factory oiling of flat surfaces and clamping elements only serves as corrosion protection and is not functional lubrication. Only mechanical running surfaces are lubricated. To avoid axial and radial concentricity errors: only lubricate the corresponding surfaces lightly. Avoid lubricants entering the areas between clamping elements and the guide cone. Period of maintenance Operating hours After each chance of the clamping device Activity Perform a visual inspection of all parts, particularly inspect the mounting taper and mounting flat surface for damage. Clean and lubricate the flexible adapter and the contact surface ROTA FSW en 29

30 Maintenance Operating hours Every 8 operating hours Every 1,200 hrs, by replacing the Flexible adapter and the draw tube adapters, or as required. Activity Perform a visual inspection of the complete system and lubricate the funnel grease nipple. Full cleaning with disassembly of the ROTA FSW Chuck quick-change and inspection of all parts. After 250,000 or 5,000 changes of the clamping device, the flexible adapter and draw tube adapter must be replaced. 9.4 Storing the ROTA FSW Chuck quick-change Store the ROTA FSW Chuck quick-change in its original packaging under the following conditions: Do not store outdoors. Store in a dry and dust-free environment. Do not expose it to aggressive media. Protect against sunlight. Avoid mechanical vibrations. Storage temperature: 15 to 35 C. Relative humidity: max. 60%. If stored for more than 3 months: Check the general condition of all parts and the packaging regularly. If necessary, freshen up or replace the preservation. Re-storing the ROTA FSW Chuck quick-change Clean the ROTA FSW Chuck quick-change thoroughly before restoring (see chapter "Disassembling and assembling the ROTA FSW Chuck quick-change" ( 7.5, Page 24)). Oil and/or grease the Chuck quick-change (see chapter "Disassembling and assembling the ROTA FSW Chuck quickchange" ( 7.5, Page 24)). Pack the ROTA FSW Chuck quick-change air-tight in film. The ROTA FSW Chuck quick-change must be stored in a stable position. If that is not guaranteed, use a suitable container for the ROTA FSW or equip the shelf with a surrounding safety border ROTA FSW en

31 Disposal 10 Disposal After decommissioning, place the ROTA FSW Chuck quick-change in a position that enables any liquids in the Chuck quick-change to drain out. Collect the escaping liquids and dispose of them properly in line with the statutory provisions. Remove any identifiable plastic or aluminum parts installed in or on the ROTA FSW Chuck quick-change and dispose of them properly in line with the statutory provisions. Dispose of the ROTA FSW Chuck quick-change's metal parts as scrap metal. Alternatively, you can return the ROTA FSW Chuck quick-change to SCHUNK for proper disposal ROTA FSW en 31

32 Spare parts 11 Spare parts When ordering spare parts, it imperative to state the type, size and above all the manufacturing no. of the ROTA FSW Chuck quick-change. Seals, sealing elements, screw connections, springs, bearings, screws and wiper bars plus parts coming into contact with the clamping device are not covered by the warranty. Item Designation Quantity 1 Housing 1 2 Drive ring 1 3 Clamping slide 6 4 Lever 1 5 Screw 1 6 (Safety) indicator pin 2 7 Retainer ring (specific*) 1 8 Set-screw 2 9 Flexible adapter (specific*) 1 10 Draw tube adapter (specific*) 1 13 Shoulder screw 5 19 Key 1 20 Screw 5 21 Lubrication nipple 1 22 Cylindrical pin 1 23 Positioning block 1 24 Screw 1 26 Compression spring 2 * Parts are contained in the machine or chuck-specific attachment ROTA FSW en

33 Assembly drawing 12 Assembly drawing ROTA FSW en 33

34 Translation of original EC declaration of incorporation Translation of original EC declaration of incorporation in terms of the Directive 2006/42/EG, Annex II, Part 1.B of the European Parliament and of the Council on machinery. Manufacturer/ Distributor H.-D. SCHUNK GmbH & Co.Spanntechnik KG Lothringer Str. 23, D-88512Mengen We hereby declare that on the date of the declaration the following incomplete 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. The declaration is rendered invalid if modifications are made to the product. Product designation: Manually actuated chuck quick-change with through hole FSW 220-A8, FSW 290-A11, FSW 400-A15 ID number ; ; ; / The incomplete machine may not be put into operation until conformity of the machine into which the incomplete machine is to be installed with the provisions of the Machinery Directive (2006/42/EC) is confirmed. Applied harmonized standards, especially: DIN EN ISO 12100:2010 DIN EN ISO 1550: 1997+A1:2008 Safety of machinery - General principles for design - Risk assessment and risk reduction Machine-tools safety Safety requirements fort the design and constructions of work holding chucks Other related technical standards and specifications: DIN ISO 702-1: Machine tools - Connecting dimensions of spindle noses and work holding chucks - Part 1: Conical connection DIN ISO 702-2: Machine tools - Connecting dimensions of spindle noses and work holding chucks - Part 2: Camlock type DIN ISO 702-3: Machine tools - Connecting dimensions of spindle noses and work holding chucks - Part 3: Bayonet type VDI 3106: DIN EN ISO 23125: A1: Determination of permissible speed (rpm) of lathe chucks (jaw chucks) Machine tools - Safety - Turning machines ROTA FSW en

35 Translation of original EC declaration of incorporation The manufacturer agrees to forward on demand the special technical documents for the incomplete machine to state offices. The special technical documents according to Annex VII, Part B, belonging to the incomplete machine have been created. Person authorized to compile the technical documentation: Philipp Schräder, Address: see manufacturer's address Mengen,January2015 p.p. Philipp Schräder; Director for Development ROTA FSW en 35