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Montage- und Betriebsanleitung

Installation- and operating instruction

Zentrischspanner
Centric vise

KSC3

H.-D. SCHUNK GmbH & Co.

Spanntechnik KG
Lothringer Strasse 23
D-88512 Mengen

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1 User information 2.3 Residual risk
The user is responsible for applying the correct workpiece tension.
1.1 Purpose of document, validity New clampings have to be carefully checked by qualified personnel with relevant training.
These instructions are an integral part of the product supply and contain important information One always needs to allow for the risk that the workpiece may slip or be dislodged, even
for the safe installation, commissioning, operation, servicing and maintenance. when the clamping device is functioning correctly. This is due to the different geometries
These instructions must be read before using the product and must be observed during operation, to be clamped, contact surfaces, clamping friction values, processing force, wrong
in particular the "General safety instructions" section. manipulation of the milling machine etc.
Protective devices are to be attached to the processing machine that will protect the
1.2 Illustration of safety instructions operator from any tool or workpiece parts that may be ejected.
Danger: It is mandatory that operators and others in the proximity of the processing machine
Indicates imminent danger. wear protective goggles.
Do not use methods of operation that impair the function and operational safety.
If the information is ignored, death or serious injuries
(permanent disability) will result. 2.3.1 Jaw change
Warning: Damage may result if system jaws are insufficiently tightened.
Indicates a potentially dangerous situation. 2.3.2 Notes on clamping technology
If the information is ignored, it is possible that death or serious injuries The operator is responsible for ensuring that the clamping geometry and clamping forces
(permanent disability) will result. are suitable for the intended processing.
Warning: We recommend that clamping be carried out with a torque wrench in order to achieve
Indicates a potentially dangerous situation. consistent clamping results.
If the information is ignored, it is possible that material damage and light The clamping forces can only be achieved if the clamping device functions correctly
to medium injuries will result. and the workpiece is correctly held in the device.
Indication on useful tips or for preventing material damage Regular servicing and cleaning in accordance with the operating instructions is
Note: mandatory in order to ensure correct function.
Indicates general information, useful tips for users and work When clamping thin-walled elastic workpieces, e.g. tubes or packages, it is possible
recommendations which, however, do not have an impact on the health that the clamping force is significantly reduced due to yielding of the workpiece.
and safety of operators. When clamping with a high degree of force, the clamping force is significantly reduced
due to the increased frictional forces in the carriages.
… underscores useful tips and recommendations as well as information
for efficient and trouble-free operation.
2.4 Duties of the organisation in charge
The organisation in charge of the device undertakes to only allow operatives to work on the device:
Important for preventing more extensive material damage
Caution:  who are familiar with the basic health and safety regulations and regulations for the
Indicates a potentially dangerous situation. prevention of accidents.
If the information is ignored, material damage will result.  who have completed appropriate induction for working with the machine.

… points out a potentially dangerous situation that can lead to  who have read and understood these operating instructions.
material damage if it is not avoided. The requirements of the EC Directive 2007/30/EC on the use of work machinery must be
complied with.
2 General safety instructions
2.5 Operator duties
2.1 Intended use All persons who have been instructed to work with the machine undertake to:
The clamping device may only be used in accordance with the technical data. The clamping device
 observe the basic regulations for health and safety and for the prevention of accidents.
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  read and understand the section on safety and the safety instructions in these operating
commissioning, installation and operating instructions, and with the environmental and service instructions prior to working with the machine, and to observe these instructions.
conditions as provided by the manufacturer.
The manufacturer accepts no liability for damage resulting from non-intended use.
2.6 Operator qualification
The installation, initial setup, fault analysis and periodic monitoring have to be carried out
2.1.1 Technical data by competent personnel with the relevant qualifications.
Version Max. torque Max. clamping force
KSC3 80 90 Nm 25 kN
2.7 Personal protective equipment
KSC3 125 100 Nm 35 kN Warning:
KSC3 160 175 Nm 50 kN Risk of eye injury through ejected hot chips!
Ejected hot fragments can lead to serious eye injury.
Clamping torque / Clamping force 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.
2.8 Warranty
The warranty period is 24 months from the date of delivery, the warranty applies subject
to being used as intended and to the following conditions:
 Compliance with concurrent documents.
 Compliance with environmental and operating conditions.
 Compliance with the specified maintenance and lubrication intervals.
 Observance of the maximum service life.
Exposure to loads in excess of the max. pull-in torque results in damage to the spindle. Any parts in contact with workpieces are not covered by the warranty.
Weight: Warranty – Maximum service life
KSC3 80 L-130 without system jaws: 3.0 kg 24 months or 50‘000 clamping cycles
KSC3 80 L-190 without system jaws: 4.5 kg
KSC3 125 L-160 without system jaws: 6.4 kg
KSC3 125 L-235 without system jaws: 9.5 kg
KSC3 125 L-300 without system jaws: 12.5 kg
KSC3 160 L-280 without system jaws: 25.0 kg
KSC3 160 L-480 without system jaws: 35.0 kg
For further data, please see Homepage >> schunk.com <<
2.2 Reasonably foreseeable misapplication
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 of havy workpieces in vertical position without an additional safeguard to prevent the
workpiece falling out during loading and unloading.
2.2.1 Alterations and modifications
In the case of unauthorised alterations and modifications of the clamping device, the
manufacturer's liability ceases and any warranty is voided.
2.2.2 Spare and wear parts and auxiliary material
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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3 Description of the clamping device 4.2 Jaw change
The KSC3 has been designed for centric clamping of raw parts and finished workpieces. The reliable function of the clamping device is significantly affected by the selection of the
The force is generated mechanically and the power gear ratio is linear across the whole correct top jaws.
clamping range. 4.3 Clamping
3.1 Function
The KSC3 is a direct vise with a mechanical drive via a capsuled thread. Reduce force
The force is generated directly and without a force amplifier.
Both jaws and carriages close respectively open synchronously and are symmetrical with
respect to the position holes in the base plate.
The vise is also suitable for workpiece clamping from the inside to the outside.

4 Operation (standard operation)

4.1 Clamping / aligning
Important:
When using the Schunk quick-change palleting system, only the clamping pins VERO-S
SPA 40-K (ID: 0432369), SPB 40-K (ID: 0432370) with short screw and the indexing bolt Important:
VERO-S IXB V1-K (ID: 0432371) may be used. The clamping force must be adapted to the jaw width / workpiece width.
4.4 Jaw change
KSC3 80-130 KSC3 80-190  Release cylinder screws and remove the jaws.
 Clean and oil the contact surfaces, e.g. with MOTOREX Supergliss 68 K to ISO VG 68.
 Changing the jaws or moving them in the carriages, tightened the cylinder screw to the
prescribed torque:
KSC3 80 50 Nm
KSC3 125 60 Nm
KSC3 160 140 Nm
Failure to comply with this rule can result in insufficient workpiece clamping and hence to
workpieces loss and damage.
4.5 Maximum carriages opening
KSC3 125-160 KSC3 125-235
The clamping range depends on the type of vise and the selected system respectively top
jaws. There is therefore a marking on the carriages when the maximum opening of the
carriages is reached. If this range is exceeded, one leaves the encapsulated area and
contamination can occur under the carriages and in the bearing area due to chips
penetrating.

Clamping

Clamping
Cleaning

KSC3 125-300
Workpiece clamping outside the specified markings can lead to workpiece loss and
damage the vise.

5 Servicing, cleaning and maintenance

Make sure that the sliding surface between the system jaws as well as the
spindle is free of chips when adjusting the clamping range.
For cleaning under the carriages, the KSC3 80, KSC3 125-160 and KSC3 160-280 vises
can be opened above the maximum and flushed.
This is not possible with all others because the slides are secured with a circlip or snap ring.
Clean and oil the running surfaces and guides of the vise regularly,
e.g. with MOTOREX Supergliss 68 K to ISO VG 68.
The KSC3 160 has a lubrication nipple in the carriage groove. It is recommended that a lubrication
nipple be applied monthly. The carriages must be completely closed.

6 Troubleshooting, eliminating faults

KSC3 160-280 Device is hard to operate
Disassemble system jaws and clean the entire devices.
If this does not result in an improvement of the function, the device can
be further dismantled in accordance with the description below.
6.1 Removal
The carriages can be completely removed from the base plate by turning the spindle to
the left with a T20 Torx-Screwdriver.
On the KSC3 125-235, KSC3 125-300 and KSC3 160-480 must the circlip be removed
from the spindle before.
The inner wipers are usually pulled out of the carriages and remain on the inside of the
spindle.
(If the wipers are pulled over the thread, they must be carefully returned to the inside of
the spindle).

KSC3 160-480

Important:
The high degree of precision of the KSC3 is achieved using a processing step while it is
mounted.
The components of different vises must not be interchanged.
Both carriages and the base plate must have the identical serial number.
This is imperative in order to ensure the consistent central position of the system and the
fitting of the guide between the carriages and base plate.
Further dismantling by the user is not permitted but can be carried out by the manufacturer or an
Important: authorised service agent.
All tolerances are without nickel layer of 5µm per surface. Non-compliance with this rule invalidates the warranty.

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6.2 Installation 8 Aluminium jaws
 Clean the system completely. The aluminium jaws are designed for producing workpiece-specific clamping contours. In
 Re-grease the thread of the spindle and at the carriages using e.g. EP high-performance order to achieve maximum precision of the contour, it is recommended that the contour
grease, such as LAGERMEISTER WHS 2002, NLGI class 1-2. milling is carried out with pre-clamping of the aluminium jaws. For this purpose, a
 Oil the running surfaces and bearing of the vise using e.g. with MOTOREX Supergliss 68 K to narrow spacer piece can be clamped at the bottom and the pre-clamped aluminium jaws
ISO VG 68. can then be milled to achieve the desired clamping contour.
 Insert both carriages into the base plate up to the thread beginnings of the spindle.
Important:
Both carriages and the base plate must have the identical serial number.
 Screw in the threads by turning the spindle clockwise and pressing on both carriages ends
at the same time.
Important:
Both carriages must come together and engage in the threads at the same time. This is
imperative in order to ensure the consistent central position of the system.
Checking the central position Important:
The gap between the carriage slot and the end face of the base plate must be Mill the system jaw to a maximum depth of the screw head.
identical on both sides. If this is not the case, remove the carriages again and repeat Ensure that the clamping cross-section is sufficient.
the process.
9 Service / Maintenance
Note:
It is not possible to supply spare parts for the carriage, base plate and spindle, as these
are designed and fitted at the factory to work together.
XXX Repairs can be carried out by the manufacturer or an authorised service agent.
Serial number
10 Taking out of service
The clamping device and all accessories can be disposed of as scrap metal without any
risk.

 Finally, fully join the carriages together so that the inside wipers on the vises
KSC3 125-300 and KSC3 160-480 are again pressed into the carriages via the spacer
O-rings.
 If present, refit end stops.

Important:
The high degree of precision of the KSC3 is achieved using a processing step while it
is mounted.
The components of different vises must not be interchanged.
Both carriages and the base plate must have the identical serial number.
This is imperative in order to ensure the consistent central position of the system and the
fitting of the guide between the carriages and base plate.

7 Swivel and adapter plate

OP10: Clamping with grip clamping steps of 3, 8 or 18 mm.
OP20: Clamping on tungsten carbide coated side. When clamping
the system jaws may yield slightly. The workpiece position must
be measured.
7.1 Fitting the swivel and adapter plate
With the KSC3 80, KSC3 125-235 and KSC3 125-300 are the workpieces are clamped
asymmetrically to the base plate.
Depending on the selected mounting position of the swivel plate and the 6-fold
reversible jaws, a centric workpiece position is possible with theKSC3 125 L-160 and
KSC3 160 in relation to the base plate.
For reasons of stability, the swivel plate with the bearing journal must not be inserted in the
outermost sliding groove.
7.2 Fitting the 6-fold reversible jaws
 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 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.
7.3 Troubleshooting, eliminating faults
Swivel plate is difficult to turn
 Disconnect the swivel plate and push the swivel peg from below out of the swivel plate.
 Check the vise guide and swivel plate surface for indentations or deformations.
If necessary, re-grind the plate and the vise guide.
 Check the peg for soiling.
 Check that the O-rings are correctly positioned. The upper O-ring must make good contact.
 Lubricate the entire system with grease and reassemble.
When handling, the swivel plate should not be turned upside down.

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H.-D. Schunk GmbH & Co.

Spanntechnik KG
Lothringer Strasse 23

D-88512 Mengen

Tel.: +49-7572-7614-0
Fax: +49-7572-7614-1039

[email protected]
schunk.com

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