Kurt VersatileLock 3800H Instruction Manual

3800H™
VERSATILELOCK®
HYDRAULIC VISE
Operating Instruction Manual
3800H/3810H(Reverse)
ENGLISH

2
TABLE OF CONTENTS
Introduction ................................................................................................................. 3
Setup Instructions ........................................................................................................ 4
Operating Instructions ..............................................................................................5-14
3800H Parts List........................................................................................................... 15
3800H Mechanical Drawing ....................................................................................... 16
Maintenance Schedule ......................................................................................... 20-22
Troubleshooting Tips .................................................................................................. 23
VISE DATA
Use this to fill out information about your vise for quick reference.
Purchase Date: _________ -________ -_________
Purchase Order: ______________________________
______________________________
______________________________
Purchased From:
Delivery Date:
Serial No.: ______________________________
NOTE: MAKE SURE TO REGISTER YOUR WARRANTY ONLINE AT
KURTWORKHOLDING.COM
TABLE OF CONTENTS
3810H Parts List................................ .......................................................................... 17
3810H Mechanical Drawing ....................................................................................... 18
Maintenance Log/Notes ............................................................................................. 24
Warranty ..................................................................................................................... 25
KHU8 Mechanical Drawing ......................................................................................... 19

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3 | ENLGISH
Table of Contents
Introduction .................................................................................................................3
Setup Instructions......................................................................................................4
Operating Instructions .........................................................................................5-7
DX6 Parts List ...............................................................................................................8
DX6 Mechanical Drawing........................................................................................9
Maintenance Schedule....................................................................................10-12
Troubleshooting Tips............................................................................................. 13
Vise Data
Use this to ll out information about your vise for quick reference.
Purchase Date: _______ -_______- _______
Purchase Order: _______________________
Purchased From: _______________________
Delivery Date: _______________________
Serial No.: _______________________
Note:
Make sure to register your warranty online at kurtworkholding.
Introduction
Thank you for purchasing a Kurt DX6 vise. You have just purchased one
of the best machine vises in the industry. The outstanding accuracy
of this product is second to none. Backed by a lifetime warranty, this
product will last forever when used and maintained properly.
The original Kurt Anglock vises are designed for precision clamping on
basic machine tools such as knee-type mills, grinders and machining
centers. They can be used for, but are not limited to, operations like
precision boring, drilling, tapping, grinding & nishing.
The patented Anglock design allows the movable jaw to advance in
such a way that each pound of force forward induces a ½ pound force
downward which minimizes the jaw lift and increases accuracy. This
combined with the needle bearings increases jaw clamping pressure.
Other features include: 80,000 psi ductile iron body, hardened vise bed
& jaw plates, semi-hard steel screw.
Table of Contents Introduction
INTRODUCTION
Thank you for purchasing a Kurt 3800H. You have just purchased one
of the best machine vises in the industry. The outstanding accuracy of this
product is second to none. Backed by a lifetime warranty against
workmanship and material defects, this product is built to last when used
and maintained properly.
The original Kurt Anglock vises are designed for precision clamping on
basic machine tools such as knee-type mills and machining centers. They
can be used for, but are not limited to, operations like precision boring,
drilling, tapping, & finishing.
The patented Anglock design allows the movable jaw to advance in such a
way that each pound of force forward induces a ½ pound of force
downward which minimizes the jaw lift and increases accuracy. This,
combined with the needle bearings, increases jaw clamping pressure.
Other features include: 80,000 psi ductile iron body, hardened vise bed &
jaw plates, and a semi-hard steel screw.
INTRODUCTION
Fig.1

4
SET-UP INSTRUCTIONS
Now that you have your new Kurt Vise, it’s time to set-up and begin using it.
You will see that your new vise comes with a Kurt swivel handle and chip
guard in the shipping carton (instruction manual available online at
www.kurtworkholding.com). The chip guard rests between the ways of the
vise and can be trimmed to size (see pg. 14) to help keep the chips away
from the screw. The handle is specifically designed to provide maximum
torque to your vise ( clamping force provided below). Your vise should be
mounted to a clean, flat surface. The surface and the vise must be free of
any chips, dirt, or debris of any kind. The mounting surface can be honed if
necessary. Clean the bottom of the vise with solvent or another cleaner if
needed.
To minimize vise bed deflection, clamp your Kurt vise to your machine table,
pallet, or sub-plate using the built-in clamping slots or through the body
holes provided.
Additional clamping can be used, but may not be necessary. Please be sure
to exercise good judgment when securing your vise to the mounting surface.
Be sure your vise is secured and will not move when applying the machine
pressure.
Torque Ft.-Lbs. Clamping Force Lbs.
10 600
20 1000
30 1600
40 2000
50 2600
60 3450
70 4050
80 5100
SET-UP INSTRUCTIONS
Hydraulic PSI
3800H/3810H
500 1500
1000 3000
1500 4500
2000 6000
2500 7500
3000 9000
11,000
Manually Hydraulically
3200
90 6150
100 6550
Clamping Force Lbs.

5
OPERATING INSTRUCTIONS
HYDRAULIC OPERATING INSTRUCTIONS
The 3800H/3810H can be operated hydraulically by hooking up the Kurt 8"
Hydraulic Unit with a typical hydraulic pump or an air over hydraulic pump.
Kurt offers several solutions for hydraulic pumps ,one being the KHP3 air
over hydraulic pump. Kurt offers other pump solutions and can be found
on kurtworkholding.com.
The hydraulic unit (KHU8), on the end of the 3800H/3810H, has a 1/4 inch
stroke. The KHU8 can be used in both single and double acting
applications. For single acting, a spring will return the vise to the opened
position when hydraulics are disengaged. If double acting is desired, both
ports on the hydraulic unit will need to be hooked up to a pump (See
figure 2).
Fig.2

HYDRAULIC OPERATING INSTRUCTIONS
Jaw Positioning:
Once all plumbing is set up, it time to position jaws for hydraulic clamping.
1. Position jaws less than 1/4 inch from the part being clamped as is
shown in figure 3 above. This is done manually by putting the handle
onto the hex end and turning the screw until the jaws are in position.
2. Make sure the jaws are less than 1/4 inch from the part since the
hydraulic unit has only a 1/4 inch stroke.
3. The vise is now ready to have the hydraulics engaged for clamping
the part.
For basic hydraulic set-up instructions, go to the next page (pg. 7)
OPERATING INSTRUCTIONS
Fig.3
6

7
OPERATING INSTRUCTIONS
HYDRAULIC OPERATING INSTRUCTIONS
For Basic Hydraulic Set-Up:
1. Remove plastic caps from pressure and release ports on Hydraulic pump.
Install 90° fittings.
2. Remove plastic caps from pressure and release ports on hand or foot
valve. Install straight fitting.
3. Install straight fitting on the Hydraulic Unit (1/8 NPTF) of the 3800H vise.
4. A filter-lubricator-regulator combination is recommended to insure
clean air coming into the unit. See Clamping Force Chart for air pressure
required to attain desired clamping force (pg. 4 & 8).
5. Connect the FRL to the input air port on the KHP3 hydraulic pump.
6. Connect the hydraulic line to the hydraulic unit on the vise and then to
the output side of the hydraulic pump
7. If using a hand valve connect the 3-line cluster
8. Apply air pressure (80 PSI maximum) to system. Loosen swivel fitting at
vise and bleed air. Tighten fitting. Release air pressure.
9. Repeat previous step until all air is purged
10. System is now ready for use.
NOTE: For multiple vise hook-ups, call factory for recommendations.

OPERATING INSTRUCTIONS
HYDRAULIC OPERATING INSTRUCTIONS
Air Pressure Input to Hydraulic Pressure Output
for Kurt Hydraulic Pump, KHP3
00 0.1 0.4 0.5
500
1000
1500
2000
2500
3000
3500
4000
KHP3 Fluid Flow Against Pressure
0.2 0.3
Hydraulic Flow in GPM
Hydraulic Pressure in PSI
Max. Flow .68 gpm
Max. Pressure 4,000 psi
Flow and Pressure Performance Guides
Air Pressure at:
100 psi
90 psi
75 psi
60 psi
45 psi
0
500
1000
1500
2000
2500
3000
3500
20 30 40 50 60 70 80 90 100
Oil PSI Output
Air PSI Input
Ai r t o Oil PSI Results
Air PSI Input Oil PSI Output
20
30
40
50
60
70
80
90
100
150
500
900
1300
1800
2200
2600
3000
3400
Fig.4
8

9
MANUAL OPERATING INSTRUCTIONS
For proper vise operation, insert the handle on to the hex end of the
vise. Rotate clockwise to clamp and counterclockwise to unclamp your
vise. This handle, combined with the correct amount of torque, will
provide you with all the clamping force you will need to machine your
parts. DO NOT use any other type of pressure to open or close your vise.
The uses of handle extensions, air impact wrenches, breaker bars, or
hammer strikes are not recommended and will void the warranty if
used. This will also cause damage to the thrust bearing and screw
threads. If you need more clamping force you may require a larger
vise.
To properly clamp a part in your Kurt vise you should place the part in
the center of the jaws resting on the ways of the vise. Clamping only on
one side or above the movable and stationary jaws can result in jaw lift
or loss of accuracy. (See Fig. 5 on next page)
If one-sided clamping is necessary, you MUST use a dummy part on
the other side. When using parallels or step jaws, you must select a size
that keeps the bottom of the clamped part at or below the top of the
movable and stationary jaws. Always use jaw plates for clamping. If jaw
plates are not used, damage to the mounting surface of the movable
and stationary jaw will occur. This will result in reduced clamping
accuracy and repeatability.
OPERATING INSTRUCTIONS

10
Fig.5
Sketch #2A
Incorrect part
clamping.
Vise width
centerline
Sketch #2B
Correct part
clamping.
Sketch #2C
Correct part
clamping.
Sketch #2D
Correct part
clamping.
Dummy
part
OPERATING INSTRUCTIONS

11
OPERATING INSTRUCTIONS
JAW POSITIONING
Fig.6
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
SIDE & END VIEW
12
Fig.7
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
MOUNTING LOCATIONS
Fig.8
Note: Dimensions below are in inches unless specified.
13

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2ENGLISH |
Table of Contents
Introduction .................................................................................................................3
Setup Instructions......................................................................................................4
Operating Instructions .........................................................................................5-7
DX6 Parts List ...............................................................................................................8
DX6 Mechanical Drawing........................................................................................9
Maintenance Schedule....................................................................................10-12
Troubleshooting Tips ............................................................................................. 13
Vise Data
Use this to ll out information about your vise for quick reference.
Purchase Date: _______ -_______- _______
Purchase Order: _______________________
Purchased From: _______________________
Delivery Date: _______________________
Serial No.: _______________________
Note:
Make sure to register your warranty online at kurtworkholding.com
Table of Contents
CAUTION:
Is used when your action or lack of action may cause serious
injury.
OPERATING INSTRUCTIONS
PROPER CHIP GUARD INSTALLATION AND USAGE
Example: Part plus 1 inch = Length of Chip Guard.
Note: Remove Chip Guard stock. If left uncut, the excess material could
cause injury.
CAUTION:
Chip Guard stock shown above is provided to keep chips from
the nut and screw assembly and must be cut and deburred to
meet your application and safety needs.
SURFACE MOUNT USING SINE KEYS
Mounting the new 3800H can be done by the use our new sine keys as
well as our standard keys. The fixture keys are available in several different
sizes that are listed on our website at www.kurtworkholding.com. The keys
are sold in sets of 2 per package.
English Mounting:
The 3800H can be properly located using the two English sine key holes
indicated by the Y's in figure 5 above or by using a standard 13/16 fixture
key in the key way. The 3800H can be bolted down using the two 5/8 bolt
holes indicated in figure 5 above by OO. The 3800H vise can also be
mounted using the 4 bolt slots on the sides of the vise as well.
Metric Mounting:
The 3800H can be properly located using the two Metric sine key holes
indicated by the X's in figure 5 above.
Fig.9

3800H Parts List
3800H PARTS LIST 15

3800H MECHANICAL DRAWING
98 | ENLGISHENGLISH | DX6 Parts List DX6 Mechanical Drawing
DX6 Parts List DX6 Mechanical Drawing
ITEM# PART # DESCRIPTION QT Y.
1 DX6-1 Body 1
2 DX6-2 Movable Jaw 1
3 DX6-3 Nut 1
4 DX6-5 Screw. 1
5 DX6-6 Stationary 1
6 D60-7 Jaw Plate 1
7 3600V-8 Retaining ring 1
*8 D60-9 Segment 1
*9 D60-41 Thrust Bearing 1
*10 3600V-42 Thrust Bearing Washer 2
11 WSRL46 WorkStop 1
12 DLU4-96 O-ring #16 4
*13 3600V-99 O-ring #117 1
14 DX6-102 Model Tag 1
15 DX6-111 Kurt Logo Label 2
*16 3600V-128 O-ring #129 1
*17 3600V-147 Spiral Retaining Ring 2
18 3600V-191 Protective Cap 4
*19 D688-211 Internal Brush Seal 2
20 DX6-223 Model Tag 2
21 DX6-224 Screw Support 1
22 DL600-249 Chip Guard (LONG) 1
*23 DX6-311 Wave Spring 2
24 D60-315 Grooved Jaw Plate 1
25 07-0230 U-Type Drive Screw 2
26 00-1191 SHCS 8-32 x .375LG 4
27 00-1414 SHCS 1/2-13 x 3/4 LG 4
28 01-3134 HDOG SHSS 1/2-13 x .625 LG 1
29 00-3392 LHCS 7/16-14 x 2.00 LG 4
30 D60I-10A-SA Handle Assembly 1
*DX6-KIT Includes.1-d60-9 1-d60-41 2-3600v-42 1-3600v-99
1-3600v-128 2-3600v147 2-d688-211 2-dx6-311
3800H Mechanical Drawing
16
Fig.10

17
3810H PARTS LIST
3810H Parts List

3810H MECHANICAL DRAWING
3810H Mechanical Drawing
18
Fig.11

KHU8 MECHANICAL DRAWING
KHU8 Mechanical Drawing
Fig.12
19

Maintenance Schedule
It is very important to perform regular maintenance on your Kurt vise to
ensure proper operation. Improper maintenance will result in poor vise
performance and may void your warranty.
Daily/ Weekly
1. Remove chips from surface of vise.
2. Visually inspect seals for damage and cleanliness.
3. Visually inspect for chip entrapments and remove when necessary.
4. Air-dry and apply rust inhibiting oil to the machined surface of the vise.
Monthly
MAINTENANCE SCHEDULE
1. Open the vise to the maximum opening.
2. In the back of the movable jaw (handle end, center hole) loosen the
socket head set screw (approx. 6 turns). With the hex key (Allen wrench) in
the set-screw socket, lift up and forward to pivot the Jaw off of the vise
bed.
3. Slide the Jaw slightly toward the stationary jaw and lift up to remove the
jaw from the “beak” of the nut.
Note: A spherical segment (shaped as ½ of a steel ball) is inside the cavity
of the movable jaw and may fall out as the jaw is removed. Take care not
to lose or misplace the spherical segment.
4. Turn the movable jaw over and clean the inside cavity. Also clean the
spherical segment.
5. Remove chips, clean and apply a light coat of machine oil to the machined
surface of the following item:
a. Nut & Screw assembly (clean exposed threads on the screw)
b. Bed of vise (top of “rails”)
c. Inside of the vise between the center ways.
6. To re-assemble the movable jaw, apply a “glob” of grease to the under
side of the movable jaw in the pocket. Place the spherical segment in the
mating pocket and push into the grease. The grease will hold the segment
in place when the jaw is turned over to replace.
20