SCHUNK KSC-D 125 User guide

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schunk.com XND.00033.002_B –05/2022 1
Montage- und Betriebsanleitung
Installation- and operating instruction
Doppelspanner
Double vice
KSC-D 125
H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Strasse 23
D-88512 Mengen

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Table of contents:
1User information..................................................................................... 20
1.1 Purpose of document, validity.................................................................................... 20
1.2 Illustration of safety instructions ............................................................................... 20
2General safety instructions .................................................................... 21
2.1 Intended use ................................................................................................................ 21
2.1.1 Technical data ................................................................................................................ 21
2.2 Reasonably foreseeable misapplication..................................................................... 22
2.2.1 Alterations and modifications.......................................................................................... 22
2.2.2 Spare and wear parts and auxiliary material..................................................................... 22
2.3 Residual risk ................................................................................................................. 22
2.3.1 Jaw change .................................................................................................................... 22
2.3.2 Notes on clamping technology........................................................................................ 22
2.4 Duties of the organisation in charge.......................................................................... 23
2.5 Operator duties............................................................................................................ 23
2.6 Operator qualification................................................................................................. 23
2.7 Personal protective equipment................................................................................... 23
2.8 Warranty ...................................................................................................................... 23
3Description of the clamping device ....................................................... 24
3.1 Application................................................................................................................... 24
3.1.1 Adjusting jaws ................................................................................................................ 24
3.1.2 Setting up the third-hand function.................................................................................. 25
3.1.3 Clamping process ........................................................................................................... 25
4Operation (standard operation)............................................................. 25
4.1 Clamping / aligning ..................................................................................................... 25
4.2 Corrosion...................................................................................................................... 26
4.3 Jaw range..................................................................................................................... 26
4.4 Jaw change................................................................................................................... 26
5Servicing, cleaning and maintenance .................................................... 27
5.1 General cleaning / lubrication..................................................................................... 27
6Troubleshooting, eliminating faults ...................................................... 28
7Removal................................................................................................... 28
8Assembly ................................................................................................. 29
9Assembly drawing .................................................................................. 30
9.1 Parts list........................................................................................................................ 31
10 Swivel and adapter plate ....................................................................... 33
10.1 Function........................................................................................................................ 33
10.2 Servicing, cleaning, maintenance ............................................................................... 33
10.3 Troubleshooting, eliminating faults........................................................................... 33
10.4 Removing and replacing parts .................................................................................... 34
10.5 Fitting the 6-fold reversible jaws................................................................................ 34
11 Aluminium jaws ...................................................................................... 34
12 Fixed jaw vise.......................................................................................... 35
13 Positioning bar........................................................................................ 35
14 Taking out of service .............................................................................. 35

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1User information
1.1 Purpose of document, validity
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.
1.2 Illustration of safety instructions
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
information 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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2General safety instructions
2.1 Intended use
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.
2.1.1Technical data
Exposure to loads in excess of the max. clamping torque results in damage to the spindle.
Weight:
KSC-D 125-320 without system jaws: 14.0 kg
KSC-D 125-390 without system jaws: 17.0 kg
KSC-D 125-460 without system jaws: 20.0 kg
KSC-D 125-530 without system jaws: 24.0 kg
KSC-D 125-600 without system jaws: 27.0 kg
KSC-D 125-670 without system jaws: 30.0 kg
KSC-D 125-740 without system jaws: 34.0 kg
For further data, please see the catalogue >> Schunk stationary Workholding <<
Version
max. torque
max. clamping
force
KSC-D 125
100 Nm
40 kN
Clamping torque / clamping force

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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 workpieces with a weight of over 20 kg in vertical position without an additional
safeguard to prevent the workpiece falling out.
2.2.1Alterations and modifications
In the case of unauthorised alterations and modifications of the clamping device,
the manufacturer's liability ceases and any warranty is voided.
2.2.2Spare 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.
2.3 Residual risk
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.
2.3.1Jaw change
Damage may result if system jaws are insufficiently tightened.
2.3.2Notes on clamping technology
The operator is responsible for ensuring that the clamping geometry and clamping forces
are suitable for the intended processing.
We recommend that clamping be carried out with a torque wrench in order to achieve
consistent clamping results.
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.
When clamping with a high degree of force, the clamping force is significantly reduced
due to the increased frictional forces in the carriages.

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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:
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.
2.5 Operator duties
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.
2.6 Operator qualification
The installation, initial setup, fault analysis and periodic monitoring have to be carried out by
competent personnel with the relevant qualifications.
2.7 Personal protective equipment
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.
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.
Any parts in contact with workpieces are not covered by the warranty.
Warranty –maximum service life
Warranty period
24 months
Maximum service life [clamping cycles]
50,000

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3Description of the clamping device
The KSC-D has has been designed as a double vice to clamp two parts, raw parts and
processed workpieces.
The force is built up mechanically and applied via a trapezoidal thread featuring a bearing that
has been sealed on one side. The power gear ratio is linear across the entire clamping range.
The entire vice has been encapsulated from the top and front and can be cleaned using
compressed air.
The third-hand operation function when clamping is guaranteed by pre-clamping the rear
carriage using a pressure spring.
3.1 Application
3.1.1Adjusting jaws
For two identically sized or differently sized workpieces
Important:
The lateral clamping screw (pos. 230) has not been tightened, open by approximately ½ turn.
Fully open the vice and position the moving clamping jaws in the matching grooves of the
moving carriages depending on the workpiece size and tighten the cylinder screws M10
with property class 12.9 with torque 60 Nm.
Since the carriage have a maximum adjustment range of 45 mm, it is possible to clamp two
workpieces with different sizes. If this is insufficient, the system jaws can be moved by 35 mm
into another groove of the carriage.

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3.1.2Setting up the third-hand function
Insert the workpiece and move the jaws together so that rear jaw B is at 2–4 mm from the
workpiece.
Tighten the lateral clamping screw (pos. 230) to 15 Nm.
Exceeding the clamping torque by 15 Nm may lead to damage on the clamping unit.
3.1.3Clamping process
By clamping the rear carriage that has been pre-tensioned using a spring, it is possible to
guarantee that when you close the vice, the front clamping jaw Ais guided to the workpiece
first where it pre-tensions to around 500 N. After the front jaw Acomes into contact with the
workpiece, the rear clamping jaw Bstarts to close. Once both workpieces have been
clamped, the last step is to completely apply the entire clamping torque.
When opening the clamping jaws the workpiece at the rear clamping jaw Bis released before
the workpiece at the front clamping jaw Ais released (after the third-hand function has fully
retracted).
4Operation (standard operation)
4.1 Clamping / aligning
Push parts of the entire carriage unit from the base body to attach the vice.
For this purpose, see Section 7 Removal and Section 8 Assembly.
Important:
The base body and entire carriage must not be interchanged.
The parts have been manufactured together and are not interchangeable.
A
B

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The KSC-D offers a host of attachment options on the supporting table that have all been
integrated into the device.
(Illustration of principle: KSC-D 125 L-460)
The following interfaces are included in the basic variant:
Positioning holes Ø12 H7 to align the vice.
Positioning holes Ø12 H7 so the vice can be positioned and secured to grid plates with a size 50
and on T-slot tables using fitting screws Ø12 f7/M12 or cylinder screws M12.
Locating holes Ø25 H6 for the clamping pin of the VERO-S quick-change palleting system.
Important:
When using VERO-S clamping bolts, make sure that a shortened screw is used, otherwise
the slide may be damage. (See Schunk catalogue)
Longitudinal grooves to attach clamping claws.
Attachment thread M4 in the base body for alignment using alignment and centring sets.
Threads M12 at the front on reference surface.
The KSC-D 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.
4.2 Corrosion
The KSC-D's base body has been nickel-plated. Carriages and jaws are made of steel. Well-
maintained coolant is necessary to guarantee ideal functionality which must demonstrate
specified concentrations,
pH values and conductivity properties.
Deviations from manufacturer data may lead to a formation of corrosion.
4.3 Jaw range
The reliable function of the clamping device is significantly affected by the selection of the
correct top jaws.
4.4 Jaw change
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 (12.9) with a
torque of 60 Nm.

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5Servicing, cleaning and maintenance
No special maintenance required, the spindle and the internal vice components have been
protected by the carriage and central jaw design. Regularly grease carriage contact surfaces,
e.g. with MOTOREX Supergliss 68 K to ISO VG 68.
We recommend cleaning the double vice when replacing jaws as these components are
fast and easy to remove.
Regularly clean the vice through the two cleaning holes on the face of the
front carriage using a compressed-air gun to prevent deposits of small chips and swarf.
5.1 General cleaning / lubrication
Lubricate the lubrication nipples (pos. 200) on both carriages using multi-purpose grease once
a month. For this purpose, turn the carriages towards the far inside.
If you have applied excessive amounts of grease, it may be possible that the closing disc
(pos. 170) in the carriage (pos. 60) is pressed out.

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6Troubleshooting, eliminating faults
Clamping using the lateral clamping screw (pos. 230) is not possible
The clamping element on the inside is not in the correct position.
See Section 8 Assembly
Unable to disassemble the carriage unit from the base body
Unscrew the clamping screw. (pos. 230)
Remove the central jaw and blow-out the body through the blow-out holes on the front
carriager. (pos. 70)
Important:
Vice functions can exclusively be guaranteed if the central jaw has been installed.
Cylinder screw (pos. 160) has not been removed.
7Removal
Removing the carriage unit
Removing the system jaws.
Remove the cylinder screw (pos. 160).
Undo the clamping screw (pos. 230) by a minimum of 4 turns.
Cylinder screw (pos. 40) must never be unfastened.
Pull the entire carriage unit from the base body.

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8Assembly
Installing the carriage unit
Fully contract the carriage unit.
Push the carriage unit into the guide until it comes into contact with the other component.
The carriage unit is now positioned around 20 mm over the centre.
Important:
Carriage unit must not come into contact with the rear cylinder screw. (pos. 160)
Fully tighten the clamping screw (pos. 230) and undo by ½ turn.
Extend the carriage unit and check whether or not the cylinder screw (pos. 40) and the
clamping screw (pos. 230) have correctly engaged in the clamping piece. (pos. 220).
Install the front cylinder screw. (pos. 160)
Install the system jaws in the carriages and tightened the cylinder screw (12.9) with a torque
of 60 Nm.

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9Assembly drawing

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9.1 Parts list
Pos.
Part. No.
Designation
Quantity
10
DGM.125.501.82
DGM.125.511.82
DGM.125.521.82
DGM.125.531.82
DGM.125.541.82
DGM.125.551.82
DGM.125.561.82
L-320 base body
L-390 base body
L-460 base body
L-530 base body
L-600 base body
L-670 base body
L-740 base body
1
20
DGM.125.513.11
Plate
1
30
XNZ.10611.359
Countersunk screw M6x12
2
40
XNN.10360.413
Internal hexagon cylinder screw NK M8x20 10.9
1
50
DGM.125.504.11
DGM.125.514.11
DGM.125.524.11
DGM.125.534.11
DGM.125.544.11
DGM.125.554.11
DGM.125.564.11
L-320 threaded spindle
L-390 threaded spindle
L-460 threaded spindle
L-530 threaded spindle
L-600 threaded spindle
L-670 threaded spindle
L-740 threaded spindle
1
60
DGM.125.506.81
DGM.125.516.81
DGM.125.526.81
DGM.125.536.81
DGM.125.546.81
DGM.125.556.81
DGM.125.566.81
L-320 rear carriage
L-390 rear carriage
L-460 rear carriage
L-530 rear carriage
L-600 rear carriage
L-670 rear carriage
L-740 rear carriage
1
70
DGM.125.505.81
DGM.125.515.81
DGM.125.525.81
DGM.125.535.81
DGM.125.545.81
DGM.125.555.81
DGM.125.565.81
L-320 front carriage
L-390 front carriage
L-460 front carriage
L-530 front carriage
L-600 front carriage
L-670 front carriage
L-740 front carriage
1
80
XNN.61072.117
O-ring NBR21.95x1.78
1
90
DGM.125.517.11
Spring washer
1
100
XNN.20073.304
Axial cylindrical roller bearing 81104-TV
1
110
DGM.125.512.11
Adjusting nut
1
120
XNN.30030.006
Pressure spring 2.5x15x47.5
2
130
DGM.125.508.11
Ram
2
140
DGM.125.509.11
Retaining panel
1
150
XNN.65114.100
Scraper SA Ø10
2
160
XNN.10301.359
Internal hexagon cylinder screw M6x12
4
170
XNN.12620.250
Closing disc Ø25
1
180
XNN.90004.040
Spring-loaded pressure piece Ø4
8
190
XNN.63028.353
X-ring 28.17x3.53
1
200
XNN.90102.040
Grease nipple Ø4
2
210
DXM.100.010.11
Centring socket
1
220
DGM.125.507.11
Clamping piece
1
230
DGM.125.510.11
Clamping screw
1
240
XNN.61071.085
O-ring NBR/70 10.82x1.78
1
250
XNN.10706.306
Internal hexagon threaded pin SP M5x6
1

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Pos.
Part. No.
Designation
Quantity
260
XNN.10706.520
Internal hexagon threaded pin SP M10x20
1
270
DGZ.125.063.11
Position bar
2
280
XNN.10311.463
Internal hexagon cylinder screw M10x20 12.9
4
Note:
Pos. 10, 60 and 70 cannot be supplied as individual spare parts as these are designed
and fitted at the factory to work together.
Repairs can be provided by the manufacturer or an authorised service point.
Pos. 270 and 280 are only available for vises with length 530, 600, 670, 740 mm

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10 Swivel and adapter plate
10.1Function
Slanted and curved items can be securely clamped with 4-point clamping using the protected
O-ring 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
straightforward 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.
Handling the demounted swivel plate
The conical swivel peg can be pulled out since it is only held in position by an O-ring
in the counter direction. When handling the swivel plate, it should not be turned upside
down since this could cause the peg to fall out.
10.2Servicing, cleaning, maintenance
The upper shoulder of the swivel peg must be oiled regularly.
In order to ensure that the areas under stress remain well lubricated, the swivel plate should
be turned around its entire axis once a week so that the lubrication film can be renewed.
Lubrication of the entire peg is recommended once a year.
10.3Troubleshooting, 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 vice guide and swivel plate surface for indentations or deformations. If necessary,
re-grind the plate and the vice 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.

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10.4Removing and replacing parts
Release cylinder screws and remove the jaws.
Clean and oil the contact surfaces, e.g. with MOTOREX Supergliss 68 K to ISO VG 68.
Place the swivel- and adapter plate and tighten the cylinder screws to 60 Nm.
10.5Fitting 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 to the required clamping surface and slightly pre-clamp the
workpiece so that the clamping faces are parallel to 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.
11 Aluminium jaws
The aluminium jaws are designed for producing workpiece-specific clamping contours.
In order to achieve maximum precision of the contour, it is recommended that the
contour milling be carried out with pre-clamping of the aluminium jaws. For this purpose,
a narrow spacer piece can be clamped at the bottom and the pre-clamped aluminium
jaws can then be milled to achieve the desired clamping contour.
In view of the fact that clamping may be carried out in different ways, the setting-up
technician is responsible for ensuring that adequate clamping cross sections exist
and that the workpiece is safely clamped.

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12 Fixed jaw vise
The double vise can be used also as a fixed jaw vise.
Remove the middle jaw, the clamping and cylinder screw (Pos. 230 and 40) and slide the
carriage unit on the cylinder screw (Pos. 160).
To fix the carriage unit, the threaded pin (Pos. 260) must be clamped through the slider
into the counterbore in the base body with 20 Nm.
A cover for the area of the disassembled middle jaw is not included in the standard
scope of delivery of the double vise.
The disassembly to the double clamp is done in reverse order.
13 Positioning bar
For the lengths 530, 600, 670, 740 mm are two positioning bars (pos. 270) included in the
scope of delivery, so that a lowering of the slide ends and thus not possible penetration of
chips between the guide surfaces.
If the clamping range is small, we recommend mounting the positioning bars on the slide
ends as support with the cylinder screws (pos. 280) and a tightening torque of 60 Nm.
14 Taking out of service
The clamping device and all accessories can be disposed of as scrap metal without any risk.

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H.-D. Schunk GmbH & Co.
Spanntechnik KG
Lothringer Strasse 23
D-88512 Mengen
Tel.: [phone]
Fax: [phone]
[email protected]
schunk.com