ATS ULTIMATE CHUCK UC2 User manual

ATS SYSTEMS
30222 Esperanza
RSM, CA 92688
P 800/321.1833
800.423.4651
F 949/888.8336
www.ats-s.com
VERSION
7.28.17

ATS Systems Ultimate Chuck Installation and Operation Manual
TABLE OF CONTENTS
PRECAUTIONS
Summary of safety instructions
Safety warning label
Safety precautions 1.1 – 1.3
SPECIFICATIONS
Specification data sheets and drawings 2.1
INSTALLATION
Installation procedure 3.1 Checking jaw stroke 3.2
OPERATION
Basic operating points 4.1
Positioning base jaws in chuck 4.2
Use of half-pitch base jaws 4.3 Bolting top jaws to base jaws 4.4
Estimating safe chuck speed (RPM) 4.6
MAINTENANCE
Disassembly and assembly of chuck 5.1
Lubrication 5.2 Spare Parts 5.3
OTHER INFORMATION
Spare parts identification drawing and chart 6.1 Summary document for
Operator training 6.2 ATS Systems Product Warranty 6.3

ATS Systems Ultimate Chuck Installation and Operations Manual
Summary of Safety Instructions
1. Always follow all safety and maintenance instructions in this manual and all other standard
safe shop practices.
2. All operating and maintenance personnel must be properly trained and qualified before
operating, servicing, or repairing the ATS power chucking equipment.
3. Use this power chuck only for its intended purpose.
4. Chuck and workpiece must be protected by an adequate guard at all times when it is rotating.
5. The lathe should be equipped with a chuck actuating cylinder stroke control system and
cylinder pressure control systems as described in this manual section 1.3.2.
6. The operation, lubrication, and maintenance safety warning label shown on the following
page must be attached and prominently displayed on the lathe to which the power chuck
is installed. Carefully heed all points including those relating to:
- maximum RPM limits, use of excessive weight or height top jaws
- proper top jaw mounting bolts
- master base jaw position not extending beyond witness line / "safe" zone
- lubrication
- use of jaw change wrench
7. Take careful note of the sections of this manual marked with the following symbols:
WARNING
ATTENTION
The following maintenance and safety warning label must be attached and
prominently displayed on the lathe to which the Ultimate Chuck is installed.
Danger of injury to personnel if instructions are not followed.
Danger of damage to the machine or the power chuck if
instructions are not followed.

ATS Systems Ultimate Chuck Installation and Operations Manual
WARNING
THE ULTIMATE CHUCK ™
By ATS Systems [phone]
Recommended Operation, Lubrication & Maintenance For
Models UC2 & UC2B Chucks
1. Read the Installation, Operation and Maintenance Manual.
2. Do not exceed RPM rating marked on the chuck or safe speed for the top jaw configuration or for the
application, whichever is less. The maximum rated speed is only valid for maximum drawbar pull using
the standard hard jaws model GUA designed for the chuck. For all other conditions speed must be
reduced. Failure to do so may have catastrophic consequences. (See manual)
3. Do not use top jaws of excessive weight, height, or extended beyond the outside diameter of the chuck. See
Manual for more specific guidelines.
4. Insure top jaw mounting bolts are grade 12.9, in new condition and the proper length for a minimum
thread engagement of two times the thread diameter.
5. Inside end of base jaw must never be extended outward beyond the witness line or "SAFE" zone marked
on face of chuck. (See manual)
6. Set jaw adjustment to grip the part as close to the start of the jaw stroke as possible, especially when
chucking irregular castings, forgings, etc. As you chuck each part, observe that adequate jaw stroke
remains to grip the part.
7. Use only ATS Systems’ KO5 grease (Part #1113-9101). Grease chuck every 24 hours of operation, two
shots of KO5 per grease fitting with the chuck in the full “open-jaws out” position.
8. At the start of each shift and after every 50 clamping cycles, actuate the chuck full stroke 5-10 times
without gripping a workpiece to internally redistribute grease throughout the chuck.
9. Clean jaw guide ways when changing jaws, or at least once per shift if no jaw change is required, and
lightly coat sliding jaw surfaces with KO5.
10. Do not exceed the maximum allowable drawbar pull.
11. Test chuck and record grip force at least once per month. If baseline grip force decreases more than
15%, the chuck should be disassembled, cleaned, and all internal parts coated with a film of KO5.
12. Never remove your hand from the jaw changing wrench - it could fly out if the chuck is rotated. Never
actuate the chuck with the wrench inserted - severe internal chuck damage will occur.

ATS Systems Ultimate Chuck Installation and Operations Manual
PRECAUTIONS:
SAFETY
Many sections in this manual deal with the issue of
safety. Safe operation of CNC lathes and
workholding is the responsibility of the user. The
manufacturer of the Ultimate Chuck has used the
latest technology in the design and manufacturing of
this product. Careful consideration has been given to
safety, and the authors of this manual make many
recommendations regarding safe operation and safe
chucking practices. The user of the lathe and chuck
are responsible to understand these safe practices and
precautions and to implement them into the operation
and maintenance of the equipment.
All who use or maintain this equipment must have
read, understand, and follow all instructions in this
manual and other normal safe shop practices.
Maintenance and repair work must be done only by
personnel who have been properly trained. It is the
responsibility of the buyer/user of this equipment to
ensure all appropriate training is received.
1.1 Safety Precautions
1.1.1 The Ultimate Chuck by ATS Systems
This power operated chuck complies with all specific
and general safety regulations valid at the time of
delivery. Safe operation requires it be used only in
proper applications with all necessary user
precautions including but not limited to those
specified below.
1.1.2 Use for Intended Purpose
The safe function of the power chuck is, as far as can
be foreseen, guaranteed when being used for its
intended purpose in accordance with appropriate
safety regulations.
Improper use of the power chuck can result in
• Danger to life and limb of the operator
• Danger to the power chuck and to the machine
tool
Unintended and improper use of the power chuck
includes, for example:
• Workpieces that are not clamped properly
• Safety regulations that are disregarded
• A chuck being used for machines or applications
for which it is not intended
• Too large of a jaw being used especially if the
speed is excessive for the size of the jaw.
• Any use of a chuck that has not been properly
installed, maintained, and lubricated.
WARNING
Improper or unintended use of the power chuck, and
disregard of safety standards and safety regulations
can threaten life and limb of the operator!
1.1.3 Technical Conditions
The power chuck should only be used if it is in
perfect condition, for its intended purpose, with total
awareness of safety and hazards, and in accordance
with all appropriate regulations.
In the event any faults are recognized, they must be
eliminated immediately!
1.1.4 Use
The power chuck is intended solely for the use as
agreed in the contract between the
manufacturer/supplier and the user. Any other or
further use is regarded as unintended. The
manufacturer/supplier is not liable for any damage

ATS Systems Ultimate Chuck Installation and Operations Manual
resulting from misapplication and unintended use. All
risk is borne entirely by the user.
Intended use includes due regard of the appropriate
operating and maintenance instructions and
compliance with the inspection and maintenance
requirements.
1.2 Users Organizational Requirements
1.2.1 Compliance with Regulations
The user must ensure that suitable actions in
organization and instruction are taken to ensure that
all appropriate safety rules and regulations are
complied with by the persons entrusted with
operation, maintenance and repair of the power
chuck.
1.2.2 Supervision of Chuck Operators
The user is required to routinely check their
personnel’s conduct regarding awareness of safety
and hazards, and the safe and proper use of the
chuck.
1.2.3 Hazard Notices
The user must ensure that the warning labels
regarding safety and hazards for the machine to
which the power chuck is mounted are observed and
that the warning labels are clearly legible.
1.2.4 Defects, faults, hazardous conditions
If faults occur at the chuck which affect safety, or
production indicates that faults are in existence, then
the machine to which the power chuck is mounted
must be brought to a complete and immediate stop
for as long as is required to locate and eliminate the
fault.
Faults may only be eliminated by trained and
authorized personnel.
1.2.5 Modifications
Do not make any alterations, add any fixtures or carry
out any modifications to the power chuck which
could affect safety without the prior agreement of the
supplier.
This also applies to the installation of safety devices.
1.2.6 Spare Parts
Only use spare parts which meet the requirements of
the manufacturer. This is guaranteed only if original
spare parts are used.
Improper repair or use of incorrect spare parts will
result in the manufacturers and suppliers exclusion
from product liability.
1.2.7 Periodic Inspection
Follow the instructions in this manual and carry out
the required routine inspections and service at the
time intervals specified.
1.2.8 Choice of Personnel, Personnel qualifications
• Work on/with the power chuck may only be
done by qualified personnel.
• Allow only personnel that have been properly
trained to operate the power chuck. ATS offers
training programs.
• Clearly define the areas of responsibility for all
personnel for operation, maintenance and repair.
• Allow only personnel that are well informed of
the safety requirements to carry out maintenance
and repair work on the power chuck.
• Make it clear to the operator his responsibility
for safety conscious conduct. Enable him to
refuse instructions by third parties which are
irresponsible with regard to safety.
1.3 Product Safety Notes
1.3.1 Important!
These operating instructions are only valid for the
model UC2 and UC2B power chucks.

ATS Systems Ultimate Chuck Installation and Operations Manual
The recommended maximum speed given is only
valid for maximum draw bar pull using the standard
stepped hard jaws model GUA or GST designed for
the chuck, and only for a chuck that has been
properly maintained and lubricated.
WARNING
During machining, testing, and set up or whenever the
chuck is rotating, the chuck and the clamped
workpiece must at all times be protected by an
adequate guard.
Excessive top jaw weight must be avoided! Pay
careful attention when designing or using soft jaws or
special jaws. Jaw weight, their distance from
centerline and the RPM of the lathe dramatically
effect remaining chuck grip force during chuck
rotation. In extreme cases of unsafe use it may even
be possible for the top jaws themselves to fly off the
chuck. See this manual section 1.3.6 and 4.6 for
more information.
WARNING
Avoid standing directly in line with a rotating
chuck or workpiece! It is good safety practice to
assume the lathe’s guard may not prevent a thrown
workpiece or broken top jaw fragment from
penetrating the guard.
1.3.2 Safety when installing the Chuck
When installing a chuck and/or a cylinder to a
lathe, the following technical safety requirements
must be observed:
• The lathe should be equipped with safety
systems that prevent the spindle from rotating
unless the clamping pressure has built up in the
cylinder and clamping of the chuck has been
confirmed by a feedback system.
• The lathe should be equipped with safety
systems so that unclamping is only possible
when the machine spindle has come to a
complete stop.
• The lathe and clamping cylinder should be
equipped with safety systems so that in the case
of a failure in the supply of pressure to the
cylinder, the workpiece remains securely
clamped until the spindle has come to a complete
stop.
• The lathe should be equipped with safety
systems so that in the case of a power failure and
re-supply, the lathe will not restart without new
commands from the lathe operator.
• Stroke control! The lathe should be equipped
with a safety system that monitors the stroke of
the actuating cylinder piston and prevents the
lathe spindle from rotating unless a workpiece is
properly clamped. One recommended system
provides a safety zone at the front and rear most
portion of the piston stroke. For the lathe
spindle to rotate, the piston must be somewhere
between the front and rear safety zones which is
only possible if a workpiece is clamped.
Caution: Whenever the chuck is removed for
maintenance or any other reason, then
reinstalled, the stroke control switch adjustments
must be checked and readjusted if necessary.
1.3.3 Inspecting chuck function and performance
After installing the power chuck, its function and
performance must be checked.
• Clamping Force! The clamping force of the chuck
and cylinder system must be checked with a grip
force gauge. Refer to the chuck and cylinder
specifications, note the hydraulic or pneumatic
operating pressure, calculate the expected grip
force and confirm the actual performance with
the grip force gauge. If it does not match within
10%, do not use the system until the cause is
determined and corrected. Important: When
using other then standard factory hard jaws, the
grip force should be checked with a dynamic grip
force gauge at the planned operating speed
(RPM) to insure there is adequate grip force
remaining to hold the workpiece. Start the
inspection at a low speed and build up to the
operating speed while observing the gauge.
(Note: Estimated grip force loss at speed can be

ATS Systems Ultimate Chuck Installation and Operations Manual
calculated to establish parameters for actual
testing with a dynamic grip force gage. See this
manual section 4.6) Jaws should never
be positioned to extend beyond the outside
diameter of the chuck more then the standard
amount as described for the standard base
jaws in the ATS technical specifications.
1.3.4 Chuck Rotational Speed (RPM)
WARNING
If the maximum speed of the lathe is greater than the
maximum recommended speed of the chuck and/or
the clamping cylinder, the machine must be equipped
with a speed limiting device.
The centrifugal force acting on the clamping jaws
must be considered when determining the required
clamping force to machine a workpiece. See
section 1.3.3 above and section 4.6.
1.3.5 Maintenance Instructions
The reliability of the chuck can only be guaranteed
if the maintenance requirements in these operating
instructions are followed exactly. In particular,
attention must be paid to:
• Lubrication: Only ATS K05 grease (Part
#11139101) should be used. (Unsuitable
lubricants can reduce the clamping force by
more than 50%). The chuck should be greased
each 24 hours of
operation under normal conditions. (See 5.2.3)
• All surfaces that require lubrication must be
reached. (The close fits of mating parts require
a high injecting pressure. For this reason a high
pressure grease gun should be used).
Important: Grease must be injected into the
three fittings on the face of the chuck when the
chuck jaws are fully opened (jaws outward
from centerline). It is only in this position
that lubrication will properly reach the
internal components of the chuck.
• To ensure good grease distribution, inject one
shot of grease into each of the three grease
fittings, actuate the chuck full stroke several
times, and then inject a second shot of grease
into each of the three fittings. Check the
clamping force with a grip force gauge.
• After each 50 clamping strokes it is advisable
to actuate the chuck several times without
gripping a workpiece so that the chuck is
stroked to its extreme limits. When this is
done, lubricant that has been displaced is
returned to the pressure surfaces and the
clamping force is retained for a longer period
of time without re-lubrication.
• Depending on the application and the
workpiece materials being machined, the chuck
will periodically need to be disassembled and
cleaned. After cleaning, all internal parts must
be coated with a film of KO5 grease, and the
chuck body cavities at either end of the wedge
bars filled 50% with KO5 grease. Each time
the chuck is actuated and the wedge bars
stroke, this “reservoir” of grease is pumped
back through ports in the wedge bar to lubricate
critical surfaces.
• Ultimate Chucks were designed primarily for
JIT applications with frequent jaw changeover.
No grease fitting ports lubricate the jaw guide
ways. Whenever jaws are changed, inspect the
chuck guide ways for cleanliness and put a film
of grease on the sliding surfaces of the master
base jaws before inserting them into the chuck.
For high volume production applications when
jaws aren’t changed frequently, the jaws should
be removed once per shift (depending on
machining cycle time), cleaned and re-
lubricated.
• It is recommended that the clamping force be
checked using a grip force gauge before
beginning a new production batch and between
maintenance checks. Only regular checks can
guarantee safety.
1.3.6 Use of Special Design jaws
When using special design jaws the following rules
must be observed:

ATS Systems Ultimate Chuck Installation and Operations Manual
• The jaws should be designed to be as light and as
low as possible. The clamping point should be
located as close to the chuck face as possible.
(Clamping points with greater distances cause
increased surface pressure in the jaw guides and
can reduce clamping force substantially).
• If the design of the special jaws requires them to
be wider and/or higher than the standard factory
stepped jaws designated for the chuck, then it is
important to consider the higher centrifugal
forces involved when calculating the resulting
clamping force and maximum speed allowed
with these jaws. Caution: Jaws should never be
positioned to extend beyond the outside diameter
of the chuck more then the standard amount as
described for the standard base jaws in the ATS
technical specification. Caution: Jaws should
never extend from the face of the chuck a
distance more then 30% of the diameter
measurement of the chuck. Excessively tall jaws
that are operated with either high grip force or
high speed or a combination of speed and grip
force can over stress the bolts that hold the top
jaw to the base jaw.
• Do not use welded jaws.
• The mounting bolts must be arranged in such a
way as to ensure that greatest possible strength is
achieved.
• The maximum recommended speed may only be
used in conjunction with maximum draw bar
pull, only with chucks that are in perfect working
order, and only with standard hard jaws
positioned within the chuck diameter (or
equivalent jaw and diameter) .
• After a crash, the chuck must be examined for
cracks and other damage, and grip performance
inspected before being put back into operation.
Damaged parts must be replaced with original
ATS spare parts.
• Top jaw mounting bolts must be replaced if they
show signs of wear or damage. Only use grade
12.9 bolts of sufficient length to engage at least a
thread length equal to 1 ½ - 2 times the screw
diameter.
1.3.7 Safety during Maintenance
Follow all normal safety precautions when
performing maintenance on the chuck or any portion
of the machine tool, such as turning off the electrical
power and locking out electrical service, wearing
safety equipment, etc.
Only operate power chucks when all safety guards
have been installed and are in full working order.
Check the power chuck at least once per shift for
externally visible damage and faults.
Report any changes including changes in operational
behavior to the responsible persons immediately. If
necessary bring the spindle to an immediate stop and
lock out the electrical supply.
Only restart the machine to which the power chuck is
installed when the cause of the problem has been
eliminated.
1.3.8 Notes on Instruction of Operating Personnel
We recommend that the user of our power chucks
make the operating instructions, in particular the
“Precautions” section, available to all persons who
will be operating, maintaining or repairing the chuck
or the machine tool to which it is installed. We
further recommend that the owner issue “operating
instructions” which consider the qualifications of the
operating personnel known to him.
Participation in training programs and courses etc.
with the aim of gaining knowledge in operation,
maintenance and repair of the power chuck should be
confirmed in writing for the business operator. For
this purpose we recommend duplicating and using the
following form.

ATS Systems Ultimate Chuck Installation and Operations Manual
Declaration of knowledge by Personnel (Operator)
It is confirmed herewith that the person of
Mr./Mrs./Miss
being charged by the business operator with
responsibility to operate chucking equipment has
read and understands the operating instructions, in
particular the section on “Precautions”, for the ATS
power chuck.
Operator Date
Business Operator/ Date
Authorized person
SPECIFICATIONS:
2.1 Specifications and dimensions
The following pages in this section include drawings
and specification data sheets for both chuck models
that direct mount to A-type lathe spindle noses, and
models that require an adapter plate between the
chuck and the lathe spindle nose. The data sheets
show all models that are possible, but not all models
are regularly stocked.

Specifications subject to change without notice. Contact SMW Systems for the latest specifications and dimensions.
Not all models shown are available from stock.
Ultimate Chuck Model UC 2
Direct Mount Models
Model 180-53 215-66 260-81 315-104 400-128 500-155
Diameter A 180 215 260 315 400 500
Thru hole B 53 66 81 104 128 155
Piston stroke C 21 24 28 28 30 35
Stroke/jaw D 6.9 7.8 8.8 9.1 9.8 11.4
Jaw adjust pitch 4.8 4.8 5.5 5.5 5.5 7.0
Max RPM 6300 6000 4700 4000 3500 2200
Max drawbar
pull
daN
Lb
3300
7400
5300
11915
7300
16400
10000
22400
13300
29900
13300
29900
Total grip force daN
Lb
6000
13500
10000
22480
13500
30300
18000
40500
24000
54000
23500
52900
Weight w/o jaws Kg
Lb
17.5
38.5
24
54
47
104
67
148
113
249
225
495
Max. drawtube
thread
E M60x1.5 M75x1.5 M90x1.5 M110x2 M138x2 M165X2
E1 65 81 97 120 125 160
Min. adapter
length
F 15.5 18 17.3 25 29 29
Spindle nose A5 A6 A6 A8 A6 A8 A8 A11 A11 A15 A11 A15
Length H 104.8 105.8 119 121 136 138 146 148 156 157 180 181
I 16 17 18 23.5 26 24 26 24 28 36.5 30 37
J 111.2 112.2 119.9 121.9 144.5 146.5 155 157 165 166 190 191
K 16 17 17 19 16.5 21 19 21 21 23 21 23
Max
Min
L 35
14
36
15
39
15
41
17
45.5
17.5
47.5
19.5
45.5
17.5
47.5
19.5
49.5
19.5
50.5
20.5
54.5
19.5
55.5
20.5
M 104.8 133.4 133.4 171.4 133.4 171.4 171.4 235 235 330.2 235 330.2
Bolt thread N M10 M12 M12 M16 M12 M16 M16 M20 M20 M24 M20 M24
O M72x1.5 M87x2 M130x1.5 M120x1.5 M160x2 M188x2
P 78 95 140 130 175 207
Base jaw R 82 103 117.5 115 125 160
Maximum safe
jaw position X 41.4 48.9 51.8 59.9 86.5 100.9
Max
Min
a 87.4
59.1
110.9
77.73
129.8
96.8
148.9
110.4
181.5
121
225.9
155.9
b 18 20 20 20 26 30
Jaw width e 20 22 26 32 32 45
e1 8 10 12 12 12 18
e2 32 40 40 54 60 60
f1 M6 M6 M8 M8 M8 M8
f2 M8 M10 M10 M12 M16 M20
g1 83 94 124 140 170 200
g2 155 190 220 268 330.2 420
h1 60° 60° 60° 60° 60° 60°
h2 60° 70° 77° 77° 70° 77°
j1 35° 37° 30° 40° 42.5° 30°
j2 45° 47° 40° 45° 45° 45°
Bolt thread k M8 M8 M12 M12 M16 M16

Ultimate Chuck Model UC 2
Plain-Back Adapter Plate Mounted Models
Model 180-53 215-66 260-81 315-104 400-128 500-155 630-167
Diameter A 180 215 260 315 400 500 630
Thru hole B 53 66 81 104 128 155 167
Piston stroke C 21 24 28 28 30 35 40
Stroke/jaw D 6.9 7.8 8.8 9.1 9.8 11.4 12.6
Jaw adjust pitch 4.8 4.8 5.5 5.5 5.5 7.0 7.0
Max RPM model
UC2 6300 6000 4700 4000 3500 2200 1700
Max RPM model
UC2B 3500 2750 1800 1500
Max drawbar
pull
daN
Lb
3300
7400
5300
11915
7300
16400
10000
22400
13300
29900
13300
29900
13300
29900
Total grip force daN
Lb
6000
13500
10000
22480
13500
30300
18000
40500
24000
54000
23500
52900
23500
52900
Weight w/o jaws Kg
Lb
17.5
38.5
24
54
47
104
67
148
113
249
225
495
383
845
Max. drawtube
thread
E M60x1.5 M75x1.5 M90x1.5 M110x2 M138x2 M165X2 M180x2
E1 65 81 97 120 125 160 200
Min. adapter
length
F 15.5 18 17.3 25 29 29 35
Adapter pilot G 140 170 170 220 220 300 380 520
Length H 91.8 105 121 121 130 138 162 179.5
I 14 17 17 26 22 26 37 36
J 98.2 109.9 129.5 129.5 149 147 172 189.5
K 6 6 6 6 6 8 8 8
Max
Min L 22 1 25 1 28 0 28 0 29.5 1.5
31.5
1.5
36.5
1.5
41.5
1.5
M 104.8 133.4 133.4 171.4 171.4 235 330.2 463.6
Bolt thread N M10 M12 M12 M16 M16 M20 M24 M24
O M72x1.5 M87x1.5 M130x1.5 M120x1.5 M160x2 M188x2 M215x2
P 78 95 140 130 175 207 235
Base jaw R 65 85 104 115 125 160 200
Maximum safe
jaw position X 41.4 48.9 51.8 59.9 86.5 100.9 120.4
Max
Min
a 87.4
59.1
110.9
77.73
129.8
96.8
148.9
95.9
181.5 121 225.9
155.9
285.4
187.4
b 18 20 20 20 26 30 30
Jaw width e 20 22 26 32 32 45 45
e1 8 10 12 12 12 18 18
e2 32 40 40 40 54 60 60
f1 M6 M6 M8 M8 M8 M8 M8
f2 M8 M10 M10 M12 M16 M20 M16
g1 83 94 124 140 170 200 245
g2 155 190 220 268 330.2 420 520
h1 60° 60° 60° 60° 60° 60° 60°
h2 60° 70° 77° 77° 70° 77° 77°
j1 35° 37° 30° 40° 42.5° 30° 45°
j2 45° 47° 40° 45° 45° 45° 60°
Bolt thread k M8 M8 M12 M12 M12 M16 M16
Specifications subject to change without notice. Contact ATS Systems for the latest specifications and dimensions.
Not all models shown are available from stock.

ATS Systems Ultimate Chuck Installation and Operations Manual
INSTALLATION:
3.1 Installing the chuck to the machine
spindle
See 6.1 in OTHER INFO section of this manual for
parts identification.
3.1.1 Checking the chuck and machine spindle
• Check the machine’s spindle nose and flange, or
the finished machined adapter plate concentricity
and face runout. Maximum allowable runouts are
0.005 mm.
• All mating surfaces must be clean and free of
nicks, dents, chips, dirt, etc.
3.1.2 Installing the chuck
• Remove the chuck from the package, check for
damage and that it is complete.
• If there are any base jaws installed in the chuck,
unlock and remove them. (see this manual
section 4.1).
• You need to determine the actual maximum
stroke of your hydraulic cylinder and drawtube.
Actuate the cylinder and extend the drawtube
fully forward. Using calipers, measure from the
end of the lathe spindle nose to the front of the
drawtube and record the dimension. Now
actuate the cylinder and fully retract the
drawtube and record the measurement from the
same point on the spindle nose to the same point
on the end of the drawtube. Subtract these two
numbers and record here the actual drawtube
stroke for future reference.
Cylinder stroke = ___________
• Actuate the cylinder so that the
drawbar/drawtube once again extends fully
forward. (see figure 3.1).
• Push the chuck piston into its forward most
position.
• Confirm R2 dimension is .010" - .080" less than
R1 dimension measured to the inside bottom of
the drawtube adapter. If R2 is not shorter than
R1 STOP and rework the drawtube adapter if
possible or shorten the drawtube.
• Use supplied T-wrench (60) to tighten drawtube
adapter retaining ring (5) with drawtube adapter
(4) in place in chuck. Confirm drawtube adapter
is free to rotate but has less than .008" of end
play (allowable drawtube Z axis free motion).
Rework drawtube adapter if necessary. Remove
drawtube adapter retaining ring and remove
drawtube adapter. Screw drawtube adapter fully
onto drawtube to confirm tread fit.
• Put a small amount of never-seize or grease on
the front and the rear of the drawtube adapter
flange (not on the threads). Put the drawtube
adapter into the chuck keeping the never-seize
off of the threads. Install drawtube adapter
retaining ring with several drops of thread-locker
and tighten retaining ring with T-wrench. (Don't
use excessive thread-locker.)
Actuate lathe cylinder to push drawtube to
forward most position.
R1 = Push the chuck piston fully forward
and measure with a depth gauge.
R2 = R1 – 0.01" (max .080")
Fig 3.1

ATS Systems Ultimate Chuck Installation and Operations Manual
• Coat threads on drawtube and drawtube adapter
with never-seize. Using a sling or a lifting eye
bolt, hold the chuck in alignment with the center
of the spindle in front of the spindle nose.
• Using the supplied T-wrench (51), rotate the
threaded draw tube adapter bushing in the chuck
fully onto the drawtube or drawbar.
• Actuate cylinder to close the chuck. Tighten the
chuck mounting bolts in a crosswise pattern.
Torque bolts to specification.
M12 85 ft-lb ½-13 90 ft-lb
M16 190 ft-lb 5/8-11 190 ft-
lb
M20 365 ft-lb ¾-10 365 ft-lb
M22 520 ft-lb 7/8-9 560 ft-lb
M24 660 ft-lb 1"-8 800 ft-lb
• Check the chuck concentricity on the O.D.
indicating surface, and face runout.
• Check the operation of the drawbar/drawtube.
• Actuate the cylinder so that it reaches its forward
most position (jaw open). Using T-wrench (51),
unscrew drawtube adapter (counterclockwise)
until chuck actuator (3) reaches it's forward most
position and then turn the T-wrench back
clockwise a quarter turn.
• Unlock the wedge bar using special hex wrench
(47) and insert the base jaws which are marked
1,2, and 3 into the chuck jaw guideways with the
corresponding number. (See this manual section
4, Operation)
Note: If the special T-handled hex wrench will
not turn easily, the drawbar/drawtube assembly
is too short. This condition may be corrected by
rotating the drawtube adapter bushing counter
clockwise. Be sure there is sufficient thread
engagement after any adjustment.
Note: If the jaws become tight when changing
jaws and sliding them to the chuck center, the
drawtube assembly may be too long which can
be corrected by rotating the drawtube adapter
bushing clockwise.
Exact drawtube adjustment is important to ensure
full jaw stroke. Be sure the drawtube doesn't
bottom out in the chuck when forward and that
an adequate number of threads are engaged
between the drawtube and the drawtube adapter.
• Actuate the cylinder and check that the base jaws
move smoothly and that the jaw stroke is correct.
• With calipers, measure actual stroke per jaw and
record here
Actual jaw stroke per jaw = ________
Removing the chuck is done in the reverse order.
3.2 Calculate theoretical jaw stroke for this
cylinder and compare to actual measured
jaw stroke.
Generally speaking, the Ultimate Chuck has longer
jaw stroke than most power chucks but requires
longer piston stroke than simple wedge-hook chucks
to achieve full jaw stroke. Even when using the same
shorter piston stroke as simple wedge-hook chucks,
the Ultimate Chuck's shortened jaw stroke might be
longer than the simple chuck. But this jaw stroke
might not be suitable for all applications, specifically
for applications using hard jaws and the chuck's
adjustability feature to grip different diameters with
the one set of jaws. This is due to the adjustment
pitch of the chuck and jaw. For proper use in these
applications, the actual jaw stroke should be about
.050" longer or more than the adjustment pitch.
1= Chuck model size
2= Full chuck piston stroke- in.
3= Full jaw stroke using full chuck piston stroke- in.
4= Jaw adjustment pitch
5= Minimum cylinder stroke to provide jaw stroke of
.050" longer than adjustment pitch.
1 2 3 4 5
180 .82" .27" .189" .73"
215 .94 .31 .189 .72
260 1.10 .35 .216 .85
315 1.10 .36 .216 .85
400 1.18 .39 .216 .85
500 1.38 .45 .275 1.10
630 1.57 .50 .275 1.10

ATS Systems Ultimate Chuck Installation and Operations Manual
Chuck jaw stroke is directly proportional to piston
stroke. The model UC 2 has no lost motion like some
older models of wedge bar quick jaw change stokes.
As an example, if you are installing a UC 2 size 265
on a cylinder with .95" of stroke, your actual jaw
stroke should measure:
.350 = X
1.10 .95
.95 x .35 / 1.1 = .302" jaw stroke
( .302 - .216 = .086" longer than the adjustment pitch
for comfortable use with adjustable hard jaws. )
Record calculated stroke per jaw here= _________
If your measured actual jaw stroke is shorter than the
calculated jaw stroke, your drawtube length needs
adjustment. See the two Notes: in section 3.1.2
above.
3.3 Use half-pitch base jaws when required.
If your actual jaw stroke is less than .050" longer than
the jaw adjustment pitch and you are using hard jaws
and the adjustability feature of the chuck to grip
different diameters, use half-pitch base jaws as
required. Half-pitch base jaws look like standard
base jaws except the position of the groove on the top
of the base jaw that mates with the tongue on the
bottom of the top-jaw is offset from the gear-rack by
1/2 the pitch of the gear-rack teeth. Use 1/2 pitch or
standard base jaws as required to grip the diameter
you need and allow each jaw to have at least .050" of
residual travel after the part is gripped. Be sure your
lathe's stroke control system is properly adjusted in
case the chuck reaches the end of the jaw stroke
without actually securely gripping the workpiece.
OPERATION:
4.1 Function and operation
Model UC2 and UC2B wedge bar chucks are actuated
by rotary hydraulic or pneumatic cylinders. The axial
drawbar pull and push forces are converted to radial
jaw clamping force by tangential wedge bars
positioned in the chuck body.
Adjusting or changing the base jaw/top jaw position
must be done when the chuck is in the unclamped
(cylinder full forward, jaws full outward) position.
For safety reasons the base jaws and wedge bars are
still interlocked when the chuck piston is in this
position.
There is a cam bolt with hex socket in the chuck body
for each jaw guideway that can be turned with the
special chuck hex wrench only. Using a standard hex
key wrench will damage the chuck due to the chuck’s
interlock safety mechanism. By turning the cam bolt,
the teeth on the wedge bar are moved out of
engagement with the teeth on the base jaw. In this
position the base jaws can be adjusted inwards or
outwards or they can be removed. It is not possible to
remove the chuck key when it is rotated in this
position.
Caution: Safe practice requires the operator to never
remove his hand from the wrench when it is inserted
into the chuck. This practice prevents the possibility
of the lathe spindle being started and the wrench thrown
out of the chuck
ATTENTION
The chuck piston should not be actuated as long as
the chuck key is in one of the cam bolts of the chuck.
To do so will cause damage to internal chuck
components.
4.2 Base Jaw Position
An arc with a zone marked "SAFE" below it (or a witness
marking line) has been milled on the face of the chuck
between the jaw guides (see figure 4.1).
This zone or witness line marks the maximum outward
position of the base or monoblock jaw. The maximum
outward jaw position has been reached when the
chuck is in the jaw change position (chuck unclamped)
and the edge of the base jaw or the onepiece
monoblock jaw is inside (towards chuck centerline) of
the arc or the witness line.

ATS Systems Ultimate Chuck Installation and Operations Manual
WARNING
It is essential to observe this jaw position to
ensure that all teeth are interlocked for power
transmission from the wedge bars to the base
jaws. Never position jaws out past this limit.
Fig 4.1
4.3 Use half-pitch base jaws when required. See
this manual section 3.1.2
If your actual jaw stroke is less than .050" longer than
the jaw adjustment pitch and you are using hard jaws
and the adjustability feature of the chuck to grip
different diameters, use half-pitch base jaws as
required. Half-pitch base jaws look like standard base
jaws except the position of the groove on the top of the
base jaw that mates with the tongue on the bottom of the
top-jaw is offset from the gear-rack by 1/2 the pitch of the
gear-rack teeth. Use 1/2 pitch or standard base jaws as
required to grip the diameter you need and allow each jaw
to have at least .050" of residual travel after the part is
gripped. Be sure your lathe's stroke control system is
properly adjusted in case the chuck reaches the end of the
jaw stroke without actually securily gripping the
workpiece.
4.4 Bolting top jaws to base jaws
Torque top jaw to base jaw mounting bolts to the
following specifications. Over tightening these bolts can
distort the base jaw and cause them to bind in the jaw
guideway. Under tightening could allow the top jaw to
come loose from base jaw.
M8 18-24 ft-lb M12 60-80 ft-
lb
M16 140-180 ft-lb
ATTENTION
Never tighten jaw mounting bolts with a wrench
extension (cheater bar) or by striking the wrench
with a hammer! This can damage the bolts and lead
to bolt failure.
4.5 Top Jaw Concentricity
For best chucking concentricity, soft jaws must be bored
in the chuck while gripping on a plug or ring with the
same clamping force that will be used for the workpiece.
• When boring the jaws it is important that the
boring ring or plug is clamped by the top jaws and
not by the base jaws.

ATS Systems Ultimate Chuck Installation and Operations Manual
Keep base and top jaws screwed together for
subsequent use without the need to rebore. Always
tighten the jaw mounting bolts with the specified
torque.
4.6 Estimating chuck grip force loss and
approximate safe speed.
Proper determination of safe operating speed
requires a dynamic grip force gage that allows the
actual jaws in question to be run at operating
speed. Start the test at a slow speed and increase
speed until the minimum grip force to safely hold
and machine the workpiece is reached. Only this
empirical testing will guarantee accurate
conclusions. To approximately determine the
theoretical allowable speed for a particular set of
jaws, one can weigh the jaws, measure their center
of gravity by balancing them on a knife edge, and
then make some calculations. These calculations
assume the weights and measurements have been
made accurately, that the chuck is well
maintained, lubricated and working properly, that
the starting static grip force is accurately known
(cylinder size, pressure and resulting drawbar pull
x chuck grip/pull ratio specification), and that the
chuck is a high quality power chuck of modern
design and construction. Since there are so many
variables it would be dangerous to only make
these theoretical calculations and then run the
jaws at speed. But to give an estimate so that
empirical testing can be planned, the following
formulas can be used.
Fstatic = lbs. of total starting grip force (all three or
two jaws) with the chuck not rotating,
using the draw bar pull (cylinder pressure)
planned for the job.
F@ speed = lbs. of total grip force (all three or two
jaws) you require remaining at operating
RPM. You will need to determine this
minimum grip force you require to safely
hold the workpiece.
wju = lbs., weight of one jaw unit = one master
jaw plus one top jaw plus bolts (plus T-
nuts plus master jaw for conventional
chucks), or one monoblok jaw for wedge
bar type quick jaw change chucks, such as
the Ultimate Chuck. For conventional
wedge hook or lever chucks, don't use the
weight of just the top jaw or your theoretical
allowable speed will be way too high. (You
must
disassemble and weigh a master jaw to add to
the top jaw weight. When you do this you'll also
want to determine the center of gravity and
record these figures for future use.)
rc = in., radius dimension from centerline of chuck
to the center of gravity of the jaw unit. For quick
jaw change chucks where the entire jaw unit can
be removed this can easily be done by balancing
the jaw unit on a knife edge, marking the balance
point and then inserting the jaw into the chuck to
measure the distance from the chuck centerline
to the balance point. For chucks with normal
master jaws this radius is more difficult to
determine.
n = RPM, speed of rotation
nmax = RPM, theoretical approximate maximum
allowable speed for the residual grip force you
determined is required. a = number of jaws (three or
two)
Calculated maximum speed:
nmax = Fstatic - F@ speed x 188
wju x rc x a
Grip force loss (all three jaws, lbs.):
= wju x a x rc x n2
35,196
Example 1:
Ultimate Chuck size 210 (8") with full size monoblok
soft jaw gripping a 2" diameter part. How fast can the