Kitagawa DL200 User manual

Version 1.01 (2010.05.31)
Original instructions
INSTRUCTION MANUAL
DL200 type
Dual Lock Chuck
・ This instruction manual is for production engineers and maintenance
personnel in charge of operation of this product. When a beginner uses
this product, receive instructions from experienced personnel, the
distributor or our company.
・ Before installing, operating or maintaining this equipment, carefully
read this manual and the safety labels attached to the equipment.
Failure to follow these instructions and safety precautions could result
in serious injury, death, or property damage.
・ Store this manual near equipment for future reference.
・ If any questions related to safety arise about this manual, please
confirm them with the distributor or our company.
DANGER
KITAGAWA IRON WORKS CO., LTD.
77-1 Motomachi, Fuchu, Hiroshima 726-8610 Japan
TEL [phone]
FAX [phone]

Preface
This manual provides detailed information about how to safely and correctly use the power
chuck (DL200 type) for a lathe.
Before starting to use this power chuck, read this manual carefully and always follow the
instructions and warnings in "Important Safety Precautions" and "Precautions for Use"
at beginning of the manual. Failure to follow these precautions could result in a serious
accident.
Terms and Symbols Used for Safety Messages
In this manual, precautions for handling that are considered especially important are
classified and displayed as shown below depending on the damage of risk including the
seriousness of the harm that could result. Please sufficiently understand the meanings of
these terms and follow the instructions for safe operation.
Safety Alert Symbol
The triangle is the safety alert symbol used to alert you to potential safety hazards that
could result in injury or death.
1
Indicates a hazardous situation which, if you not avoided, will
result in death or serious injury.
Indicates a hazardous situation which, if you not avoided,
could result in death or serious injury.
Indicates a hazardous situation which, if you not avoided,
could result in minor or moderate injury.
Indicates instructions which, if not avoided, could result in
damage to the equipment or a shortened work life.

2
Liability and How to Use this Manual
This product is suitable for gripping a workpiece on the lathes or rotary tables. This product
is equipped with the jaws to clamp the workpiece and they operate by means of a rotary
cylinder. For any other applications, please contact us.
Our company will not assume responsibility for injury, death, damage, or loss resulting from
not following the instructions in this manual.
There are countless things that cannot or should not be done, and it is impossible to cover
all of them in this manual.
Therefore, do not perform any actions unless they are specifically allowed in this manual. If
any questions related to safety arise about operation, control, inspection and maintenance
which are not specified in this manual, please confirm them with our company or distributor
before performing them.
Guarantee and Limitation of Liability
The guarantee period of this product is 1 year after delivery.
Use the parts delivered by Kitagawa Iron Works for all the parts including consumable parts.
We will not assume responsibility for injury, death, damage, or loss caused by usage of
parts not manufactured by Kitagawa Iron Works. Additionally, if parts other than genuine
parts manufactured by Kitagawa Iron Works are used, this guarantee will be completely
invalid.
The chuck and cylinder from Kitagawa Iron Works should be used together. If you must use
a part not made by Kitagawa, check with us or our distributor to be sure it is safe to do so.
We will not be responsible for injury, death, damage or loss caused by use of a chuck or
cylinder made by another company unless this use has been approved by Kitagawa or its
distributor.

Table of Contents
1. Structural Drawing and Parts List -----------------------------------------------------------------------5
1-1. Type display
1-2. Structural drawing
1-3. Scope of product
1-4. Parts list
2. Important Safety Precautions ----------------------------------------------------------11
3. Specifications ----------------------------------------------------------------------------------------------19
3-1. Specifications
3-2. Relationship between gripping force and rotation speed
3-3. Relationship between gripping part center height, static griping force and input
force / Relationship between top jaw mass moment and gripping force loss
4. Forming Soft Jaw ------------------------------------------------------------------------------------------32
4-1. Attachment of soft jaw
4-2. Forming jaw
4-3. Forming soft jaw with outside diameter gripping
4-4. Forming soft jaw with inside diameter gripping
4-5. Jaw with grooves / jaw with grip piece
5. Usage --------------------------------------------------------------------------------------------------------43
5-1. Precautions during gripping work with chuck
5-2. Precautions during gripping work in irregular shape
5-3. Precautions related to usage of jaw
5-4. Precautions related to processing
5-5. Attachment of locator and jig
5-6. Change of inner / outer diameter gripping
5-7. Dust-proof measures
5-8. Adjustment of retracting amount
6. Maintenance and Inspection ---------------------------------------------------------------------------56
6-1. Periodic Inspection
6-2. Grease lubrication
6-3. Disassembling
3

4
7. Malfunction and Countermeasures ------------------------------------------------------------------63
7-1. In the case of malfunction
7-2. Where to contact in the case of malfunction
For Machine Tool Manufacturers (Chapter 8)
8. Attachment -------------------------------------------------------------------------------------------------65
8-1. Outline drawing of attachment
8-2. Manufacturing and attaching of draw bar
8-3. Attachment of chuck
9. Other Information ----------------------------------------------------------------------------------------74
9-1. About standards and orders
9-2. Information about markings of product
9-3. About disposal

1. Structural Drawing and Parts List
1-1. Type display
Type display as shown below
Fig.1
1-2. Structural drawing
Table 1
Type A B C D E F Gmax Gmin H J K L M
DL206 169 105 140 104.8 3-M10 20 34 22.5 30 42 17 M26×1.5 -
DL208 210 110 170 133.4 3-M12 20 37.5 26 31 45 17 M28×1.5 75
DL210 254 132 220 171.4 3-M16 20 38.5 24.5 39.5 50 17 M30×1.5 -
DL212 304 132 220 171.4 3-M16 50 33.5 19.5 44.5 75 17 M30×1.5 -
Type N P Q R Smax Smin Tmax Tmin U V W X Y Z
DL206 55 - 7 20 14.25 8.25 23.7 20.8 72 41.5 31 10.3 12 32
DL208 60 2 5 25 25.25 16.25 28.9 25.3 95 45 35 7.8 14 32
DL210 65 - 5 30 26.25 12.75 32.8 28.3 101.5 59 45 14.7 18 35
DL212 - - - 30 26.25 12.75 57.8 53.3 129 64 50 14.7 18 50
Type A1 A2 A3 A4 A5 A6 A7 A8max A8min A9max A9min
DL206 4 3×7-M6 12 10.5 15 116 6-M6 23.7 20.8 21.25 15.25
DL208 5.5 3×4-M8 16 11.5 16 150 6-M6 26.2 22.6 20.25 11.25
DL210 5.5 3×4-M8 16 14 24 190 6-M8 29.7 25.2 35.25 21.75
DL212 14 3×4-M8 16 14 24 190 6-M8 54.7 50.2 35.25 21.75
5

Fig.2
6

1-3. Scope of product
This instruction manual is for the chuck part.
Fig.3
・ To prevent the work from flying, safe design, maintenance and erroneous
action prevention of the hydraulic system to maintain the gripping force of the
chuck is extremely important. Thoroughly read the “Important Safety
Precautions” on and after page 11 in this manual.
・ As for the cylinder, follow the instruction manual for the cylinder.
7

8

1-4. Parts list
Fig.4
9

10
Table 2 ■Parts list
15
3 6 3 6 3 1 1 3 1 1 1 1 3 3 1 1
Cover mounting bolt Plate mounting bolt Jaw mounting bolt Chuck mounting bolt Set screw Set screw Set screw Set screw Steel ball Grease nipple O-ring O-ring O-ring O-ring O-ring O-ring Mounting hundle
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 1 1 3 3 1 1 1 3 1 3 3 3 1 4 4 3 6
Body Rear body Plunger Bush Master jaw Cover Draw screw Nut Flat spring Plate T-nut Soft jaw Seal Pusher Pin Spring Spring Rear body mounting bolt
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Q'tyNameNo. Q'ty NameNo.
■Consumables
Q'ty
1 1 1 3 3 1
DL212
S 60
G 65
JASO 3075
G 75
S 85
S 290
DL210
S 22.4
JASO 2028
P 50
G 75
S 85
S 240
DL208
S 22.4
JASO 2028 JASO 2045 JASO 2056
S 67
S 200
DL206
S 22.4
JASO 1028
P 42
JASO 2047
S 55
S 160
Name
O-ring O-ring O-ring O-ring O-ring O-ring
No.
29 30 31 32 33 34

2. Important Safety Precautions
Important safety precautions are summarized below. Please read this section before first
starting to use this product.
DANGER Failure to follow the safety precautions below will result in
serious injury or death.
！
Turn off main power supply before attaching, inspecting or replacing
chuck, and before adding oil.
11
・ The chuck may start rotation
suddenly, and a part of the body or
clothing may be caught.
For All Users
Close door before rotating spindle.
・ If the door is not closed, you may touch
the rotating chuck or the work may fly out,
which is very dangerous. (In general, the
safety interlock function which allows
rotation only when the door is the manual
mode or the test mode)
For All Users
During spindle rotation, do not turn off hydraulic pump power supply and
do not operate switching valve.
・ Cutting off hydraulic pressure
causes a drop in the gripping
force which could result in the
work being released and flying
out.
・ Operating the manual switching
valve or solenoid valve will lead
to a drop of hydraulic pressure.
For All Users

Important Safety Precautions
DANGER Failure to follow the safety precautions below will result in
serious injury or death.
！
Do not allow the rotation speed of the chuck to exceed the maximum
allowable speed limit. (Refer to pages 21-31)
12
・ If the rotation speed of the chuck
exceeds the rotation speed limit,
this is very dangerous as the
chuck and work will fly out.
For All Users
The input force of the chuck (piston thrust, pulling force of the draw bar)
must not exceed the allowable maximum input force.
(Refer to pages 21-31)
・ Input must match the specification of the
chuck.
・ Adjust the hydraulic pressure to the
cylinder so that the input force, which
determines the gripping force of the
chuck, does not exceed.
・ Excessive input force can lead to
breakage of the chuck, which is very
dangerous, as the chuck can work can
be damaged and fly out.
For All Users

Important Safety Precautions
13
DANGER Failure to follow the safety precautions below will result in
serious injury or death.
！
Keep the height of the jaw within the range specified in the gripping force
limit table (Refer to pages 26-27). If you must use a jaw taller than a
standard soft jaw, use less than the input (piston thrust force, draw bar
drawing force) specified in the gripping force limit table.
・ Do not use a jaw of a height out
of the range of the gripping force
limit table or a jaw with mass
moment out of the range of the
gripping force limit table. The
chuck will break and the chuck
and work will break and fly out.
When the protrusion of the work is long, support it with the steady rest or
For All Users
center.
・ If the protrusion is long, the tip of the work can turn and the work fly out.
For All Users
Determine the gripping force required for processing by the machine tool
manufacturer or user, and check that the required gripping force is
provided before processing.
(Refer to pages 21-30 and cylinder manual)
・ Adjust the hydraulic pressure to the
cylinder to obtain the required gripping
force. If the gripping force is insufficient,
this is dangerous as the work will fly out.
For All Users

Important Safety Precautions
DANGER
14
Failure to follow the safety precautions below will result in
serious injury or death.
！
Use of a chuck and cylinder that cannot be used together safely may
cause the cylinder to break at high pressure resulting in the chuck and
work flying out.
・ Check that the chuck and the cylinder are in the “safe combination” when using at high
pressure with our company or the distributor. Especially when the cylinder of our
company and a high pressure chuck of other company are combined, confirmation is
necessary.
・ If one of the abnormal events shown below occurs during operation, immediately stop
the machine and consult with our company or the distributor.
For All Users
・ The work slips.
・ Loss of accuracy.
・ The work begins to chatter.
・ The machine's vibration significantly
increases.
・ The griping force does not rise even if
hydraulic pressure is raised.
In the case of processing a significant unbalanced work, lower the
rotation speed.
・ Unbalanced work generates dangerous centrifugal forces and the work could fly out.
For All Users

Important Safety Precautions
DANGER Failure to follow the safety precautions below will result in
serious injury or death.
！
Always tighten the bolts at the specified torque. If the torque is
insufficient or excessive, the bolt will break, which is dangerous as the
chuck or work will fly out. Use the bolts attached to the chuck, and do not
use bolts other than these.
・ If the torque is insufficient or
excessive, the bolt will break, which
is dangerous as the chuck or work
will fly out.
・ Fix the lathe spindle or the chuck
when you tighten bolts. Your hand
could slip and get injury when you
work without fixing the spindle.
15
・ You cannot control the torque by a
hex key. You must use a torque
wrench for torque control.
For All Users
Specified torque for
socket head cap screw
Bolt size Tightening torque
M5 8
N・m
M6 13
N・m
M8 33
N・m
M10 73
N・m
M12 107
N・m
M14 171
N・m
M16 250
N・m
M20 402
N・m
・ Tightening torque is moment of force when you tighten a bolt. Tightening torque= F×L.

Important Safety Precautions
DANGER
16
Failure to follow the safety precautions below will result in
serious injury or death.
！
Provide sufficient strength for the draw bar (Refer to pages 67-68).
Provide sufficient screw depth for the draw bar.
Firmly tighten the draw bar.
・ If the draw bar break, the gripping force is instantly
lost and this is dangerous as work will fly out.
・ If the screw depth of the draw bar is insufficient, the
screw will break and the gripping force will be lost
instantly, and this is dangerous as work will fly out.
・ If the engagement of the screw of the draw bar is
loose, vibration may occur resulting in breakage of
the screw. If the screw breaks, the gripping force will
be lost instantly, which is dangerous as the work will
fly out.
・ If the draw bar is unbalanced, vibration occurs, the
screw is broken and the gripping force will be lost
instantly, which is dangerous as the work will fly out.
Use a cylinder with a lock valve (safety valve, check valve) incorporated in
case of sudden hydraulic pressure drop due to blackout, malfunction of
the hydraulic pump, etc. Further, use a solenoid valve with a circuit that
For Machine Tool Manufactures
retains the gripping position when no current is carried.
・ If the hydraulic pressure
suddenly drops due to blackout
or malfunction of the hydraulic
pump, etc., this is dangerous
as work will fly out.
・ Lock valve retains the hydraulic
pressure inside the cylinder
temporarily, when the hydraulic
pressure suddenly drops due
to blackout or malfunction of
the hydraulic pump, etc.
For Machine Tool Manufactures

Important Safety Precautions
WARNING
Failure to follow the safety precautions below could result
in serious injury or death.
！
17
Do not modify the chuck in a way not permitted by the manufacturer.
・ It may not only break the chuck but the chuck
and the work may fly out, which is dangerous.
・ If you attach a locator or jig on the chuck body
surface, only process work in an acceptable
range (Refer to page 48).
For All Users
Periodically supply adequate grease (Refer to page 56). Turn off power
before adding grease.
・ Insufficient grease supply lowers the gripping
force, causes operation failure due to lower
hydraulic pressure, lowers the gripping precision,
and causes abnormal wearing and seizing, etc.
・ This is dangerous as the work could fly out from
a drop in the gripping force.
Do not operate the machine
after drinking alcohol or taking
medication.
For All Users
Do not operate the machine wearing
gloves, a necktie, and other loose
clothing or
jewelry.
・ Dangerous since
these lead to
operation mistakes
and misjudgment.
・ Dangerous since
it will be caught.
For All Users For All Users
Do not grip a chuck with a chuck.
・ Because it is easy to confuse the specifications of
each chuck and the protrusion become long and is
apt to raise rotation speed, it is apt to exceed the
specifications of the base chuck. The chuck may
break and the chuck or work could fly out.
For All Users

Important Safety Precautions
WARNING
Failure to follow the safety precautions below could result
in serious injury or death.
！
18
If the T-nut is protruded from the master jaw, the T-nut and master jaw are
damaged.Also, thejaw or work-piece will scatter, thus
resulting in danger.
・ Danger of scattering of chuck or workpiece.
For All Users
Grip work in the place where it is obliquely cut by master jaw.
・ Danger of scattering of chuck or workpiece because of chuck damage.
For All Users

19
3. Specifications
3-1. Specifications
Table 3
Outer gripping
Type DL206 DL 208 DL 210 DL 212
Plunger stroke mm 11.5 11.5 14 14
Jaw stroke （in diameter）mm 5.8 7.2 9.0 9.0
kN 19 35 50 50Allowable maximum
input force (kgf) (1937) (3569) (5099) (5099)
kN 54 84 110 110
Maximum static gripping force (kgf) (5506) (8566) (11217) (11217)
kN 5 6.2 10 10
Minimum input force (kgf) (510) (632) (1020) (1020)
Allowable maximum
rotation speed min-1 6000 5000 4000 3000
Gripping range
(outside diameter gripping) mm φ25～140 φ30～210 φ40～234 φ90～304
Mass
(standard soft jaw included) kg 18 30 52 74
Moment of inertia kg・m20.08 0.135 0.41 0.88
Matching cylinder Y1020R Y1225R Y1530R Y1530R
MPa 2.7 3.2 3.4 3.4
Maximum oil pressure (kgf／cm2)(27.5) (32.6) (34.7) (34.7)
MPa 0.9 0.8 0.9 0.9
Minimum oil pressure (kgf／cm2)(9.2) (8.2) (9.2) (9.2)
Standard soft jaw SB06D1 SB08B1 SB10D1 SB12A1
Option jaw SB06B1 －SB12A1 －
Gripping range
(Option jaw) φ25～158 －φ40～254 －