Kurt CROSSOVER DX6A Instruction Manual

DX6A™ CROSSOVER™
PNEUMATIC VISE
Operating Instruction Manual
DX6A / DX6AR
ENGLISH

TABLE OF CONTENTS
Introduction ................................................................................................................. 3
Setup Instructions ........................................................................................................ 4
Operating Instructions ............................................................................................8-13
DX6A Parts List............................................................................................................ 14
DX6A Mechanical Drawing ........................................................................................ 15
Maintenance Schedule ......................................................................................... 19-21
Troubleshooting Tips ................................................................................................. 24
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
DX6AR Parts List.................................. ....................................................................... 16
DX6AR Mechanical Drawing ...................................................................................... 17
Maintenance Log/Notes ............................................................................................ 25
Warranty .................................................................................................................... 26
KAU6 Mechanical Drawing ........................................................................................ 18
2
Pneumatic Set-up ...................................................................................................... 5-7

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 DX6A 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 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
3

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. 15) 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. Force in Lbs.
10 500
20 1450
30 2450
40 3450
50 4400
60 5400
70 6350
80 7350
SET-UP INSTRUCTIONS
Pneumatic PSI Force in Lbs.
10 300
20 800
30 1250
40 1750
50 2200
60 2700
70 3200
Manual Pneumatic
4
90 4350
100 5000
80 3800

PNEUMATIC SET-UP
5
Fig.2
PNEUMATIC OPERATING INSTRUCTIONS
The DX6A can be operated pneumatically by hooking up the Kurt 6" KAU6
pneumatic unit.
The pneumatic unit (KAU6) on the end of the DX6A has a 1/4 inch stroke.
The KAU6 is a double acting pneumatic unit that opens and closes with
pneumatic pressure. This pneumatic unit can be operated remotely or
directly using the level directly on the pneumatic unit. For direct use, hook
up one air line to the KAU6 unit and use the level directly on the pneumatic
unit to actuate the vise. If remote use/control is desired, both ports on the
pneumatic unit will need to be hooked up to an air pressure source (See
figure 2).
CAUTION: ALL NPT CONNECTIONS IN THE PNEUMATIC SYSTEM MUST
UTILIZE PIPE DOPE, NOT TEFLON TAPE. TEFLON TAPE CAN GET DISLODGED
BY FLUID AND END UP IN PUMP OR UNIT, POSSIBLY VOIDING WARRANTY.

6
1. Install straight fitting(s) on the Pneumatic Unit (1/8 NPT) of the DX6A vise
2. A filter-lubricator-regulator combination (KURT Part Number 312-06,
Figure 4) is recommended to insure clean air coming into the unit. See
Clamping Force Table for air pressure required to attain desired clamping
force (pg. 4).
3. Connect the pneumatic line to the pneumatic unit on the vise and then to
shop air or an air pressure source. For remote use, a hand control valve can
be used (See figure 3 below).
4. Apply air pressure to the system. Loosen swivel fitting at vise and bleed
air. Tighten fitting. Release air pressure.
5. System is now ready for use.
NOTE: For multiple vise hook-ups, call factory for recommendations.
PNEUMATIC SET-UP
PNEUMATIC OPERATING INSTRUCTIONS
Basic Pneumatic Set-Up
Fig.3Fig.4
Filter Regulator Lubricator
Part Number: 312-06
Hand Control Air Valve
Part Number: KHV-71

PNEUMATIC SET-UP
Jaw Positioning:
Once all plumbing is set up, it time to position jaws for pneumatic clamping.
1. Position jaws less than 1/4 inch from the part being clamped as is
shown in figure 5 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
pneumatic unit has only a 1/4 inch stroke.
3. The vise is now ready to have the pneumatics engaged for
clamping the part.
Fig.5
PNEUMATIC SET-UP
7

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. A torque wrench may be used if set within the torque limits
shown in the tables on page 4.
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. 6 on page 11)
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 8

9
Fig.6
Sketch #2A
Incorrect part
clamping.
Vise width
centerline
Sketch #2B
Correct part
clamping.
Sketch #2C
Correct part
clamping.
Sketch #2D
Correct part
clamping.
Dummy
spacer
OPERATING INSTRUCTIONS

10
OPERATING INSTRUCTIONS
JAW POSITIONING
Fig.7
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
SIDE & END VIEW
11
Fig.8
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
MOUNTING LOCATIONS
Fig.9
Note: Dimensions below are in inches unless specified.
12

13
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
Locating the new DX6A with keys requires the use of sine keys instead of
standard keys. They 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 DX6A can be properly located using the four English sine key holes
indicated by the Y's in figure 9. The DX6A can be bolted down using the
four 1/2" bolt holes indicated in figure 9 by NN. The DX6A vise can also be
mounted using both bolt slots on the sides of the vise.
Metric Mounting:
The DX6A can be properly located using the four Metric sine key holes
indicated by the X's in figure 9.
Fig.10

DX6A Parts List
DX6A PARTS LIST 14

DX6A 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
DX6A Mechanical Drawing
15
Fig.11

16
DX6AR PARTS LIST
DX6AR Parts List

DX6AR MECHANICAL DRAWING
DX6AR Mechanical Drawing
17
Fig.12

KAU6 MECHANICAL DRAWING
KAU6 Mechanical Drawing
18
Fig.13

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.
19

Fig.14
Segment
(Half Moon)
Socket Head Set
Screw Location
Screw Screw Brush Seals
MAINTENANCE SCHEDULE
7. Tip the jaw so the front of the jaw (the side with the jaw plate) is on the
vise bed. Lower the jaw on to the bed so that the segment contacts the
hook part of the nut and rest the jaw on to the vise bed.
8. Tighten the setscrew to firmly contact the nut. Back off the setscrew ¼
turn (approx.).
Note: DO NOT leave the setscrew tightened firmly to the nut as this may
cause improper operation. The movable jaw is designed to move slightly
(pivot side to side) so maximum jaw plate contact is maintained when
clamping out-of-parallel, sawed, or cast parts.
9. Your vise is now ready for use. Open and close your vise to check
for proper operation. Center the part to be clamped in the vise and close.
Your parts should be centered from side to side to ensure proper
clamping.
Jaw
Plate
Movable
Jaw
Stationary
Jaw
20