Kurt CROSSOVER DX4HR Instruction Manual
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Introduction ................................................................................................................. 3
Setup Instructions ........................................................................................................ 4
Operating Instructions...........................................................................................10-15
DX4H Parts List............................................................................................................ 16
DX4H Mechanical Drawing ........................................................................................ 17
Maintenance Schedule ......................................................................................... 21-23
Troubleshooting Tips .................................................................................................24
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Use this to fill out information about your vise for quick reference.
Purchase Date: _________ - ________ - _________
Purchase Order: ______________________________
______________________________
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Purchased From:
Delivery Date:
Serial No.: ______________________________
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DX4HR Parts List.................................. ....................................................................... 18
DX4HR Mechanical Drawing ...................................................................................... 19
Maintenance Log/Notes ............................................................................................ 25
Warranty .................................................................................................................... 26
KHU4 Mechanical Drawing ........................................................................................ 20
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Hydraulic Set-up ........................................................................................................ 5-9
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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.
dŽƌƋƵĞ&ƚͲ>ďƐ Force in Lbs.
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Hydraulic PSI Force in Lbs.
7
1450
2250
3100
3800
4750
4950
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Hydraulic
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Fig.2
HYDRAULIC OPERATING INSTRUCTIONS
The DX4H can be operated hydraulically by hooking up the Kurt 4" Hydraulic
Unit with a typical hydraulic pump or an air over hydraulic pump. Kurt offers
several solutions for hydraulic pumps, one being the KHP3 air over hydraulic
pump. Kurt offers other pump solutions and can be found on
kurtworkholding.com.
The hydraulic unit (KHU4) on the end of the DX4H has a 1/4 inch stroke.
The KHU4 can be used in both single and double acting applications. For
single acting, a spring will return the vise to the opened position when
hydraulics are disengaged. If double acting is desired, both ports on the
hydraulic unit will need to be hooked up to a pump (See figure 2).
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CAUTION:
ALL NPT CONNECTIONS IN HYDRAULIC 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.
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HYDRAULIC OPERATING INSTRUCTIONS
Basic Hydraulic Set-Up:
1. Remove plastic caps from pressure and release ports on Hydraulic pump.
Install 90° fittings.
2. Remove plastic caps from pressure and release ports on hand or foot
valve. Install straight fitting.
3. Install straight fitting on the Hydraulic Unit (1/8 NPTF) of the DX4H vise.
4. A filter-lubricator-regulator combination is recommended to insure clean
air coming into the unit. See Clamping Force Chart for air pressure required
to attain desired clamping force (pg. 5 & 9).
5. Connect the FRL to the input air port on the KHP3 hydraulic pump (See
Fig. 4)
6. Connect the hydraulic line to the hydraulic unit on the vise and then to
the output side of the hydraulic pump (Fig.2 & 4)
7. If using a hand valve or foot valve, connect the 3-line color-coded airline
cluster to the corresponding ports on the valve and pump (Fig. 3 & 4).
8. Apply air pressure (80 PSI maximum) to system. Loosen swivel fitting at
vise and bleed air. Tighten fitting. Release air pressure.
9. Repeat previous step until all air is purged
10. The KHP3 hydraulic pump will come pre-filled with oil (use #13 or DTE
lite if needed)
11. System is now ready for use.
NOTE: For multiple vise hook-ups, call factory for recommendations.
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NOTE - The following set-up is specifically for the KHP3 pump
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NOTE - The following set-up is specifically for the KHP3 pump
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Jaw Positioning:
Once all plumbing is set up, it time to position jaws for hydraulic clamping.
1. Position jaws less than 1/4 inch from the part being clamped as is
shown in figure 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
hydraulic unit has only a 1/4 inch stroke.
3. The vise is now ready to have the hydraulics engaged for clamping
the part.
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HYDRAULIC WhDWWZ&KZDE;<,WϯͿ
Air Pressure Input to Hydraulic Pressure Output
for Kurt Hydraulic Pump, KHP3
00 0.1 0.4 0.5
500
1000
1500
2000
2500
3000
3500
4000
KHP3 Fluid Flow Against Pressure
0.2 0.3
Hydraulic Flow in GPM
Hydraulic Pressure in PSI
Max. Flow .68 gpm
Max. Pressure 4,000 psi
Flow and Pressure Performance Guides
Air Pressure at:
100 psi
90 psi
75 psi
60 psi
45 psi
0
500
1000
1500
2000
2500
3000
3500
20 30 40 50 60 70 80 90 100
Oil PSI Output
Air PSI Input
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o Oil PSI Results
Air PSI Input Oil PSI Output
20
30
40
50
60
70
80
90
100
150
500
900
1300
1800
2200
2600
3000
3400
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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 NOTuse 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. 7 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.
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SURFACE MOUNT USING SINE KEYS
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