Kurt CROSSOVER DX6H Instruction Manual

DX6H™ CROSSOVER™
ANGLOCK VISE
HYDRAULIC VERSION
Operating Instruction Manual
DX6H/DX6HR
ENGLISH

TABLE OF CONTENTS
Introduction ................................................................................................................. 3
Setup Instructions ........................................................................................................ 4
Operating Instructions ...........................................................................................10-15
DX6H Parts List............................................................................................................ 16
DX6H Mechanical Drawing ........................................................................................ 17
Maintenance Schedule ......................................................................................... 21-23
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
DX6HR Parts List.................................. ....................................................................... 18
DX6HR Mechanical Drawing ...................................................................................... 19
Maintenance Log/Notes ............................................................................................ 25
Warranty .................................................................................................................... 26
KHU6 Mechanical Drawing ........................................................................................ 20
2
Hydraulic Set-up ........................................................................................................ 5-9

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 DX6H 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
Hydraulic PSI Force in Lbs.
500 800
1000 2050
1500 3000
2000 4050
25005100
3000 6100
3200 6700
Manual Hydraulic
4

HYDRAULIC SET-UP
HYDRAULIC OPERATING INSTRUCTIONS
The DX6H can be operated hydraulically by hooking up the Kurt 6" 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 (KHU6) on the end of the DX6H has a 1/4 inch stroke.
The KHU6 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).
5
Note: A female #4 JIC fitting(s) is required at the end of the hydraulic line
to mate up with the male #4 JIC fitting(s) on the hydraulic unit.
Fig.2
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.

6
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 DX6H 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.
HYDRAULIC SET-UP
NOTE - The following set-up is specifically for the KHP3 pump

7
Fig.3
HYDRAULIC SET-UP
Fig.4
HYDRAULIC SET-UP
NOTE - The following set-up is specifically for the KHP3 pump

HYDRAULIC SET-UP
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.
Fig.5
8
HYDRAULIC SET-UP

HYDRAULIC PUMP PERFORMANCE (KHP3)
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
Ai r t 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
Fig.6
9HYDRAULIC SET-UP

10
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. 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.
OPERATING INSTRUCTIONS

11
Fig.7
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

12
OPERATING INSTRUCTIONS
JAW POSITIONING
Fig.8
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
SIDE & END VIEW
13
Fig.9
Note: Dimensions below are in inches unless specified.

OPERATING INSTRUCTIONS
MOUNTING LOCATIONS
Fig.10
Note: Dimensions below are in inches unless specified.
14

15
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
Mounting the new DX6H 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 DX6H can be properly located using the four English sine key holes
indicated by the Y's in figure 10. The DX6H can be bolted down using the
four 1/2" bolt holes indicated in figure 10 by NN. The DX6H vise can also be
mounted using both bolt slots on the sides of the vise.
Metric Mounting:
The DX6H can be properly located using the four Metric sine key holes
indicated by the X's in figure 10.
Fig.11

DX6H Parts List
DX6H PARTS LIST 16

DX6H 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
DX6H Mechanical Drawing
17
Fig.12

18
DX6HR PARTS LIST
DX6HR Parts List

DX6HR MECHANICAL DRAWING
DX6HR Mechanical Drawing
19
Fig.13

KHU6 MECHANICAL DRAWING
KHU6 Mechanical Drawing
Fig.14
20