SCHUNK BAV User instructions

Assembly and Operating Manual
Jaw turning fixture
BAV / BSA
Translation of Original Operating
Manual

Imprint
2 01.00 | Jaw turning fixture | Assembly and Operating Manual | en | 1540578
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1540578
Version: 01.00|21/03/2023|en
Dear Customer,
Thank you for trusting our products and our family-owned company, the leading technology
supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions. Ask
us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[e-mail]
Please read the operating manual in full and keep it close to the product.

Table of Contents
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Table of Contents
1 General ............................................................................................. 5
1.1 About this manual............................................................................... 5
1.1.1 Presentation of Warning Labels ..................................................... 5
1.1.2 Definition of Terms ..................................................................... 6
1.1.3 Applicable documents ................................................................. 6
1.2 Warranty ........................................................................................... 6
1.3 Scope of delivery................................................................................. 6
2 Basic safety notes ................................................................................ 7
2.1 Intended use...................................................................................... 7
2.2 Inappropriate use ............................................................................... 7
2.3 Constructional changes......................................................................... 7
2.4 Spare parts ........................................................................................ 8
2.5 Environmental and operating conditions.................................................. 8
2.6 Personnel qualification ........................................................................ 8
2.7 Personal protective equipment .............................................................. 9
2.8 Notes on safe operation........................................................................ 9
2.9 Transport........................................................................................... 10
2.10 Malfunctions ...................................................................................... 10
2.11 Disposal ............................................................................................ 10
2.12 Fundamental dangers .......................................................................... 11
2.12.1 Protection during handling and assembly ....................................... 11
2.12.2 Protection during commissioning and operation ............................... 11
3 Technical data ..................................................................................... 12
3.1 Ambient conditions and operating conditions ........................................... 12
3.2 BAV/BSA............................................................................................. 12
4 Design and description .......................................................................... 13
4.1 Design .............................................................................................. 13
4.2 Description of function......................................................................... 14
5 Assembly and operation......................................................................... 15
5.1 Basic information................................................................................ 15
5.2 Application of the product .................................................................... 17
5.2.1 BAV - internal turning (for O.D. clamping) ....................................... 18
5.2.2 BAV - external turning (for I.D. clamping)........................................ 20
5.2.3 BAV - Reversing the adjusting jaws ................................................ 22
5.2.4 BSA - internal turning (for O.D. clamping) ....................................... 22
5.2.5 BSA - internal turning (for O.D. clamping) in power lathe chucks.......... 24
5.2.6 BSA - external turning (for I.D. clamping)........................................ 26
5.2.7 BSA - external turning (for I.D. clamping) in power lathe chucks .......... 28

Table of Contents
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5.3 Unclamping the product ....................................................................... 29
6 Maintenance ....................................................................................... 30
6.1 Basic information................................................................................ 30
6.2 Intervals and tasks .............................................................................. 30
6.2.1 Cleaning and testing the product................................................... 31
6.2.2 Lubricate plane thread ................................................................ 31
7 Disassembly ........................................................................................ 32
7.1 Basic information................................................................................ 32
7.2 Disassembling the product .................................................................... 32
7.3 Disassembling the adjusting jaws ........................................................... 32
8 Storage.............................................................................................. 33
9 Disposal ............................................................................................. 34

General
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1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working
is the observance of all safety instructions in this manual.
In addition to these instructions, the documents listed under
Link Mitgeltende Unterlagen are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Dangers for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.

General
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1.1.2 Definition of Terms
The term "product" replaces the product name on the title page in
this manual.
1.1.3 Applicable documents
lGeneral terms and conditions*
lContractual agreements
lAssembly and operating manual of the lathe chuck used
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.2 Warranty
If the product is used as intended, the warranty is valid for 12
months from the date of delivery from the production facility.
1.3 Scope of delivery
BAV
The scope of delivery includes
1BAV jaw turning fixture
(ID 119100; 119101; 119102; 119103; 119104)
1Assembly and operating manual
(ID 1540578)
BSA
The scope of delivery includes
1BSA jaw turning fixture
(ID 119110; 119111; 119112)
1Ball handle
(ID 9150050)
1Assembly and operating manual
(ID 1540578)

Basic safety notes
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2 Basic safety notes
2.1 Intended use
lThe product is used for turning and grinding out chuck jaws.
lThe product may only be used and applied within the scope of
the information in the technical data, }3 [/12].
lThe product may only be used and operated with suitable,
prescribed or approved attachment parts.
lThe product is intended for industrial use.
lAppropriate use of the product includes compliance with all
instructions in this manual.
2.2 Inappropriate use
The product is not being used as intended if, for example:
lThe product is not clamped correctly.
lThe information in the technical data is not observed when
using and operating the product }3 [/12].
lThe product is used and operated with non-approved
attachment parts.
lThe product is used in corrosive media.
lThe maintenance and storage instructions are not
observed }6 [/30].
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of
the product or damage it.
lStructural changes should only be made with the written
approval of SCHUNK.

Basic safety notes
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2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
lUse only original spare parts or spares authorized by SCHUNK.
2.5 Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the product
unsafe, leading to the risk of serious injuries, considerable material
damage and/or a significant reduction to the product's life span. See
also }3.1 [/12].
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
lAll work may only be performed by qualified personnel.
lBefore working with the product, the personnel must have
read and understood the complete assembly and operating
manual.
lObserve the national safety regulations and rules and general
safety instructions.
The following personal qualifications are necessary for the various
activities related to the product:
Qualified personnel Due to its technical training, knowledge and experience, qualified
personnel is able to perform the delegated tasks, recognize and
avoid possible dangers and knows the relevant standards and
regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.

Basic safety notes
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2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
lWhen working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
lObserve the valid safety and accident prevention regulations.
lWear protective gloves to guard against sharp edges and
corners or rough surfaces.
lWear heat-resistant protective gloves when handling hot
surfaces.
lWear protective gloves and safety goggles when handling
hazardous substances.
lWear close-fitting protective clothing and also wear long hair
in a hairnet when dealing with moving components.
2.8 Notes on safe operation
lInstall and clamp the product according to the specifications
in this manual.
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
lAvoid any manner of working that may interfere with the
function and operational safety of the product.
lUse the product as intended.
lObserve the safety notes and assembly instructions.
lDo not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
lEliminate any malfunction immediately.
lObserve the care and maintenance instructions.
lObserve the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.

Basic safety notes
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2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
lWhen handling heavy weights, use lifting equipment to lift the
product and transport it by appropriate means.
lSecure the product against falling during transportation and
handling.
lStand clear of suspended loads.
2.10 Malfunctions
Behavior in case of malfunctions
lImmediately remove the product from operation and report
the malfunction to the responsible departments/persons.
lOrder appropriately trained personnel to rectify the
malfunction.
lDo not recommission the product until the malfunction has
been rectified.
lTest the product after a malfunction to establish whether it still
functions properly and no increased risks have arisen.
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's safety
and cause serious injuries as well as considerable material and
environmental harm.
lFollow local regulations on dispatching product components
for recycling or proper disposal.

Basic safety notes
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2.12 Fundamental dangers
General
lObserve safety distances.
lNever deactivate safety devices.
lBefore commissioning the product, take appropriate
protective measures to secure the danger zone.
lDisconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
lIf the energy supply is connected, do not move any parts by
hand.
lDo not reach into the open mechanism or movement area of
the product during operation.
2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
lHave all work carried out by appropriately qualified
personnel.
lFor all work, secure the product against accidental operation.
lObserve the relevant accident prevention rules.
lUse suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
lStand clear of suspended loads and do not step into their
swiveling range.
lNever move loads without supervision.
lDo not leave suspended loads unattended.
2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious
injuries and even death.
lTake appropriate protective measures to secure the danger
zone.
lNever step into the danger zone during operation.

Technical data
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3 Technical data
3.1 Ambient conditions and operating conditions
Operating temperature range +18°C to +25°C
Maximum product temperature +35°C
Storage temperature range +20°C ±10°C
NOTE: The temperatures refer to the product.
3.2 BAV/BSA
Description BAV 0 BAV 1 BAV 2 BAV 3 BAV 4
ID 119100 119101 119102 119103 119104
for chuck size 125 200 250 250 315
Outer Ø [mm] Ø 153 Ø 176 Ø 215 Ø 244 Ø 290
Inner Ø [mm] Ø 110 Ø 110 Ø 135 Ø 162 Ø 208
Weight [kg] 1.5 3.3 5.2 5.6 6.8
Clamping mounting range
Ø A [mm]
Ø 150 to
Ø 215
Ø 170 to
Ø 260
Ø 215 to
Ø 285
Ø 240 to
Ø 315
Ø 290 to
Ø 360
Clamping mounting range
Ø I [mm]
Ø 50 to
Ø 115
Ø 35 to
Ø 125
Ø 70 to
Ø 140
Ø 100 to
Ø 175
Ø 145 to
Ø 215
Permissible clamping force
[kN]
15 30 30 30 30
Description BSA 10 BSA 20 BSA 30
ID 119110 119111 119112
for chuck size 250 315 400
Outer Ø [mm] Ø 225 Ø 288 Ø 384
Inner Ø [mm] Ø 135 Ø 184 Ø 256
Weight [kg] 7.0 11.5 21.0
Clamping mounting range
Ø A [mm]
Ø 229 to
Ø 305
Ø 292 to
Ø 368
Ø 388 to
Ø 464
Clamping mounting range
Ø I [mm]
Ø 81 to
Ø 157
Ø 128 to
Ø 204
Ø 208 to
Ø 284
Permissible clamping force [kN] 45 60 75

Design and description
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4 Design and description
4.1 Design
NOTE: The illustration may differ from the actual design.
1 Inner mounting range
2 Outer mounting range
3 Mounting screw
4 Housing
5 Adjusting jaw

Design and description
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4.2 Description of function
The product is used for turning and grinding out chuck jaws.
NOTE: With regard to the max. permissible total clamping force
with which the fixture may be clamped, the cutting and
machining parameters must be adjusted accordingly.
BAV:
The light BAV design is suitable for low clamping forces up to 30
kN.
The knurled spiral ring is turned by hand. This causes 3
adjustment jaws to move, each of which has a mounting screw
attached. The adjusting jaws of the jaw turning fixture are
reversible and infinitely adjustable. The mounting range is
adjusted by the knurled spiral ring or by turning the adjustment
jaws.
1. Turn clockwise: the mounting diameter decreases.
2. Turn counterclockwise: the mounting diameter increases.
ATTENTION: The mounting ranges must not be exceeded,
otherwise damage to the turning fixture may occur!
BSA:
Heavy-duty BSA design for high clamping forces up to 75 kN.
The spiral ring is turned by hand via the ball handle supplied. This
causes 3 adjustment jaws to move, each of which has a mounting
screw attached. The mounting screw can be screwed in internally
or externally. The adjusting jaws are not reversible. The
adjustment range is limited inwards by a clamping sleeve in the
adjusting jaw.
1. Turn clockwise: the mounting diameter increases.
2. Turn counterclockwise: the mounting diameter decreases.
ATTENTION: The mounting ranges must not be exceeded,
otherwise damage to the turning fixture may occur!

Assembly and operation
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5 Assembly and operation
5.1 Basic information
WARNING
Risk of injury if the product falls during transport, assembly or
disassembly.
Due to the oily surface required to preserve it, the product can
slip through your hands, resulting in injury.
lTake appropriate safety measures to prevent the product from
falling.
lWear suitable protective equipment, especially protective
gloves and safety boots.
WARNING
Risk of injury when the product is rotating, due to the
possibility of parts flying off!
lDo not exceed the maximum permissible clamping force.
lMake sure that the product is mounted correctly.
lTake suitable protective measures to secure the danger zones.
lWear suitable protective equipment.
WARNING
Danger of crushing, impact and cutting when clamping and
unclamping the product!
lWhen clamping and unclamping the product, do not reach
between the product and the chuck jaws.
lPrevent unintentional actuation of the lathe chuck.
lRemove sharp edges on the chuck jaws after turning.
lWear suitable protective equipment, especially gloves.
CAUTION
Risk of crushing and impact when assembling and
disassembling the product.
lDo not reach between the product and the chuck jaws.
lWear suitable protective equipment.

Assembly and operation
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CAUTION
Risk of injury from sharp edges and corners!
Sharp edges and corners on the machined chuck jaws can cause
cuts.
lWear suitable protective equipment, especially gloves.
NOTICE
Risk of damage to the product
If the permissible clamping force is exceeded, the product may be
damaged.
lDo not exceed the permissible clamping force.

Assembly and operation
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5.2 Application of the product
lTurning or skimming chuck jaws:
If the turning fixture is used for turning or skimming
monoblock jaws, it is recommended (for the user) to drill a
hole in the flat surface at the front of each jaw. The position
of the holes depends on the desired turning area (it is
possible to drill to the crack).
lGrinding out clamping jaws:
If the turning device is used for regrinding jaw steps,
excessive contamination of the adjusting jaw serration should
be avoided (brush off dust from time to time).
NOTE: With regard to the max. permissible total clamping force
with which the fixture may be clamped, the cutting and
machining parameters must be adjusted accordingly.
ATTENTION: The mounting ranges must not be exceeded,
otherwise damage to the turning fixture may occur!
Grinding chuck jaws
Proceed in the same way as for turning. Avoid excessive
contamination of the adjusting jaw serration. Clean serration if a
lot of dirt accumulates }6 [/30].

Assembly and operation
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5.2.1 BAV - internal turning (for O.D. clamping)
NOTE: The illustration may differ from the actual design.
To clamp the product, proceed as follows:
1. Mount the chuck jaws to be turned according to the
specifications in the operating manual of the lathe chuck
used.
2. Ensure that the lathe chuck is in an unclamped state. Observe
the specifications in the operating manual of the lathe chuck
used.
3. Move the jaws of the lathe chuck to be turned to the desired
clamping diameter (consider how much material will be
removed during turning).
4. Place the turning fixture in the correct position.
5. Insert the adjusting jaws of the jaw turning fixture into the
counterbores of the jaws using the adjustment screws until
they come into contact.
ATTENTION: The screw heads of the adjustment screws must
be inserted into the counterbores of the chuck jaws as far as
the stop!
6. Turn the knurled spiral ring counterclockwise until the turning
fixture is firmly seated.

Assembly and operation
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7. Clamp the lathe chuck inward according to the specifications
in the operating manual of the lathe chuck used (without
workpiece). Observe the specifications for the permissible
clamping force according to the technical data }3 [/12].
ðThe product is reliably clamped.
For turning, proceed as follows:
1. Ensure that the product is securely clamped.
2. Pre-turn chuck jaws to the preliminary size.
3. If the results are OK, remove the jaw turning fixture
}7 [/32] and make sure that the jaw turning fixture is not
misaligned.
4. Remove the pre-turned jaws and deburr them.
NOTE: Select large enough chamfers so that the pre-turned
jaws are not sharp-edged even after finish turning.
5. Mount the pre-turned jaws according to the specifications in
the operating manual of the lathe chuck used.
6. Clamp the chuck jaws again via the jaw turning fixture
according to this assembly and operating manual.
7. Turn the chuck jaws to the finished size.
8. If the results are OK, remove the jaw turning fixture
}7 [/32].

Assembly and operation
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5.2.2 BAV - external turning (for I.D. clamping)
NOTE: The illustration may differ from the actual design.
To clamp the product, proceed as follows:
1. Mount the chuck jaws to be turned according to the
specifications in the operating manual of the lathe chuck
used.
2. Ensure that the lathe chuck is in an unclamped state. Observe
the specifications in the operating manual of the lathe chuck
used.
3. Move the jaws of the lathe chuck to be turned to the desired
clamping diameter (consider how much material will be
removed during turning).
4. Place the turning fixture in the correct position.
5. Insert the adjusting jaws of the jaw turning fixture into the
counterbores of the jaws using the adjustment screws until
they come into contact.
ATTENTION: The screw heads of the adjustment screws must
be inserted into the counterbores of the chuck jaws as far as
the stop!
6. Turn the knurled spiral ring clockwise until the turning fixture
is firmly seated.