SERVICE MANUAL KSZ-DZ KSZ-AZ - SMW Autoblok

KSZ-DZ, KSZ-AZ 2004-05-E
Contents
General safety instructions 4
Structure / principle of function 5
Assembly instruction 6
Changing the collets
with manual collet changer 7
Changing the collets
with pneumatic collet changer 8
Technical details KSZ-DZ / KSZ-AZ 9-11
Collets 12-13
SERVICE MANUAL
KSZ-DZ
KSZ-AZ
SERVICE MANUAL
SMW-AUTOBLOK 3

General safety instructions
1. Correct use
SMW-AUTOBLOK power chucks work safely
and troublefree if they are used according to
WARNING! their specification i.e. to clamp components on
turning machines.
Any other use can cause hazards.
WARNING!
4 SMW-AUTOBLOK
2. Personnel
Power chucks must be installed, operated and
maintained only by qualified and regularly trained
personnel.
3. Safety precautions to the lathe
During machining the power chuck and the
clamped component must be protected by
WARNING! safety guards. Open machine door only when
machine spindle is completely stopped. Maintenance and
actuation of the power chuck must only be carried out
when machine spindle is stopped.
4. Technical details
The max. data, max. actuating force F, max.
spindle speed n are engraved on the chuck
WARNING! body. They must not be exceeded. Also the
summary of the total static gripping force Fsp at max.
actuating force is engraved on the chuck body.
5. Max. speed
The max. spindle speed is only valid at max.
actuating force. For special applications clam-
WARNING!
ping force and the max. speed must be calculated
according to VDI 3106 but not exceeding the max.
permitted speed.
6. Remaining risks
The type of components (shape, weight, unbalance,
material etc.) has a big influence on the
WARNING!
system “machine tool - power chuck - component”.
For that reason there is always a residual risk.
These residual risks must be calculated by the user and have
to be eliminated by suitable actions.
WARNING!
GENERAL SAFETY INSTRUCTIONS
7. Collets
Always use original-SMW-AUTOBLOK-collets.
Collets of other manufacturers can cause
damage to the chuck or accidents.
8. Maintenance
The power chuck must be maintained at regular
intervals. Check the conditions by measu-
WARNING!
ring the gripping force with static gripmenter.
Replace damaged parts with original-SMW-AUTOBLOK
spare parts only.
Maintenance must only be carried out at safe spindle stop
of the machine!
9. Actuating cylinder
The actuation of the power chuck must only be
carried out by suitable cylinders in accordance
WARNING!
with safety precautions.
When installing the power chuck on the machine with an
existing cylinder be sure that the actuating force of the
cylinder does not exceed the max. permitted actuating
force of the chuck.
If necessary reduce the actuacting force of the cylinder.
Connecting and adapter parts must be specified for permanent
load. Adjust and check the proximity switches for
the stroke control before starting the production.
For any problems or questions please contact SMW-
AUTOBLOK directly or one of out authorized offices.

Structure
The KSZ base chuck consists of:
- Base body (07) (collet seat)
- Chuck flange (04)
- Workstop (08/09) (KSZ-AZ only)
- Mounting material
STRUCTURE / PRINCIPLE OF FUNCTION
The KSZ to pull type chuck can be used for bar work (KSZ-DZ) or with workstop for bar and chuck work (KSZ-AZ).
01
02
01 machine spindle
02 draw tube
03 adapter
Principle of function
04 chuck flange
05 draw piston
06 draw sleeve
03 04
05 06 07
10
09
08
04
06 07
KSZ-AZ KSZ-DZ
07 base body
08 workstop base (KSZ-AZ only)
09 workstop (KSZ-AZ only)
10 collet
By pulling the draw tube (02) the collet (10) is pulled against the taper of the base body (07). This axial movement will cause
the collet to close, and thus clamp the workpiece.
10
SMW-AUTOBLOK 5

Assembly instruction
02
01 machine spindle
02 draw tube
03 adapter
Disassembling of KSZ collet chuck
By removing the mounting bolts (11) the chuck flange (04)
and the base body (07) can be separated. The mounting
bolts (12) remain tightened. In case these bolts are opened
they have to be remounted and thightened with
a torque of 10 Nm (at KSZ-AZ only).
Mounting of the chuck flange (04)
Check the radial and axial accuracy of the machine spindle.
These values should not exceed 5 µm to allow accurate
machining with the collet chuck.
Clean the mounting faces of the machine spindle (01) and
the chuck before assembling. Put the chuck flange (04)
onto the machine spindle (01), orientate and tighten the
mounting bolts (10) according to the specification of the
machine manufacturer.
6 SMW-AUTOBLOK
01 03 04
12
04 chuck flange
05 draw piston
06 collet sleeve
10 05
07 base body
08 workstop base
09 workstop
Mounting of the base chuck body (05-07)
06
ASSEMBLY
Reduce the actuating force for the actuating cylinder to the
lowest value possible. Bring the draw tube (02) to its complete
forward (right) end position. Mount the adapter (03)
(optional: has to be machined according to the machine
specification). Screw the draw piston (05) together with the
base body (07) and the workstop base (08) (at KSZ-AZ only)
completely onto the draw tube assembly (02/03). Orientate
the through holes of the bolts (11) of the base body assembly
(05-07) to the tapped holes of the chuck flange (04).
Pull the draw tube at lowest force possible backward (left
direction) and assemble the base body assembly into the
chuck flange (04). Tighten the mounting bolts (11).
Check radial and face runout
Put a dial indicator onto the face of the base body (07) and
check the face runout. To check the radial concentricity put
the dial indicator onto the Id taper. Within the clearance of
the parts the radial runout of the base body can be fine
adjusted. In case the runout cannot be adjusted to less
than 10 µm the chuck has to be disassembled once more
and checked for contamination or damage. Repeat the
assembly process until you reach a runout of less than 10
µm.
11
07
10 mounting bolt
11 mounting bolt
12 mounting bolt
09
08

Changing the collets with manual collet changer
11
01 adapter
02 workstop base
03 locking bolt
Insert the collet
To insert the collet open the chuck (right end position of
the draw tube).
Clean the collet (07) and the taper of the base body (05).
Insert the pins of the changing unit (08) into the bores of
the collet (07) completely. Turn the handle clockwise until
the segments of the collet (07) touch each other. In case
the rubber elements interfere during mounting rotate the
handle back counter-clockwise by one revolution.
Insert the collet (07) into be base body (05) so that a slot of
a collet segment matches the position of the orientation
bolt (06). Push the changing unit lightly towards the chuck
and open the handle completely in counter-clockwise
direction.
Removing the collet
Removing the collet is only possible in chuck opened position
(right end position).
Insert the pins of the changing unit (08) into the bores of
the collet (07) completely. Rotate the hand wheel clockwise
until the collet (07) is collapsed completely. Pull out the
collet (07) from the chuck. Open the changing unit (08)
counter-clockwise and remove the collet.
CHANGING THE COLLECTS WITH MANUAL COLLET CHANGER
01 02 03 04 05 06 07 08 09 10
04 workstop
05 base body
06 orientation bolt
07 collet
08 manual changer
09 protection ring
10 bolt M12
11 orientation pin
Removing the workstop (04) (at KSZ-AZ only)
The collet (07) must be removed.
The 3 locking bolts (03) have to be opened so that the
workstop (04) can be removed by pulling it out with the
bolt (10).
Clean the inside of the chuck body thoroughly and insert
the protection ring (09). Tighten the locking bolts (03). The
Id thread M12 of the workstop (04) can be used to mount
workpiece specific workstops. It also can be remachined.
The front tapped holes at the base body (05) can be used
to mount a front workstop.
SMW-AUTOBLOK 7

Connecting the collet changer to a air service
unit
Connect the pneumatic changer to a air service unit consisting
of filter, pressure regulator and oiler.
The pneumatic port (10) is a 1/4 thread. Standard fittings
can be adapted. The Id of the pneumatic hose must be bigger
than 6 mm.
Use an oil resistant PVC textile reinforced hose as pneumatic
line. The oil level in the air service unit has to be checked
periodically. Use the pneumatic changer with oiled air only
(danger of corrosion).
The pressure for the pneumatic changing unit of the sizes
32, 42 and 65 has to be adjusted to 4-5 bar. The pressure
for the pneumatic changing unit for size 100 has to be
adjusted to 8 bar.
Attention: Hoses and the fittings have to be mounted properly.
Danger of injury!
Function
When the push button (09) is pressed air actuates the builtin
piston. The piston moves and actuates the lever system
that will actuate the pins towards an end stop. When you
releasing the push button the built-in spring will push the
piston back into its original position. The pins will open to
their complete open end position.
8 SMW-AUTOBLOK
CHANGING THE COLLETS WITH PNEUMATIC COLLET CHANGER
Changing collets with pneumatic collet changer
01 adapter
02 workstop base
03 locking bolt
01
02 03 04 05 06 07 08
04 workstop
05 base body
06 orientation bolt
09
10
07 collet
08 pneumatic changer
09 push button
Mounting of a collet
Mounting of a collet is only possible in chuck open position
(right end position).
Clean the collet (07) and the taper of the base body (05)
thoroughly.
Insert the pins of the changing unit (08) into the bores of
the collet (07) completely. Push the push button (09). This
will cause the pneumatic changing unit and thus the collet
to collapse.
Insert the collet (07) into the base body (05) completely.
Observe that a slot of a collet segment matches the position
of the orientation bolt (06). Push slightly against the
chuck body and release the push button. Remove the
pneumatic changing unit.
Removing a collet
10 pneumatic port
Removing a collet is possible in chuck open position only
(right end position).
Insert the pins of the changing unit (08) into the bores of
the collet (07) completely. Actuate the push button (09).
This will cause the pins of the pneumatic changing unit (07)
and thus the collet to collapse. Pull out the collet with the
changing unit from the chuck.
Release the push button and remove the collet.

TECHNICAL DETAILS KSZ-DZ / KSZ-AZ
Application/customer’s benefit
■ Safe clamping of bars and shafts
■ Quick change of collets with changing unit
■ Changing unit manual or pneumatic
■ Direct mounting of the collets into the body
ensures highest concentricity
■ Collets available round, square, hexagonal or as
blanks to be machined on the chuck
■ Available for stationary use
KSZ-DZ
■ Safe clamping of bars
■ No pressure forces onto the machine spindle
during clamping
■ Highest axial and radial rigidity with draw collet
system
■ Parallel clamping of the collets
■ Flexible use because of large range of the collets
KSZ-AZ
■ Rigid axial workstop for shafts
■ High axial positioning accuracy of the shafts
because of pull down effect onto the workstop
■ Full through hole available because of quick
change of axial workstop
■ Special workstops available on request
SMW-AUTOBLOK 9

Chuck in open position
Subject to technical changes
SMW-AUTOBLOK Type
Mounting
Id. No.
max. speed r.p.m.
max. actuating force
max. gripping force
Weight without
collets
rec. actuating cylinders Type
Speed r.p.m.
10 SMW-AUTOBLOK
TECHNICAL DETAILS KSZ-DZ
KSZ-DZ 42 KSZ-DZ 65
Z140 A5 A6 Z170 A5 A6 A8
193234 192154 192155 193235 192156 192157 192158
A 150 140 165 185/160 150 165 210
B 125 124 124 145 140 140 140
C 98 98 98 120 120 120 120
D M 66 x 1.5 M66 x 1.5 M66 x 1.5 M 78 x 1.5 M78 x 1.5 M78 x 1.5 M78 x 1.5
E 43 43 43 67 67 67 67
F 90 90 90 95 95 95 100
G 68.5 68.5 68.5 68.5 68.5 68.5 73.5
H 45 45 45 45 45 45 50
I - 41.5 41.5 - 41.5 41.5 46.5
I1 35.5 - - 35.5 - - -
K 17.5 17.5 17.5 17.5 17.5 17.5 17.5
P H6 140 170
R 104.8 3x120° M10 - - 133.4 6x60° M12 - - -
7000 7000 7000 6000 6000 6000 4000
daN 3500 3500 3500 4500 4500 4500 4500
daN 8000 8000 8000 10500 10500 10500 10500
kg 7.0 6.0 7.2 14.8 10.8 13.0 17.2
Ordering review
Supply range: Chuck and mounting bolts
Changing unit
VNK 102-46 VNK 102-46 VN 102-46 VNK 150-67 VNK 150-67 VNK 150-67 VNK 150-67
8000 8000 8000 5500 5500 5500 5500
Size
Spindle mounting
A 05
A 06
A 08
Accessories
manual
pneumatic
Size
KSZ-DZ 42 KSZ-DZ 65
192154 192156
192155 192157
- 192158
KSZ-DZ 42 KSZ-DZ 65
192150 192152
192151 192153

Chuck in open position
Subject to technical changes
SMW-AUTOBLOK Type
Mounting
Id. No.
max. speed r.p.m.
max. actuating force
max. gripping force
Mass without
collets
rec. actuating cylinders Type
Speed r.p.m.
Spindle mounting
Z 140
Z 170
A 05
A 06
A 08
TECHNICAL DETAILS KSZ-AZ
KSZ-AZ 42 KSZ-AZ 65
Z140 A5 A6 Z170 A5 A6 A8
192951 192145 192146 193228 192147 192148 192149
A 150 140 165 185 155 165 210
B 125 125 125 145 145 145 145
C 98 98 98 120 120 120 120
D M78 x 1.5 M78 x 1.5 M78 x 1.5 M78 x 1.5 M78 x 1.5 M78 x 1.5 M78 x 1.5
E 43 43 43 66 66 66 66
F 126 121 121 130 130 130 135
G 110.5 105.5 105.5 111.5 111.5 111.5 116.5
H 75 70 70 70.5 70.5 70.5 75.5
I - 41.5 41.5 - 41.5 41.5 46.5
I1 40.5 - - 35.5 - - -
K 17.5 17.5 17.5 17.5 17.5 17.5 17.5
L 46 46 46 55 55 55 55
Mg5 49 49 49 72 72 72 72
N 21 21 21 20.5 20.5 20.5 20.5
O M12 M12 M12 M12 M12 M12 M12
P H6 140 - - 170 - - -
R 104.8 3 x 120° M10 - - 133.4 6 x 60° M12 - - -
7000 7000 7000 6000 6000 6000 4000
daN 3500 3500 3500 4500 4500 4500 4500
daN 8000 8000 8000 10500 10500 10500 10500
kg 7.8 7.2 8.5 18.0 12.9 15.4 20.4
Ordering review
Supply range: Chuck and mounting bolts
Changing unit/Boring ring
Accessories
manual
pneumatic
VNK 102-46 VNK 102-46 VNK 102-46 VNK 150-67 VNK 150-67 VNK 150-67 VNK 150-67
8000 8000 8000 5500 5500 5500 5500
Size
Size
KSZ-AZ 42 KSZ-AZ 65
192951 -
- 193228
192145 192147
192146 192148
- 192149
KSZ-AZ 42 KSZ-AZ 65
192150 192152
192151 192153
SMW-AUTOBLOK 11

Collets for KSZ-DZ 42/KSZ-AZ 42/KSZ-NZ 42
Steel collets with axial and radial grooves (* smooth, ** radial grooves)
ROUND ¹
12 SMW-AUTOBLOK
COLLETS
Ø 4* 5* 6* 7* 8** 9** 10** 11 12 13 14 15 16
Id. No. 192173 192174 192175 192176 192177 192178 192179 192180 192181 192182 192183 192184 192185
Ø 17 18 19 20 21 22 23 24 25 26 27 28 29
Id. No. 192186 192187 192188 192189 192190 192191 192192 192193 192194 192195 192196 192197 192198
Ø 30 31 32 33 34 35 36 37 38 39 40 41 42
Id. No. 192199 192200 192201 192202 192203 192204 192205 192206 192207 192208 192209 192210 192211
Steel collets with smooth clamping surface
ROUND ¹
Ø 4 5 6 7 8 9 10 11 12 13 14 15 16
Id. No. 192173 192174 192175 192176 193135 193136 193137 193138 193139 193140 193141 193142 193143
Ø 17 18 19 20 21 22 23 24 25 26 27 28 29
Id. No. 193144 192807 193145 192808 193146 193147 193148 193149 193150 193151 193152 193153 193154
Ø 30 31 32 33 34 35 36 37 38 39 40 41 42
Id. No. 193155 193156 193083 193157 193158 193159 193160 193161 193162 193163 193164 193165 193219
SQUARE ¹¹
Id. No.
Id. No.
7* 8** 9** 10** 11** 12** 13** 14** 15** 16** 17** 18** 19**
192212 192213 192214 192215 192216 192217 192218 192219 192220 192221 192222 192223 192224
20** 21** 22** 23** 24** 25** 26** 27** 28** 29** 30**
192225 192226 192227 192228 192229 192230 192231 192232 192233 192234 192235
HEXAGONAL
7* 8** 9** 10** 11** 12** 13** 14** 15** 16** 17** 18** 19**
Id. No. 192236 192237 192238 192239 192240 192241 192242 192243 192244 192245 192246 192247 192248
20** 21** 22** 23** 24** 25** 26** 27** 28** 29** 30** 31** 32**
Id. No. 192249 192250 192251 192252 192253 192254 192255 192256 192257 192258 192259 192260 192261
¹¹
Soft steel collets (pre-bored)
Round
Ø 5 15 30
Id. No. 192262 192263 192264
Boring ring 42 for soft steel collets
Id. No.
193399
¹
concentricity similar DIN 6343
¹¹
concentricity has to be agreed

Collets for KSZ-DZ 65/KSZ-AZ 65/KSZ-NZ 65
Steel collets with axial and radial grooves (* smooth, ** radial grooves)
ROUND ¹
COLLETS
Ø 5* 6* 7* 8** 9** 10** 11 12 13 14 15 16 17
Id. No. 192265 192266 192267 192268 192269 192270 192271 192272 192273 192274 192275 192276 192277
Ø 18 19 20 21 22 23 24 25 26 27 28 29 30
Id. No. 192278 192279 192280 192281 192282 192283 192284 192285 192286 192287 192288 192289 192290
Ø 31 32 33 34 35 36 37 38 39 40 41 42 43
Id. No. 192291 192292 192293 192294 192295 192296 192297 192298 192299 192300 192301 192302 192303
Ø 44 45 46 47 48 49 50 51 52 53 54 55 56
Id. No. 192304 192305 192306 192307 192308 192309 192310 192311 192312 192313 192314 192315 192316
Ø 57 58 59 60 61 62 63 64 65
Id. No. 192317 192318 192319 192320 192321 192322 192323 192324 192325
Steel collets with smooth clamping surface
ROUND ¹
Ø 5 6 7 8 9 10 11 12 13 14 15 16 17
Id. No. 192265 192266 192267 193172 193173 192682 193174 192787 193175 193176 193177 193169 193178
Ø 18 19 20 21 22 23 24 25 26 27 28 29 30
Id. No. 193179 193180 193181 193182 192683 193183 193170 193065 193184 193066 193068 193069 193070
Ø 31 32 33 34 35 36 37 38 39 40 41 42 43
Id. No. 193185 192684 193186 193187 193188 193189 193190 193191 193192 192685 193193 193194 193171
Ø 44 45 46 47 48 49 50 51 52 53 54 55 56
Id. No. 193196 193197 193198 193199 193200 193201 193202 193203 193204 193205 193206 193207 193208
Ø 57 58 59 60 61 62 63 64 65
Id. No. 193195 193209 193210 193211 193212 193213 193214 193215 193216
SQUARE ¹¹
Id. No.
Id. No.
Id. No.
8** 9** 10** 11** 12** 13** 14** 15** 16** 17** 18** 19** 20**
192326 192327 192328 192329 192330 192331 192332 192333 192334 192335 192336 192337 192338
21** 22** 23** 24** 25** 26** 27** 28** 29** 30** 31** 32** 33**
192339 192340 192341 192342 192343 192344 192345 192346 192347 192348 192349 192350 192351
34** 35** 36** 37** 38** 39** 40** 41** 42** 43** 44** 45** 46**
192352 192353 192354 192355 192356 192357 192358 192359 192360 192361 192362 192363 192364
HEXAGONAL
10** 11** 12** 13** 14** 15** 16** 17** 18** 19** 20** 21** 22**
192365 192366 192367 192368 192369 192370 192371 192372 192373 192374 192375 192376 192377
23** 24** 25** 26** 27** 28** 29** 30** 31** 32** 33** 34** 35**
192378 192379 192380 192381 192382 192383 192384 192385 192386 192387 192388 192389 192390
36** 37** 38** 39** 40** 41** 42** 43** 44** 45** 46** 47** 48**
192391 192392 192393 192394 192395 192396 192397 192398 192399 192400 192401 192402 192403
49** 50**
192404 192405
¹¹
Id. No.
Id. No.
Id. No.
Id. No.
Soft steel collets (pre-bored)
ROUND
Ø 8 20 40
Id. No. 192406 192407 192408
Boring ring 65 for soft steel collets
Id. No.
193400
¹ concentricity similar DIN 6343
¹¹ concentricity has to be agreed
SMW-AUTOBLOK 13