ZPS BALL LOCK QUICK CHANGE FIX TURING. Ball Lock Mounting System (Inch) Zero Point Mounting System. Ball Lock Mounting System (Metric)

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1 QUICK CHANGE FIXTURING M O U NTIN G SYS TEM Ball Lock Mounting System (Inch) Ball Lock for Rotary Indexers...19 Ball Lock Accessories... Ball Lock Selector Guides Commonly Asked Questions About the Ball Lock Mounting System Fast Acting Ball Lock s... Fixture Keys, Sine... Fixture Plates...13 Fixture Plates for Multi-Purpose Subplates...11 Fixture Plates for QLS Fixture Plates for Tooling Columns Jigsaw Interlocking Plates...12 Liners Liners, Stainless Steel Modular Grid Fixture Plates...12 Multi-Purpose Subplates...11 Quick Change Kits Receiver Bushings Receiver Bushings, Stainless Steel Repair Kits s s, Stainless Steel Subplates Subplates for Tooling Columns Tooling Columns, 4 sided...17 Tooling Columns, T-Columns Ball Lock Mounting System (Metric) Jigsaw Interlocking Plates Liners Liners, Stainless Steel Modular Grid Fixture Plates Multi-Purpose Subplates Quick Change Kits Receiver Bushings Receiver Bushings, Stainless Steel Repair Kits s s, Stainless Steel Subplates Subplates for Tooling Columns Tooling Columns, 4 sided Tooling Columns, T-Columns QUICK CHANGE FIX TURING BALL LOCK ZPS ZERO.POINT.SYSTEM Zero Point Mounting System Clamping Bracket Pull Studs & Engagement Screws Clamping Plates Clamping and Positioning Flange Type Installation Module K2 ZPS Manual ZPS Rapid-Clamping Cylinder Installation Clamping Modules Raised/Mounted Clamping Module System Overview Ball Lock for Rotary Indexers Ball Lock Accessories Fast Acting Ball Lock s Fixture Plates Fixture Plates for Multi-Purpose Subplates Fixture Plates for Tooling Columns

2 We Put It All Together In Seconds. BALL LOCK Maximize productivity levels and dramatically increase throughput with Ball Lock. Looking to realize the full benefits of lean manufacturing? Then you need the one system that puts it all together, so you can put it all together and that s Ball Lock. QUICK CHANGE FIXTURING» BALL LOCK Ball Lock is the industry s most popular quick-change, fixturing-flexible mounting system that can be configured to create lean-optimized solutions for your most demanding needs. The Ball Lock Mounting System is used as a Quick Change Solution on the following: CNC Machines Palletized Fixtures Stamping Fabricating Injection Molding Packaging Machines Assembly Machines EDM Robotics Welding Fixtures 6 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

3 Lean Manufacturing and Set Up Reduction Applications Accurately Locate and Lock Fixture Plates to Subplates in Seconds With No Indicating Required. Machining Cast Previous Set Up Method: Located part with dowel pins, bolted part to tombstone fixture. Indicated part to zero datum point. Previous Set-Up Time: 15 minutes CNC Machine Base: Drilling and reaming forged part. Previous Set Up Method: Fixture plate located with dowel pins bolted to machine base. Fixture plate and parts indicated. Previous Set Up Time: 7 minutes CNC Vertical Machining Center Machining aircraft valve parts Previous Set Up Method:New Project. New Machine.No Prior History. Set Up Using Ball Lock System: Mount parts to fixture plate while machining other parts. Mount fixture plate to tombstone using Ball Lock shanks. No indicating required because system provides (±0.013mm)repeatability. Set Up Time With Ball Lock System: 60 seconds Set Up Using Ball Lock System: s are pre-mounted on fixture plate, which is then mounted to machine base using Ball Lock shanks. No need to indicate. Set Up Time with Ball Lock System: 60 seconds Set Up Using Ball Lock System:Using Ball Lock Jig Saw Plate on Multi-Purpose Subplate enables operator to mount two more vises on the fixture. No indicating needed. QUICK CHANGE FIXTURING» BALL LOCK Previous Set Up Time: New Set Up. Set Up Time With Ball Lock System: 80 seconds setting up six vises. Two-Sided Tombstone Drilling and tapping cylindrical bodies. Previous Set Up Method: Fixture located and bolted to tombstone. Had to be indicated. Set Up Using Ball Lock System: Fixture plate mounted and located with Ball Lock shanks. No need to indicate. Previous Set Up Time: 12 minutes Set Up Time with Ball Lock System: 45 seconds Phone: Fax: workholding@jergensinc.com 7

4 Locates The Ball Lock System accurately positions your fixtureplate with a repeatability of ±0.0005" (±0.013mm) or better, minimizing the need to indicate your fixture. QUICK CHANGE FIXTURING» BALL LOCK Locks The Ball Lock System securely holds fixture plates to subplates with up to,000 lbs. (9000 Kg) of hold-down force per shank. The Ball Lock Mounting System is designed to speed the accurate locating and locking of fixture plates to subplates. The system consists of three parts: a Locating, a Liner Bushing, and a Receiver Bushing. Using the Ball Lock Mounting System is a simple process: Install a subplate with receiver bushings on your machine table; add your fixture The Ball Lock Mounting System provides a method of quickly and accurately locating fixtures onto machine tables. The Ball Lock Mounting System has done for machining centers what the Japanese SMED concept did for presses. Instead of single minute exchange of dies, Ball Lock provides Difference between Aluminum and Steel (inches) (inches) plate with two locating liner bushings; then insert two locating shanks through the liners and into the receiver bushings to provide accurate location. 2 1 / 2 turns of the set screw in each of the locating shanks provides positive holding force. Additional Ball Lock s are inserted through clearance holes in the fixture plate and set screws tightened for additional single minute exchange of fixtures. Fixtures can often be exchanged in less than a minute and with position repeatability of ±0.0005" (±0.013mm). Fixtures can be exchanged between different machines when both are using the Jergens Ball Lock Mounting System. Aluminum and Steel Expansion (per inch) Change in Degrees F NOTE: Aluminum and steel expand at different rates. Please take this information into consideration when creating your own Ball Lock fixture and subplates. holding force distributed across the fixture plate. It is recommended that the use of the Ball Lock Mounting System for locating and clamping of fixture plates be incorporated in a systematic process. All fixture plates should have two locating points positioned as far apart as possible. There Commonly Asked Questions Q. What is the Ball Lock Mounting System? A. It is a means of locating and locking two flat surfaces together, normally a fixture plate and a sub-plate. Q. How does it locate? A. Similar to locating pins, two Ball Lock shanks (pins) pass through two precision liner bushings on the fixture plate and into two precision receiver bushings on the subplate. Q. How does it lock? A. Inside the shank are three balls that expand into a tapered groove in the receiver bushing. This action draws the plates together. The locking balls are activated by turning a setscrew in the head of the shank, which pushes a 4th ball to distribute the clamping forces between the 3 locking balls. 8 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

5 Ball Lock Liner Bushing Fixture Plate Ball Lock Liner Bushing Fixture Plate Slip Fit Hole Socket Head Cap Screws (3) Press Fit Hole Machine Table or Subplate Face Mount Bushing is no advantage to having more than two locating points. If more than two flanged shanks are required to provide additional hold- down force, omit liner bushings in the additional holes in the fixture plate and allow 0.030" (0.76mm) over the nominal size. The additional clearance will insure that these holes have no influence on the locating holes. Q. How many shanks are required to locate and lock each fixture? A. Only two shanks, passing through bushings in the fixture plates, are required for location. However, additional shanks passing through clearance holes in the fixture plate will provide additional holding force distributed across the plate. Q. Is there a preferable location for the liner bushing? A. System repeatability is improved if the liners are located at opposite corners of a rectangular fixture plate. For consistency, we recommend locating the liner bushings at top left and bottom right. Mounting Method With Face Mount Bushing Drilled Hole Subplate How accurate should positioning be? The center distance of the receiver bushings in the machine table, tombstone, or subplate should be as accurate as possible ±0.0002" (±0.005mm) recommended. Accurate location will assure interchangeability of numerous fixture plates. For accurate repeatability within ±0.0005" (±0.013mm) of true Q. What are the advantages of using the Ball Lock System over the conventional method of dowel pins and cap screws? A. Both locating and locking are accomplished in the same motion. Ball Lock shanks require only 2.5 turns to lock a 1/2 13 (M12) screw with ¾" (18mm) of thread engagement require 10 turns to lock. On CNC machines, the repeatability of fixture locations makes indicating of the fixture unnecessary. Q. How do I recess the fixtureplate for a clear surface? A. Counterbore the fixture plate to a diameter large enough to allow easy removal of the shank. Note: The thickness of the plate section under the head of the shank is critical and must conform to mounting instructions. Counter-Bored Back Mount Bushing Hole Mounting Method With Back Mount Bushing position, both liner bushings in the fixture plate should be primary liners and the center distance tolerance should be ±0.0002" (±0.005mm). For a slightly looser fit, repeatability within ±0.0015" (±0.04mm) of true position, use one primary and one secondary liner with a center distance tolerance of ±0.001" (±0.03mm). Q. What if my plate is thinner than the recommended thickness? A. By adjusting the depth of the counterbore for the receiver bushing in the subplate, you can still use the Ball Lock System. If there are any questions on this type of application, please call Q. Can I use the shanks in a heated environment? A. The shank is made of alloy steel, heat treated to Rc and should with stand temperatures up to 400 F.(0 C). Note: Thermal expansion of fixture plates may affect the center distance tolerance and repeatability. QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 9

6 INCH FIXTURE/SUBPLATES Ball Lock Standard Subplates x16 Subplate Wt (lbs) /8 Bored holes for sine fixture keys (2) places Equipped with four mm receiver bushings for use with 14x14 or 16x16 fixture plates. Ideal for horizontal machining centers or multiple pallet machining centers. QUICK CHANGE FIXTURING» BALL LOCK (2) mm face mount bushings installed /8 Bored holes for sine fixture keys (2) places Aluminum Steel Plate Plate Plate of Fixture Width and Plates Length "x14" "x16" "x14" (12) mm face mount bushings installed Fremax 15 steel plate or equivalent Thickness: 1-1/8" ±0.005" Parallel within 0.001" x16 Dual Station Subplate Wt (lbs) Equipped with twelve installed mm receiver bushings to easily locate and mount Jergens Standard Fixture Plates: Fremax 15 steel plate or equivalent Thickness: 1-1/8" ±0.005" Parallel within 0.001" or /4 5/8 Bored holes for sine fixture keys (2) places (4)1/2 dia. for mounting to table (2) 16mm face mount bushings installed x10 Bridgeport Style Subplate Wt (lbs) Equipped with four installed 16mm receiver bushings and 1/2" mounting holes. Used with the Bridgeport style fixture plates or Thickness: 3/4" ±0.005" Parallel within 0.001" Ball Lock Quick Change Kits include all components needed in a single package. See page 26 for details. 10 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

7 INCH FIXTURE/SUBPLATES Multi-Purpose Subplates 40x Multi-Purpose Subplate Wt. (lbs) The Jergens Multi-Purpose Subplate accommodates a wide variety of fixture plates and vises. This versatility facilitates using the same VMC for diverse products in repetitive runs, long and short batch sizes. FreMax 15 Steel or Equivalent Thickness: 1 1/4" ±0.005" Parallel within 0.001" (18) MM FACE MOUNT BUSHINGS INSTALLED 5/8" BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES (8) MM FACE MOUNT BUSHINGS INSTALLED Fixture Plate Options for Multi-Purpose Subplates Aluminum or Steel of Fixture Receiver Required Plates/Vises That Mount Bushing Receiver Ball Lock of s Fixture Plate*/Vise Thickness of on Multi-Purpose Center Bushing Required Per Fixture Plate Subplate Distance Size Fixture Plate/Vise (14 x 14) Fixture Plate (16 x 16) Fixture Plate (16 x 16) Modular Grid Plate Jigsaw Interlocking Plate ( x ) Fixture Plate ( x 16) Fixture Plate " Jigsaw Base Vise or /4" 2 12 x 12 mm /4" 2 12 x 12 mm /8"** 2 12 x 12 mm /4" 4 8 x 12 mm " 2 17 x 17 mm /4" 1 16 x 12 mm /4" 4 8 x 12 mm * See next page for dimensional data on fixture plates. numbers shown for aluminum plates, also available in steel. ** Counterbored to 1" at mounting holes QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 11

8 INCH FIXTURE/SUBPLATES Fixture Plates QUICK CHANGE FIXTURING» BALL LOCK 14x14x3/4" Fixture Plate Aluminum Plate Wt. (lbs) x16x3/4" Fixture Plate Aluminum Plate Wt. (lbs) Clearance holes for holddown (2) places 5/8" Bored hole for sine fixture keys (2) places (2) mm Primary Liners Installed Jigsaw Interlocking Fixture Plate Steel Plate Wt. (lbs) Steel Plate Wt. (lbs) Cast Aluminum or FreMax 15 Steel or equivalent Thickness: 3/4" ±0.005" Parallel within 0.001" Steel Mounts to subplates with Ball Lock ( x 3/4") Aluminum Steel Plate Jergens Vise Plate No Wt. No Wt. A B C D P/N Cast Aluminum or FreMax 15 Steel or equivalent Thickness: 3/4" ±0.005" Parallel within 0.001" Steel For use with narrow base 4" or 6" vise models Design allows close vise spacing for more parts per run Easily mounts to Subplates using the Ball Lock ( x 3/4") Useful for high density fixturing of small parts Clearance Clearance hole hole for for holddown 16x16 Modular Grid Fixture Plate Steel Plate Wt. (lbs) FreMax 15 Steel or equivalent Thickness: 1 1/8" ±0.005" Parallel within 0.001" Mounts to subplates with Ball Lock ( x 1") xx1" Fixture Plate Aluminum Plate Wt. (lbs) Cast Aluminum or FreMax 15 Steel or equivalent Thickness: 1" ±0.005" Parallel within 0.001" Steel Mounts to subplates with Ball Lock ( x 1") Clearance holes for holddown (2) places Steel Plate Wt. (lbs) A B (2) mm Primary Liners Installed D /8" Bored hole for sine fixture key (2) places (2) mm Primary Liners Installed C 12 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

9 INCH FIXTURE/SUBPLATES Ball Lock Fixture Plates Cast Aluminum or FreeMax 15 Steel or equivalent Thickness tolerance ±0.005" Parallel within 0.001" Steel 6061 T-651 Aluminum plates, within.001 available upon request Aluminum Ball Lock Fixture Plates with 2 Primary Liners Installed Plate Plate Weight Weight Aluminum (lbs) Steel (lbs) x 15 3/ x 16 3/ x14 3/ x14 3/ x 16 3/ x x x x 16 3/ x x 10 3/ x / x Custom Sizes Available Jergens will make Ball Lock fixture plate or subplates to your specifications. Call for further information. 15x10x3/4" Fixture Plate Bridgeport Style Aluminum Plate Wt. (lbs) Plate Dimensions (in.) Steel Plate Wt. (lbs) Plate Thickness (in.) ±0.005 Size Dia. (mm) Ball Lock 12x14x3/4" Fixture Plate Aluminum Plate Wt. (lbs) Machined to close tolerances Repeatability ±0.0005" or better Reduces fixture set-up and assembly time Provided with 5/8" bored holes for sine fixture keys For horizontal or vertical machining centers, Tool Room Mills, or multiple pallet machining centers Steel Plate Wt. (lbs) QUICK CHANGE FIXTURING» BALL LOCK Clearance Hole for Holddown (2) Places 5/8 Bored Holes for Sine Fixture Keys (2) Places (2) 16mm Primary Liners Installed Clearance Hole for Holddown (2) Places 5/8 Bored holes for sine fixture keys (2) places (2) mm Primary Liners Installed Phone: Fax: workholding@jergensinc.com 13

10 INCH FIXTURE/SUBPLATES 16x16 QLS Fixture Plate Steel Plate Wt. (lbs) FreMax 15 Steel or equivalent Thickness: 1.378" ± 0.002" Parallel within 0.001" Mounts to subplates with Ball Lock ( x 3/4") QUICK CHANGE FIXTURING» BALL LOCK Configuration Options Ball Lock Subplate Machine Table Drop & Lock Pallet Changers See pg , Dovetail Vises See pg Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

11 INCH FIXTURE/SUBPLATES 16x16 QLS Fixture Plate Steel Plate Wt. (lbs) FreMax 15 Steel or equivalent Thickness: 1.378" ± 0.002" Parallel within 0.001" Mounts to subplates with Ball Lock ( x 3/4") QUICK CHANGE FIXTURING» BALL LOCK ER Collet Fixtures See pg Block Dovetail Vises See pg. 81 Risers See pg Phone: Fax: workholding@jergensinc.com 15

12 INCH FIXTURE/SUBPLATES Ball Lock T-Columns Fixture Plate Class 40 Cast Iron Also available in Aluminum Ball Lock Receiver Bushings and Liner Bushings installed Perpendicularity is 0.001" per foot QUICK CHANGE FIXTURING» BALL LOCK Custom Sizes Available with or without Ball Lock We are able to quote you on your special requirement with or without the Ball Lock Mounting System. Call for design specification information. Cast Iron T-Columns With Ball Lock Receiver Bushings Installed Subplate See page 18 for Fixture Plates and Subplates Pallet O P Wt. Size (mm) C D E F G H I J K L M N (mm) (mm) (lbs) *Note: Window sections are also available on T-Columns. Specify window size and location (Q and R Dimensions). Tooling Column Corresponding Fixture Plates, Subplates and Ball Lock s Pallet T-Column Aluminum Steel Fixture Fixture Plate Subplate Size Fixture Plate Fixture Plate Plate Ball Lock Subplate Ball Lock (mm) Size Size Size x mm x 3/ mm x x mm x mm x x mm x mm x 1-1/2 Use Hoist Ring 23411, see Lifting Solutions Catalog or Master Catalog for lifting and handling Order separately. Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. 16 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

13 INCH FIXTURE/SUBPLATES Ball Lock 4-Sided Tooling Columns Class 40 Cast Iron Also available in Aluminum Ball Lock Receiver Bushings and Liners installed Provides accurate fixturing base for CNC machining centers Perpendicularity is 0.001" per foot Tooling Column Fixture Plate Custom Sizes Available with or without Ball Lock We are able to quote you on your special requirement with or without the Ball Lock Mounting System. Call for design specification information. Cast Iron 4-Sided Tooling Columns With Ball Lock Receiver Bushings Installed Subplate See page 18 for Fixture Plates and Subplates Pallet O P Wt. Size (mm) A B C D E F G H I J K L M N (mm) (mm) (lbs) QUICK CHANGE FIXTURING» BALL LOCK Corresponding Fixture Plates, Subplates and Ball Lock s Pallet T-Column Aluminum Steel Fixture Fixture Plate Subplate Size Fixture Plate Fixture Plate Plate Ball Lock Subplate Ball Lock (mm) Size Size Size x mm x 3/ mm x x mm x mm x x mm x mm x 1-1/2 Use Hoist Ring 23411, see Lifting Solutions Catalog or Master Catalog for lifting and handling Order separately. Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. Phone: Fax: workholding@jergensinc.com 17

14 INCH FIXTURE/SUBPLATES Subplates For Tooling Columns and Fixture Plates QUICK CHANGE FIXTURING» BALL LOCK 5/8 Bored holes for sine fixture keys (2) places Receiver Bushings Installed A 5/8 Bored holes for sine fixture keys (2) places Clearance Hole for Holddown (2) Places (2) Primary Liners Installed B Standard Steel Subplates for Tooling Columns Subplate Mounting holes can be provided per customer specification. Supplied with Ball Lock Receiver Bushings installed. Ball Lock Pattern Receiver Thickness of Pallet Size For Tooling A B Size Subplate Wt (mm) Columns (in.) (in.) (mm) (in.) ±0.005 (lbs) , / , / C* , /17 14/17 / 1 1/ , Dual Dual Dual 1 1/ , /8 240 *49103-C is a dual pattern subplate. Please contact Jergens Technical Service at for design specific information. Fixture Plates for Standard Tooling Columns and T-Columns Supplied with 2 primary Ball Lock Liner Bushings installed. Fixture Fixture Plate Ball Lock Pattern Liner Pallet For Tooling Plate Size Thickness H G Size Size (mm) Aluminum (lbs) Steel (lbs) Columns Type (in.) ±0.005" (In.) (In.) (mm) S 10x 3/ S 12x S 16x T 16x16 3/ T x T x Clearance Hole for Holddown (2) Places 5/8 Bored holes for sine fixture keys (2) places (2) Primary Liners Installed I F Fixture Plates for Tooling Column Subplates Supplied with 2 primary Ball Lock Liner Bushings installed. Ball Lock Pallet Plate Dim. Fixture Plate Pattern Liner Size For E F Thickness I J Size (mm) Aluminum (lbs) Steel (lbs) Subplate (In.) (in.) ±0.005" (In.) (In.) (mm) / J E 18 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

15 INCH FIXTURE/SUBPLATES Ball Lock For 4th Axis Rotary Indexers Ball Lock Subplate Ball Lock s Indexer Face Plate Problem: Rotary indexers increase the versatility of vertical machining centers, yet they offer one major challenge: set-up is so time-consuming that it may limit a machine s flexibility. In many cases, machinists dedicate their 4th Axis tool to a single machine to avoid the agony of an extended set-up and changeover. Ball Lock Fixture Plate For Holding Production Workpiece Workpiece Ball Lock Fixture Plate For Mounting Indexer to Subplate and Machine Table Subplates and fixture plates come with bushings pre-installed. Benefits: Maximize indexer utilization Eliminate lengthy set-ups Accurate fixture plate changover in seconds Jergens Solution: Ball Lock Mounting System for Indexers provides a double solution. First, Ball Lock mounting plates free up your machine for additional work by allowing a fast and accurate installation and removal of the complete indexer. Avoid hours of set up. The Ball Lock System does it in minutes, with repeatability at ±0.0005" (±0.013mm). Low profile, positive clamping, proven in over many years of field use. Second, the Ball Lock System provides your fixture plate changeover. By mounting the round subplate to the indexer faceplate, you ll plug-in new fixtures in record time (less than 60 seconds). QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 19

16 INCH FIXTURE/SUBPLATES Round Ball Lock Fixture Plates and Subplates Standard Round Fixture Plate Thickness Ball Lock Ball Lock Weight No. A B ±0.005" Liner (lbs) " 6" 3/4 16mm " 8" 1 mm " 10" 1 mm Subplate QUICK CHANGE FIXTURING» BALL LOCK Cast Aluminum, FreeMax or Steel equivalent Custom Round Plates Cast Aluminum or FreeMax is steel or equivalent Thickness ± 0.005" Paralell within 0.001" Steel Thickness Ball Lock Center Weight No. A B ±0.005" Receiver Hole (lbs) " 6" 3/4 16mm 1.00" " 8" 1 mm 2.00" " 10" 1 mm 2.00" 33.0 Metric sizes also available; please call for information. Indexer: Make: Model: Diameter: Light Duty or Heavy Duty: Through Hole Bore: CNC Machine: Make: Model: Weight Capacity: Indexer Faceplate: T-Slot Size: Configuration/Orientation: or Drilled Tapped Hole Size: Configuration/Orientation: Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change without notice. If current information is critical to your design, it is suggested that you contact Jergens Technical Sales Department to verify any dimensions or specifications. Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

17 INCH BALL LOCK COMPONENTS Locating and Clamping s Material: /Bushing, 4340 Liner, Finish: Black Oxide Heat Treat: s, RC Bushings, RC Liners, RC Operating Temperature Range - to 400 F, -30 to 0 C D C B Ball Lock Repair Kits Each Kit Includes: Replacement Screw Locking Balls Drive Ball O-Ring Locating and Clamping Dimensions Diameter (mm) A Fixture Plate Thickness ±0.005 Head of Height B Stainless Steel available. See Page Diameter C Length Under Head D Hex Wrench Size for Set Screw / / / / / / / A Any Ball Lock application requires at least two sets of shanks, receiver bushings and liners. The liners are placed into the fixture plate to insure extremely accurate positioning. If more than two shanks are required (to provide additional hold down force), omit the liner bushing so that these additional holes will not interfere with your primary locating holes. See page for Fast Acting s. Screw Torque (Ft/lb) Maximum Hold-Down Force (lbs) Recommended Screw Torque (Ft/lb) Hold-Down Force (lbs) Repair Kit QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 21

18 INCH BALL LOCK COMPONENTS Receiver Bushings Face Mount Two styles of receiver bushings are available. Generally, the face mount receiver bushing is utilized in blind hole applications (Slip Fit). The back mount receiver bushing is used in through hole applications (Light Press Fit). Note: Installed bushings should be approximately.012" below subplate surface. See reference below for installation of back mount style bushings. QUICK CHANGE FIXTURING» BALL LOCK Back Mount Installation Dimensions Face Mount Dia. (mm) Face Mount Actual O.D / x5/ / x5/ / x3/ /4-28x1/ / /4-28x3/ / /16-24x7/ / /8-24x Cap Screws Supplied with Face Mount Bushings. Liner Bushings for Fixture Plates Liner Dimensions Clearance Drill Diameter E Bore F Face Mount Bushing Installation Instructions Depth G Tap Size & Depth 1 H Bolt Circle Diameter 3 PL Equally Spaced Min. Subplate Thickness D 3/4 3/ /4 1-3/8 1-1/2 2 Locating repeatability will determine if one primary and one secondary or two primary liners are needed. With two primary liners, repeatability of ±0.0005" can be maintained if the two holes for receiver bushings are held to a centerline distance of ±0.0002" tolerance. Back Mount Dia. (mm) Back Mount Back Mount Bushing Installation Instructions Actual O.D A Depth B C-Bore ±0.006 C Min. Subplate Thickness D 3/4 3/4 7/ /4 1-5/16 1-3/4 Note on Installation of Press Fit Liners & Back Mount Style Receiver Bushings: To alleviate the possibility of binding the shank in the bore, the maximum interference fit between bore and bushing O.D. should not exceed.0005". Fixture Plate Thickness ±0.005 Diameter (mm) Primary Liner Secondary Liner Liner O.D Fixture Plate Thickness ±0.005 Diameter (mm) Primary Liner Secondary Liner Liner O.D Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

19 INCH BALL LOCK COMPONENTS Stainless Steel Locating and Clamping s Material: 17-4 PH Stainless Steel Heat Treat: Rc C B D Ball Lock Repair Kits Each Kit Includes: Replacement Screw Locking Balls Drive Ball O-Ring Stainless Steel Locating and Clamping Dimensions Diameter (mm) A Fixture Plate Thickness ±0.005 Head of Height B Diameter C Length Under Head D Hex Wrench Size for Set Screw SS / SS SS SS SS / SS SS SS SS / SS SS SS SS / SS SS SS SS / SS SS SS SS / SS SS SS SS SS SS SS SS / SS SS SS SS SS SS SS A Any Ball Lock application requires at least two sets of shanks, receiver bushings and liners. The liners are placed into the fixture plate to insure extremely accurate positioning. If more than two shanks are required (to provide additional hold down force), omit the liner bushing so that these additional holes will not interfere with your primary locating holes. Screw Torque (Ft/lb) Maximum Hold-Down Force (lbs) Recommended Screw Torque (Ft/lb) Hold-Down Force (lbs) Repair Kit QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 23

20 INCH BALL LOCK COMPONENTS Stainless Steel Receiver Bushings Face Mount Two styles of receiver bushings are available. Generally, the face mount receiver bushing is utilized in blind hole applications (Slip Fit). The back mount receiver bushing is used in through hole applications (Light Press Fit). Note: Installed bushings should be approximately.012" below subplate surface. See reference below for installation of back mount style bushings. QUICK CHANGE FIXTURING» BALL LOCK Back Mount Installation Dimensions Face Mount Dia. (mm) Face Mount Actual O.D Cap Screws Supplied with Face Mount Bushings. Back Mount Stainless Steel Liner Bushings for Fixture Plates Liner Dimensions Clearance Drill Diameter E Bore F Face Mount Bushing Installation Instructions Depth G Tap Size & Depth 1 H Bolt Circle Diameter 3 PL Equally Spaced SS / x5/ SS / x5/ SS / x3/ SS /4-28x1/ SS / /4-28x3/ SS / /16-24x7/ SS / /8-24x Min. Subplate Thickness D 3/4 3/ /4 1-3/8 1-1/2 2 Locating repeatability will determine if one primary and one secondary or two primary liners are needed. With two primary liners, repeatability of ±0.0005" can be maintained if the two holes for receiver bushings are held to a centerline distance of ±0.0002" tolerance. Dia. (mm) Back Mount Back Mount Bushing Installation Instructions Actual O.D A Depth B C-Bore ±0.006 C Min. Subplate Thickness D SS SS SS SS /4 3/4 7/ SS SS SS / / /4 Note on Installation of Press Fit Liners & Back Mount Style Receiver Bushings: To alleviate the possibility of binding the shank in the bore, the maximum interference fit between bore and bushing O.D. should not exceed.0005". Fixture Plate Thickness ±0.005 Diameter (mm) Primary Liner Secondary Liner Liner O.D SS 49805SS SS 49806SS SS 49807SS SS 49808SS SS 49801SS SS 49802SS SS 49811SS SS 49812SS SS 49821SS Fixture Plate Thickness ±0.005 Diameter (mm) Primary Liner Secondary Liner Liner O.D SS 49822SS SS 49831SS SS 49832SS SS 49833SS SS 49834SS SS 49841SS SS 49842SS SS 49843SS SS 49844SS Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

21 INCH BALL LOCK COMPONENTS Accessories Tapered Caps and Plugs Keep debris out of your subplate s receiver bushings when not in use. Polyethylene caps snap in and out easily. Packaged 10 per pack. Receiver Bushing Diameter Lifting Handles For easy handling of fixture plates up to 500 lbs. Length Ht. W Mounting Distance Multi-Slot Sine Fixture Keys Locate subplates or fixture plates to slotted machine tables without having to slot the plate. Available in inch sizes from 1/2" to 7/8" slots, and in metric sizes from 14mm to 22mm slots. NOTE: See page "Multi-Slot Sine Fixture Keys Inch/Metric" on page 230 for dimensions. Fast Acting Ball Lock s Ball Lock Diameter (mm) Fixture Plate Thickness (in.) FAST ACTING Jergens Ball Lock Jergens Ball Lock w/jergens Thumb Screw Adjustable Handle Assembly T-Screw Assembly Handle 13 1/ S N/A 3/ S N/A 16 1/ S H / S H / S H S H / S H S H / S H S H / S H S H / S N/A S N/A Key Width Size A B C D Wt. (lbs) Recommended Hole Dia. 0.6 Size / Size / Size / Size / Thumb Screw Previous s 39501, , , 39504, , Fast acting thumb screws 2 1/2 turns. No tools needed. Handle can be moved out of the work area to avoid interference. Adjustable Handle QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com

22 INCH FIXTURE/SUBPLATES QUICK CHANGE FIXTURING» BALL LOCK Quick Change Kits Aluminum Fixture Plate Steel Subplate 5/8" Bored Hole for Sine Fixture Keys 5/8" Bored Hole for Sine Fixture Keys Ball Lock Primary Liner Bushings (2 places) Receiver Bushings (4 places) The Jergens Ball Lock Quick Change Kits speed fixture changeover in all types of manufacturing operations. Each kit includes two aluminum fixture plates with two primary liner bushings installed; one steel subplate with receiver bushings installed, and four mm Ball Lock shanks with working loads of 3000 lbs. each. While one fixture plate is on the machine, the operator can load parts on the other. This minimizes downtime for true set-up reduction. To enable the subplate to be mounted on a slotted table without the need to indicate the subplate, sine fixture keys can be used. The sine fixture key bored holes are oriented parallel to the receiver bushings on the subplate and to the liner bushings on the fixture plate. These also allow the fixture plate to be mounted on a toolroom mill without the need to indicate it. This is extremely useful when machining location points on your fixture. Everything You Need to Change Fixtures in Less Than One Minute Quick Change Kits BALL LOCK No. Kit Includes (14"x14"x3/4") aluminum fixture plates with mm liner bushings installed (16"x16"x1-1/8") steel subplate with receiver bushings installed (mm) Ball Lock s (16"x16"x3/4") aluminum fixture plates with mm liner bushings installed (16"x16"x1-1/8") steel subplate with receiver bushings installed (mm) Ball Lock s Bridgeport -Style (10"x15"x3/4") aluminum fixture plates with 16mm liner bushings installed (10"x15"x3/4") steel subplate with receiver bushings installed (16mm) Ball Lock s 26 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

23 INCH FIXTURE/SUBPLATES Ball Lock Selector Guides for Popular Machine Tools Use these guides to quickly select the correct Ball Lock Mounting System for your Machine Tool. To view our Ball Lock Selector Guides visit our website at QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax:

24 METRIC We Put It All Together In Seconds. BALL LOCK METRIC Maximize productivity levels and dramatically increase throughput with Ball Lock. Looking to realize the full benefits of lean manufacturing? Then you need the one system that puts it all together, so you can put it all together and that s Ball Lock. QUICK CHANGE FIXTURING» BALL LOCK Ball Lock is the industry s most popular quick-change, fixturing-flexible mounting system that can be configured to create lean-optimized solutions for your most demanding needs. The Ball Lock Mounting System is used as a Quick Change Solution on the following: CNC Machines Palletized Fixtures Stamping Fabricating Injection Molding Packaging Machines Assembly Machines EDM Robotics Welding Fixtures 28 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

25 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Pre-Machined Ball Lock Steel Subplate (4) MM FACE MOUNT BUSHINGS INSTALLED 400 x400 Subplate Wt. (Kg) Equipped with four mm receiver bushings for use with 350x350 or 400x400 (mm) fixture plates. Ideal for horizontal machining centers or multiple pallet machining centers. METRIC MM BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES 0 16MM BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES Aluminum Steel Plate Plate Plate of Fixture Width and Plates Length (mm) x x x (12) MM FACE MOUNT BUSHINGS INSTALLED FreMax 15 steel plate or equivalent Thickness: 28.57mm ±0.13mm Parallel within 0.0mm 650x400 Dual Station Subplate Wt. (Kg) Equipped with twelve installed mm receiver bushings to easily locate and mount Jergens Standard Fixture Plates. Ideal for vertical machining centers Thickness: 28.57mm ±0.13mm Parallel within 0.0mm or QUICK CHANGE FIXTURING» BALL LOCK 16mm Bored Holes For Sine Fixture Keys (2) Places x375 Bridgeport - Style Subplate Wt. (Kg) mm Dia. For Mounting To Table (4) Places (4) 16mm Face Mount Bushings Installed Equipped with four installed 16mm receiver bushings and 12mm mounting holes. Used with the Bridgeport style fixture plates or Thickness: 19.05mm ±0.13mm Parallel within 0.0mm 375 Ball Lock Quick Change Kits include all components needed in a single package. See page 43 for details. Phone: Fax: workholding@jergensinc.com 29

26 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES METRIC Multi-Purpose Subplates 1000x500 Multi-Purpose Subplate Wt. (Kg) The Jergens Multi-Purpose Subplate accommodates a wide variety of fixture plates and vises. This versatility facilitates using the same VMC for diverse products in repetitive runs-long and short batch sizes QUICK CHANGE FIXTURING» BALL LOCK FreMax TM 15 Steel or Equivalent Thickness: 31.75mm ±0.13mm Parallel within 0.0mm (18) MM FACE MOUNT BUSHINGS I NSTALLED 16MM BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES (8) MM FACE MOUNT BUSHINGS I NSTALLED Fixture Plate Options for Multi-Purpose Subplates Aluminum or Steel of Fixture Receiver Required Plates/Vise That Mount Bushing Receiver Ball Lock of s Fixture Plate*/Vise Thickness of on Multi-Purpose Center Bushing Required Per Fixture Plate Subplate Distance Size Fixture Plate/Vise or (350 x 350) mm x 300 mm Fixture Plate (400 x 400) mm x 300 mm Fixture Plate (400 x 400) 30mm** x 300 mm Modular Grid Plate Jigsaw mm x 0 mm Interlocking Plate (500 x 500) mm 2 4 x 4 mm Fixture Plate mm x 0 mm mm Jigsaw Vise * See next page for dimensional data on fixture plates. numbers shown for aluminum plates, also available in steel. ** Counterbored to mm at mounting holes. 30 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

27 METRIC DIMENSIONS - METRIC TOOLING COLUMNS Fixture Plates for Use on Multi-Purpose Subplate 350x350xmm Fixture Plate Aluminum Plate Wt. (Kg) x400 Fixture Plate Aluminum Plate Wt. (Kg) Cast Aluminum or FreMax 15 Steel or equivalent Thickness: mm ±0.13mm Parallel within 0.0mm Steel Mounts to subplates with BallLock (xmm) CLEARANCE HOLES FOR HOLDDOWN (2) PLACES 16MM BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES (2) MM PRIMARY LINERS INSTALLED Jigsaw Interlocking FixturePlate Aluminum Plate Wt. (Kg) Steel Plate Wt. (Kg) Steel Plate Wt. (Kg) Steel Plate Wt. (Kg) Material: Cast Aluminum or FreMax 15 Steel or equivalent Thickness: mm ±0.13mm Parallel within 0.0mm Steel For use with narrow base 100mm or 150mm vise models Design allows close spacing of vises for more parts per run Mounts to Subplates using Ball Lock (xmm) Useful for high density fixturing 400x400 Modular Grid Fixture Plate Aluminum Plate Wt. (Kg) FreMax 15 Steel or equivalent Thickness: 28.57mm ±0.13mm Parallel within 0.0mm Steel (2) MM PRIMARY LINERS INSTALLED TYP CLEARANCE HOLES FOR HOLDDOWN (2) PLACES 500x500xmm Fixture Plate Aluminum Plate Wt. (Kg) MM X 6MM DEEP COUNTERBORE M12 X 1.75 TAPPED HOLE Mounts to Subplate with BallLock (xmm) Steel Plate Wt. (Kg) Cast Aluminum or FreMax 15 Steel or equivalent Thickness: mm ±0.13mm Parallel within 0.0mm Steel Mounts to Subplates using Ball Lock (xmm) METRIC QUICK CHANGE FIXTURING» BALL LOCK CLEARANCE HOLE FOR HOLDDOWN CLEARANCE HOLES FOR HOLDDOWN (2) PLACES 0 0 (2) MM PRIMARY LINERS INSTALLED MM BORED HOLE FOR SINE FIXTURE KEYS (2) PLACES (2) MM PRIMARY LINERS INSTALLED 400 Phone: Fax: workholding@jergensinc.com 31

28 METRIC DIMENSIONS - METRIC TOOLING COLUMNS METRIC QUICK CHANGE FIXTURING» BALL LOCK Ball Lock Fixture Plates Cast Aluminum; or FreMax 15 Steel or equivalent Thickness ±0.13mm Parallel within.0mm Steel 6061 T-651 plates, flat within 0.03mm available upon request Ball Lock Fixture Plates with 2 Primary Liners Installed Weight Weight Aluminum (Kgs) Steel (Kgs) Clearance Hole For Holddown (2) Places Plate Dimensions (mm) Custom Sizes Available Jergens will make Ball Lock fixture plates or subplates to your specifications. Call for further information. Plate Thickness ±0.13(mm) Ball Lock Size (mm) Ball Lock x x x x x x x x0xmm Fixture Plate Bridgeport Style Aluminum Plate Wt. (Kg) Steel Plate Wt. (Kg) x350xmm Fixture Plate Aluminum Plate Wt. (Kg) Machined to close tolerances Repeatability ±0.013mm or better Reduces fixture set-up and assembly time Provided with 16mm bored holes for sine fixture keys For horizontal or vertical machining centers, Tool Room Mills machines, or multiple pallet machining centers Steel Plate Wt. (Kg) mm Bored Holes For Sine Fixture Keys (2) Places (2) 16mm Primary Liners Installed Clearance Holes For Holddown (2) Places 16mm Bored Holes For Sine Fixture Keys (2) Places (2) mm Primary Liners Installed 32 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

29 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Pre-Machined Ball Lock T-Columns Class 40 Cast Iron Also available in Aluminum Ball Lock Receiver Bushings and Liners installed Provides accurate fixturing base for CNC machining centers Perpendicularity is 0.0 mm per 0 mm Custom Sizes Available with or without Ball Lock We are able to quote you on your special requirement with or without the Ball Lock Mounting System. Call for design specification information. Subplate Fixture Plate Tooling Column METRIC Cast Iron T-Columns With Ball Lock Receiver Bushings Installed M12 See page 35 for Metric Fixture Plates and Subplates Pallet O P Wt. Size (mm) C D E F G H I J K L M N (mm) (mm) (Kg) *Note: Window sections are also available on T-Columns. Specify window size and location (Q and R Dimensions). QUICK CHANGE FIXTURING» BALL LOCK Corresponding Fixture Plates, Subplates and Ball Lock s Pallet T-Column Aluminum Steel Fixture Fixture Plate Subplate Size Fixture Plate Fixture Plate Plate Ball Lock Subplate Ball Lock (mm) Size Size Size x x x x x x x x x 40 Use Hoist Ring 23462, see Lifting Solutions Catalog or Master Catalog for lifting and handling Order separately. Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. Phone: Fax: workholding@jergensinc.com 33

30 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES METRIC QUICK CHANGE FIXTURING» BALL LOCK Pre-Machined Ball Lock 4-Sided Tooling Columns Class 40 cast iron Also available in Aluminum Ball Lock Receiver Bushings and Liner Bushings installed Provides accurate fixturing base for CNC machining centers Perpendicularity is 0.0 mm per 0 mm Custom Sizes Available with or without Ball Lock We are able to quote you on your special requirement with or without the Ball Lock Mounting System. Call for design specification information. Cast Iron 4-Sided Tooling Columns With Ball Lock Receiver Bushings Installed Pallet O P Wt. Size (mm) A B C D E F G H I J K L M N (mm) (mm) (Kg) M12 Tooling Column Subplate Fixture Plate See page 33 for Metric Fixture and Subplates Corresponding Fixture Plates, Subplates and Ball Lock s Pallet T-Column Aluminum Steel Fixture Fixture Plate Subplate Size Fixture Plate Fixture Plate Plate Ball Lock Subplate Ball Lock (mm) Size Size Size x x x x x x x x x 40 Use Hoist Ring 23462, see Lifting Solutions Catalog or Master Catalog for lifting and handling Order separately. Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change after publishing. Contact Jergens Technical Sales Department to verify any dimensions or specifications. 34 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

31 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Subplates for Tooling Columns and Fixture Plates 16mm Bored holes for sine fixture keys (2) places Receiver Bushings A B Standard Steel Subplates for Tooling Columns Subplate Mounting holes can be provided per customer specification. Supplied with Ball Lock Receiver Bushings installed. Ball Lock Pattern Receiver Thickness of Pallet Size For Tooling A B Size Subplate Wt (mm) Columns (mm) (mm) (mm) (mm) ±0.13 (Kgs) , , C* , /4 350/4 / , Dual Dual Dual , METRIC 16mm Bored holes for sine fixture keys (2) places Primary Liners 16mm Bored holes for sine fixture keys (2) places J E Primary Liners Fixture Plates for Standard Tooling Columns and T-Columns Supplied with 2 primary Ball Lock Liner Bushings installed. Fixture Fixture Plate Ball Lock Pattern Liner Pallet For Tooling Plate Size Thickness H G Size Size (mm) Aluminum (Kg) Steel (Kg) Columns Type (mm) (mm) ±0.13 (mm) (mm) (mm) S 0x S 300x S 400x T 400x T 500x T 6x I F Fixture Plates for Tooling Column Subplates Supplied with 2 primary Ball Lock Liner Bushings installed. Ball Lock Pallet Plate Dim. Fixture Plate Pattern Liner Size For E F Thickness I J Size (mm) Aluminum (Kg) Steel (Kg) Subplate (mm) (mm) ±0.13 (mm) (mm) (mm) (mm) Difference between Aluminum and Steel ( mm ) Aluminum and Steel Expansion (per cm ) Change in Degrees C NOTE: Aluminum and steel expand at different rates. Please take this information into consideration when creating your own Ball Lock fixture and subplates. QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 35

32 METRIC DIMENSIONS - METRIC BALL LOCK COMPONENTS METRIC Ball Lock For 4th Axis Rotary Indexers Ball Lock Subplate Ball Lock s Indexer Face Plate Problem: Rotary indexers increase the versatility of vertical machining centers, yet they offer one major challenge: set-up is so time-consuming that it may limit a machine s flexibility. In many cases, machinists dedicate their 4th Axis tool to a single machine to avoid the agony of an extended set-up and changeover. QUICK CHANGE FIXTURING» BALL LOCK Ball Lock Fixture Plate For Holding Production Workpiece Workpiece Ball Lock Fixture Plate For Mounting Indexer to Subplate and Machine Table Subplates and fixture plates come with bushings pre-installed. Benefits: Maximize indexer utilization Eliminate lengthy set-ups Accurate fixture plate changover in seconds Jergens Solution: Ball Lock Mounting System for Indexers provides a double solution. First, Ball Lock mounting plates free up your machine for additional work by allowing a fast and accurate installation and removal of the complete indexer. Avoid hours of set up. The Ball Lock System does it in minutes, with repeatability at ±0.0005" (±0.013mm). Low profile, positive clamping, proven in over many years of field use. Second, the Ball Lock System provides your fixture plate changeover. By mounting the round subplate to the indexer faceplate, you ll plug-in new fixtures in record time (less than 60 seconds). 36 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

33 METRIC DIMENSIONS - METRIC BALL LOCK COMPONENTS Round Ball Lock Fixture Plates and Subplates Standard Round Fixture Plate (mm) Ball Lock Ball Lock Weight No. A B Thickness Liner (Kgs) Subplate(mm) METRIC Cast Aluminum, FreeMax or Steel equivalent Custom Round Plates Cast Aluminum or FreeMax is steel or equivalent Thickness ± 0.13" Paralell within 0.0" Steel Ball Lock Center Weight No. A B Thickness Receiver Hole (Kgs) Note: Equivalent system available in inch dimensions. Indexer: Make: Model: Diameter: Light Duty or Heavy Duty: Through Hole Bore: CNC Machine: Make: Model: Weight Capacity: Indexer Faceplate: T-Slot Size: QUICK CHANGE FIXTURING» BALL LOCK Configuration/Orientation: or Drilled Tapped Hole Size: Configuration/Orientation: Engineering Changes Product improvement is a continuing process at Jergens. Specifications and engineering data are subject to change without notice. If current information is critical to your design, it is suggested that you contact Jergens Technical Sales Department to verify any dimensions or specifications. Phone: Fax: workholding@jergensinc.com 37

34 METRIC DIMENSIONS - METRIC BALL LOCK COMPONENTS METRIC QUICK CHANGE FIXTURING» BALL LOCK Locating and Clamping s U.S. Patents: 3,498,653 4,135,418 Repair Kits Locating and Clamping Dimensions Diameter (mm) A Fixture Plate Thickness ±0.13mm Material: /Bushing, AISI 4340 Liner, Finish: Black Oxide Heat Treat: s, RC Bushings, RC Liners, RC Operating Temperature Range: -30 C to 0 C Stainless Steel available. See Page Head of Height Diameter B C D Each Kit Includes: Replacement Screw Locking Balls Drive Ball O-Ring Hex Wrench Size For Set Screw D C A Any Ball Lock application requires at least two sets of shanks, receiver bushings and liners. The liners are placed into the fixture plate to insure extremely accurate positioning. If more than two shanks are required (to provide additional hold down force), omit the liner bushing so that these additional holes will not interfere with your primary locating holes. See page 42 for Fast Acting s. Maximum Screw Holddown Torque Force (N.m) (KN) B Recommended Screw Holddown Torque Force (N.m) (KN) Repair Kit Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

35 METRIC DIMENSIONS - METRIC BALL LOCK COMPONENTS Receiver Bushings Two styles of receiver bushings are available. Installed bushings should be approximately 0.3mm below subplate surface. Face Mount Max. Corner Radius 0.5mm Installation Dimensions Face Mount Dia. (mm) Face Mount Actual O.D Clearance Drill Diameter E Bore F Depth G 1 Cap Screws Supplied with Face Mount Bushings. Face Mount Bushing Installation Instructions Generally, the face mount receiver bushing is utilized in blind hole applications (Slip Fit). Liner Bushings for Fixture Plates Locating repeatability will determine if one primary and one secondary or two primary liners are needed. With two primary liners, repeatability of ±0.013 mm can be maintained if the two holes for receiver bushings are held to a centerline distance of ±0.005 mm tolerance. Note on Installation of Press Fit Liners & Back Mount Style Receiver Bushings: To alleviate the possibility of binding the shank in the bore, the maximum interference fit between bore and bushing O.D. should not exceed mm. Tap Size & Depth 1 H M4x0.7 x 7 M4x0.7 x 7 M5x0.8 x 9 M6x1.0 x 10 M6x1.0 x 11 M8x1. x 17 M10x1.5 x 18 H Tap 3 Holes Equally Spaced On Bolt Circle Dia. Bolt Circle Diameter 3 PL Equally Spaced Max. Corner Radius 0.5mm Min. Subplate Thickness D Liner Dimensions Diameter (mm) Fixture Plate Thickness Back Mount Dia. (mm) Back Mount Bushing Installation Instructions Back Mount Actual O.D A Depth B Back Mount The back mount receiver bushing is used in through hole applications (Light Press Fit). Primary Liner I.D Secondary Liner I.D C-Bore ±0.15 C Min. Subplate Thickness D Liner O.D METRIC QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 39

36 METRIC DIMENSIONS - METRIC BALL LOCK COMPONENTS METRIC Stainless Steel Locating and Clamping s Material: 17-4 PH Stainless Steel Heat Treat: Rc Operating Temperature Range: -30 C to 0 C D C B QUICK CHANGE FIXTURING» BALL LOCK U.S. Patents: 3,498,653 4,135,418 Replacement Kits Stainless Steel Locating and Clamping Dimensions Diameter (mm) A Fixture Plate Thickness ±0.13mm Head of Height Diameter B C D 49655SS 49656SS 49657SS 49658SS 49651SS 49652SS 49661SS 49662SS 49671SS 49672SS 49681SS 49682SS 49683SS 49684SS 49691SS 49692SS 49693SS 49694SS Each Kit Includes: Replacement Screw Locking Balls Drive Ball O-Ring Hex Wrench Size For Set Screw A Any Ball Lock application requires at least two sets of shanks, receiver bushings and liners. The liners are placed into the fixture plate to insure extremely accurate positioning. If more than two shanks are required (to provide additional hold down force), omit the liner bushing so that these additional holes will not interfere with your primary locating holes. Maximum Screw Holddown Torque Force (N.m) (KN) Recommended Screw Holddown Torque Force (N.m) (KN) Repair Kit 49955SS 49956SS 49957SS 49958SS 49951SS 49952SS 49961SS 49962SS 49971SS 49972SS 49981SS 49982SS 49983SS 49984SS 49991SS 49992SS 49993SS 49994SS 40 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

37 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Stainless Steel Receiver Bushings Two styles of receiver bushings are available. Installed bushings should be approximately 0.3mm below subplate surface. Face Mount Max. Corner Radius 0.5mm Installation Dimensions Face Mount Dia. (mm) Face Mount Actual O.D Clearance Drill Diameter E Cap Screws Supplied with Face Mount Bushings. H Tap 3 Holes Equally Spaced On Bolt Circle Dia. Face Mount Bushing Installation Instructions Generally, the face mount receiver bushing is utilized in blind hole applications (Slip Fit) SS 49557SS 49551SS 49552SS 49553SS 49554SS 49555SS Bore F Depth G Stainless Steel Liner Bushings for Fixture Plates Locating repeatability will determine if one primary and one secondary or two primary liners are needed. With two primary liners, repeatability of ±0.013 mm can be maintained if the two holes for receiver bushings are held to a centerline distance of ±0.005 mm tolerance. Note on Installation of Press Fit Liners & Back Mount Style Receiver Bushings: To alleviate the possibility of binding the shank in the bore, the maximum interference fit between bore and bushing O.D. should not exceed mm. Tap Size & Depth 1 H M4x0.7 x 7 M4x0.7 x 7 M5x0.8 x 9 M6x1.0 x 10 M6x1.0 x 11 M8x1. x 17 M10x1.5 x 18 Bolt Circle Diameter 3 PL Equally Spaced Max. Corner Radius 0.5mm Min. Subplate Thickness D Liner Dimensions Diameter (mm) Fixture Plate Thickness Back Mount Dia. (mm) Back Mount Bushing Installation Instructions Back Mount 49566SS 49567SS 49561SS 49562SS 49563SS 49564SS 49565SS Actual O.D A Depth B SS 49856SS 49857SS 49858SS 49851SS 49852SS 49861SS 49862SS 49871SS 49872SS 49881SS 49882SS 49883SS 49884SS 49891SS 49892SS 49893SS 49894SS Back Mount The back mount receiver bushing is used in through hole applications (Light Press Fit). Primary Liner 49755SS 49756SS 49757SS 49758SS 49751SS 49752SS 49761SS 49762SS 49771SS 49772SS 49781SS 49782SS 49783SS 49784SS 49791SS 49792SS 49793SS 49794SS I.D Secondary Liner I.D C-Bore ±0.15 C Min. Subplate Thickness D Liner O.D METRIC QUICK CHANGE FIXTURING» BALL LOCK Phone: Fax: workholding@jergensinc.com 41

38 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES METRIC Accessories Tapered Caps and Plugs Keep debris out of your subplate s receiver bushings when not in use. Polyethylene caps snap in and out easily. Packaged 10 per pack. Receiver Bushing Diameter Lifting Handles For easy handling of fixture plates up to 500 lbs. Length Ht. W Mounting Distance mm 36mm.38 Kg 93.47mm QUICK CHANGE FIXTURING» BALL LOCK Multi-Slot Sine Fixture Keys Locate subplates or fixture plates to slotted machine tables without having to slot the plate. Available in sizes from 12mm to 32mm slots. Fast Acting Ball Lock s FAST ACTING BALL LOCK SHANKS Key Width Size A B C D Wt. (lbs) Recommended Hole Dia. 16mm Size / mm Size / mm Size /-0.01 mm Size.01 +/-0.01 Previous s 39550, , , 39553, , 39558, Ball Lock Diameter (mm) Fixture Plate Thickness (mm) with Thumb Screw with Adjustable Handle Assenbly T-Screw Assenbly Handle S H S H S H S H S H S H S H S H S H S H S H S H Fast acting thumb screws 2 1/2 turns. No tools needed. Thumb Screw Adjustable Handle Handle can be moved out of the work area to avoid interference. 42 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

39 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Quick Change Kits Everything You Need to Change Fixtures in Less Than One Minute Aluminum Fixture Plate 16mm Bored Hole for Sine Fixture Keys mm Ball Lock The Jergens Ball Lock Quick Change Kits speed fixture changeover in all types of manufacturing operations. Each kit includes two aluminum fixture plates with 2 primary liner bushings installed; one steel subplate with receiver bushings installed, and four mm Ball Lock shanks with working loads of 3000 lbs. each. While one fixture plate is on the machine, the operator can load parts on the other. This minimizes downtime for true set-up reduction. To enable the subplate to be mounted on a slotted table without the need to indicate the subplate, sine fixture keys can be used. The sine fixture key reamed holes are oriented parallel to the receiver bushings on the subplate and to the liner bushings on the fixture plate. These also allow the fixture plate to be mounted on a toolroom mill without the need to indicate it. This is extremely useful when machining location points on your fixture. Quick Change Kits No. Kit Includes BALL LOCK (400x400x) aluminum fixture plates with mm liner bushings installed (400x400x) steel subplate with receiver bushings installed 4 - mm Ball Lock s (49651) METRIC QUICK CHANGE FIXTURING» BALL LOCK Steel Subplate 16mm Bored Hole for Sine Fixture Keys (2) mm Primary Liner Bushings Installed (4) mm Receiver Bushings Installed Custom Kits Available Jergens manufactures ready to use kits including Ball Lock subplate and fixture plates. For a special kit tailored to your CNC machine, please provide: Name and Type of Machine Travel of Machine Table (x, y, z) Dimensions of Machine Table (x and y) Maximum Weight allowed on Machine Table T-slot Width and Center to Center Distance Phone: Fax: workholding@jergensinc.com 43

40 METRIC DIMENSIONS - METRIC FIXTURE/SUBPLATES Bock Brand Locator Plate System Bock Locator Plates give you the ability to mount and locate Bock Twin Vises, and to change their size, type, number and position in minutes. Using Bock s DexLoc Double-Expanding Locator Pins gives you repeatability of +/-.0005". Bock Locator Plates are made from precision machined aluminum or steel with a grid of locating/mounting holes. Each hole is identified by a letter and a number. Bock Twin Vises with standard interlocking base gives you great flexibility at tremendous setup speeds while Bock SlimLine Twin Vises give you the possibility to mount vises very close to each other for maximum number of parts in the machine. Each Locator Plate is custom-made for your particular application. Need a prompt quote? Call (877) with your specifications. QUICK CHANGE FIXTURING» BALL LOCK Bock Brand Locator Plates Repeat setups to within +/-.001" Locator Plates are available in a wide array of sizes, both in inch and metric dimensions. Jergens Bock Brand Locator Plates are made of hard coated aluminum for a durable surface Alpha-numeric coded holes for an accurate and repeatable baseline reference Compatible Machine Thickness (in) Size (in) Material HAAS VF x 36 Aluminum Robodrill x 27.5 Aluminum 9344 Mazak VTC0B 1.42 x 57.5 Aluminum HAAS VE-2YT x 36 Aluminum Every hole precision bored to fit Dex-Loc locating pins and threaded through for maximum versatility Brass protection plugs included for every hole Eliminate time consuming "dialing in" for every setup DexLoc Locator Pins Patented DexLoc doubleexpanding locator pins allow for fast and accurate location of twin vises on locator plates. Self-centering pins relocate within +/-.0005" Available in a wide variety of standard sizes and materials To order DexLoc Locator Pins in other sizes, please refer to page <?>. PAGE NUMBER REFERENCE? Standard Hex Key Size (in) Diameter Height Top Bottom /8 1-1/4 7/32 3/16 Metric Hex Key Size (mm) Diameter Height Top Bottom Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

41 ZERO POINT Features of the Jergens Zero Point Mounting System Positioning and clamping in one operation High repeatability and accuracy Low cost solution for quick pallet changing Typical applications for the Jergens Zero Point System: Milling Assembly Welding Injection Molding Grinding Measuring ZPS ZERO.POINT.SYSTEM QUICK CHANGE FIXTURING» ZERO POINT Pull Studs can also be installed directly into the workpieces, making 5-sided processing possible. Best results with large and heavy workpieces. Jergens Zero Point clamping systems are made exclusively of rust-free materials and so are ideally suited for use in the food-service area as well as in the pharmaceutical and chemical industry. Through different dimensions, the advantage of the Zero Point clamping system are optimally used. Phone: Fax:

42 ZERO POINT Pull Studs and Engagement Screws Pages Clamping Plates with Built-In Modules Pages QUICK CHANGE FIXTURING» ZERO POINT Clamping Modules Machine tables Plates 4-axis/5-axis machining Columns Pallets Surface/Mounted Clamping Modules For large & heavy workpieces Pull Studs installed directly into workpiece Flange Type Module with Centering & Cover Rings Pages Pages Page Used to fasten surface-mounted clamping modules on the machine table Hydraulic release with or without blowout Horizontal Rapid-Clamping Module For easy handling of heavy fixtures Page Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

43 ZERO POINT Jergens Zero Point Mounting System Cut Set-up Times by Up to 90%. Fix, Position and Clamp in a Single Step with Jergens Zero Point Mounting System. Jergens is proud to introduce the best-engineered Zero Point Mounting System (ZPS) on the market. This revolutionary technology cuts set-up time by up to 90% by combining fixing, positioning and clamping in a single operation. Available with either pneumatic or hydraulic release, these positive locking locating modules allow operators to quickly change out large and small machine fixtures with extreme accuracy and minimal effort. Other features include: Repeatability <0.005mm (0.0002") Minimizes set-up time Hardened stainless (AISI 440B) steel construction Integrated safety system Compact design Positive locking High retaining force K40 ø148mm Pull-in / Locking Force up to 40kN / 9000lbs. Smart Features for Process Improvement K ø112mm Pull-in / Locking Force up to kn / 4530lbs. Reduce set-up times and increase both accuracy and repeatability with design features exclusive to the Jergens ZPS: Self Guiding K10 ø78mm K5 ø45mm Pull-in / Locking Force Pull-in / Locking Force up to 10kN / 2290lbs. up to 5kN / 1100lbs. QUICK CHANGE FIXTURING» ZERO POINT The self-guiding, tapered profile of the mounting stud allows heavy plates to be installed more easily. Alignment Unique design eliminates the need for perfect lifts on entry and exit. Phone: Fax: workholding@jergensinc.com 47

44 ZERO POINT Mechanical Locking System Experience high holding force without the need to maintain hydraulic pressure. Large Ball Diameter QUICK CHANGE FIXTURING» ZERO POINT Provides increased strength and even load distribution. No Ball Cage Free movement of the bearing balls reduces friction. Form Fit Ball Channel Tapered contact areas eliminate point loads and reduce failures. Three-Point Load Distribution Equal load spacing optimizes force distribution. Integrated Safety System Process-sure clamping module can always be opened, eliminating the need to forcibly remove modules if a failure should occur. 48 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

45 ZERO POINT Clamping and Positioning On each fixture use: 1 Zero Point Pull Stud 1 Timing Pull Stud The Zero Point and Timing Stud should be perpendicular Use any combination of clearance and/or protection Pull Stud ZERO POINT PULL STUD CLEARANCE PULL STUD FOR HOLD DOWN Dimensions for machining pull stud mountings CLEARANCE PULL STUD FOR HOLD DOWN TIMING PULL STUD Size ØD1 ØM S1 S2 K5 10 M K10 15 M K M K40 M Note: Pull Stud with internal thread for clamping from above Pull Studs with different diameter D1, preventing interchange of the Zero Point, timing and clearance Pull Stud during installation. Pull Stud for series production, (notch type), Floating Pull Stud for compensation of thermal expansion Automatic lifting of the pallet / fixture QUICK CHANGE FIXTURING» ZERO POINT Figure: Shown with Pull Stud and engagement screw Phone: Fax: workholding@jergensinc.com 49

46 ZERO POINT 2-Way Clamping Station Hydraulic Unlocking Repeatability < mm (0.0002") QUICK CHANGE FIXTURING» ZERO POINT Pull-In/Locking Force Size up to kn / (lbs) A B HA K L L1 ØN R S SM Kg x / (2 x 4500) G1/ x 40 / (2 x 9000) G1/ All linear dimensions in (mm) Note: On request, we can incorporate mounting holes to your requirements in the base plate. Other dimensions, gauges and number of clamping module layouts on request. 4-Way Clamping Station Hydraulic Unlocking Repeatability < mm (0.0002") Size Pull-In/Locking Force up to kn / (lbs) A B HA K L L1 ØN R S SM Kg x / (4 x 4500) G1/ x 40 / (4 x 9000) G1/ All linear dimensions in (mm) Note: On request, we can incorporate mounting holes to your requirements in the base plate. Other dimensions, gauges and number of clamping module layouts on request. 50 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

47 ZERO POINT Pull Studs K5 Modules Hardened Stainless Steel, for hydraulic and pneumatic clamping modules Zero Point Timing Clearance Protection Pull Stud K10 Modules Hardened Stainless Steel, for hydraulic and pneumatic clamping modules K Modules Hardened Stainless Steel, for hydraulic and pneumatic clamping modules Engagement Size Description ØDN ØD1 ØD2 H H1 M T g Screw PN K5 Zero Point Stud K5 Timing Stud K5 Clearance Stud K5 Protection Plug M Engagement Size Description ØDN ØD1 ØD2 H H1 M T g Screw PN K10 Zero Point Stud K10 Timing Stud K10 Clearance Stud K10 Protection Plug M Engagement Size Description ØDN ØD1 ØD2 H H1 M T g Screw PN K Zero Point Stud K Timing Stud K Clearance Stud K Protection Plug M QUICK CHANGE FIXTURING» ZERO POINT K40 Modules Hardened Stainless Steel, for hydraulic and pneumatic clamping modules Engagement Size Description ØDN ØD1 ØD2 H H1 M T g Screw PN K40 Zero Point Stud K40 Timing Stud K40 Clearance Stud K40 Protection Plug M8 180 Phone: Fax: workholding@jergensinc.com 51

48 ZERO POINT Engagement Screws For Pull Studs Strength class 10.9 For installation and surface mounted clamping modules Size M L L1 g K5 M K10 M K M K40 M QUICK CHANGE FIXTURING» ZERO POINT Pull Stud Clamping Nuts Size M SW H Weight K5 M K10 M K M K40 M Floating Pull Stud Hardened for hydraulic and pneumatic clamping modules Size Description ØDN ØD2 H1 g K10 Zero Point Stud K Timing Stud K40 Clearance Stud Note: The floating pull stud is supported by bearings so that it is axially mobile and is used when large distance and angle tolerances between the stud holes have to be compensated. The stud has only a holding function and does not take on any lateral load. Engagement Screw For Floating Pull Stud Strength class 10.9 Size Description ØD2 M L L1 L2 L3 g K10 Zero Point Stud 11.0 M K Timing Stud 13.5 M K40 Clearance Stud 17.0 M Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

49 ZERO POINT K2 Installation Clamping Module The compact size of the Jergens Mini ZPS Module is perfect for applications where space is limited and accuracy and speed of changeover time is required. Mechanical Lock / Pneumatic Unlock Opening operating pressure: min. 6 bar - max. 14 bar (87psi - 3psi) Repeatability <0.02 mm ( in) Installation Diagrams Available by Request Size Pull-in Locking Force up to kn / (lbs) K2 Pull Stud Hardened for pneumatic clamping module Holding Force kn / (lbs) D DN D1 D2 D3 H HA T T1 T2 Size Version DN D1 H H1 M T 4-Way Clamping Station Pneumatic Aluminum body, anodized Repeatability <0.02 mm ( in Net Weight (kgs) K2 Zero Point Stud M K2 Timing Stud M K2 Clearence Stud M Net Weight (kgs) K2 235 / (53) 6000 / M x M Installation Diagrams Available by Request QUICK CHANGE FIXTURING» ZERO POINT Size Opening Pull-in Locking Force up to kn / (lbs) Holding Force kn / (lbs) A B C G H J dia. K S SM K2 Pneumatic 4 x.235 / (53) 4 x 6 / (1349) M Net Weight (kgs) K2 Machineable Block High-strength aluminum, anodized Size A B S SM Net Weight (kgs) K Phone: Fax: workholding@jergensinc.com 53

50 ZERO POINT Threaded Clamping Modules (K5) Screw-In Version Hydraulic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") QUICK CHANGE FIXTURING» ZERO POINT Hardened Stainless Steel With a small footprint for installation in base plates, machine tables, clamping profiles, columns and towers, swivel bridges, machine pallets and clamping pallets. Installation diagrams on request Size Pull-In/Locking Holding Force Force up to kn / (lbs) kn / (lbs) ØD ØDN ØD1 H HA ØLK T g K5 5 / (1100) 13 / (2900) M45 x All linear dimensions in (mm) Note: Threaded clamping module with a low installation height of 19.8 mm and an installation diameter of 45 mm (M45 x 1). Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 7psi, max. 60 bar / 870psi). The threaded clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping Screw-in Version Pneumatic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") With a small footprint for installation in base plates, machine tables, clamping profiles, columns and towers, swivel bridges, machine pallets and clamping pallets. Pneumatic modules are optimally suited for use in the food, pharmaceutical and chemical industries, as well as in oil-free applications. Installation diagrams on request Hardened Stainless Steel Size Pull-In/Locking Holding Force Force up to kn / (lbs) kn / (lbs) ØD ØDN ØD1 H HA ØLK T g K5 1.5 / (330) 13 / (2900) M45 x All linear dimensions in (mm) Note: Threaded clamping module with a low installation height of 19.8 mm and an installation diameter of 45 mm (M45 x 1). Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The threaded clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 54 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

51 ZERO POINT Installation Clamping Modules (K10, K, K40) Hydraulic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") Hardened Stainless Steel Pneumatic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") With a small foot-print for installation in base plates, machine tables, clamping profiles, columns and towers, swivel bridges, machine pallets and clamping pallets. Installation diagrams on request Pull-in/locking Holding force Size force up to kn / (lbs) kn / (lbs) Blow out ØD ØDN ØD1 H HA ØLK M T Kg K10 10 / (20) / (56) Yes M K / (4500) 55 / (12350) Yes M K40 40 / (9000) 105 / (23600) Yes M All linear dimensions in (mm) Note: Threaded installation clamping modules have high holding and pull-in forces with very small installation dimensions. Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 7psi, max. 60 bar / 870psi). The threaded clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping With a small footprint for installation in base plates, machine tables, clamping profiles, columns and towers, swivel bridges, machine pallets and clamping pallets. Installation diagrams on request QUICK CHANGE FIXTURING» ZERO POINT Hardened Stainless Steel Pull-In/Locking Holding Force Size force up to kn / (lbs) kn / (lbs) Blow out ØD ØDN ØD1 H HA ØLK M T Kg 4802 K10 8 / (1800) / (56) Yes M K 17 / (3800) 55 / (12350) Yes M K40 30 / (6700) 105 / (23600) Yes M All linear dimensions in (mm) Note: The installation clamping modules have high holding and pull-in forces with very small installation dimensions. Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. Phone: Fax: workholding@jergensinc.com 55

52 ZERO POINT Installation Clamping Modules (K10, K) with Indexing Low Pressure Pneumatic Unlocking Cover and piston hardened. Repeatability < mm ( ) With a small fooprint for installation in base plates, machine tables, clamping profiles, columns and towers, swivel bridges, machine pallets and clamping pallets QUICK CHANGE FIXTURING» ZERO POINT Size Pull-in Locking Force up to kn / (lbs) Holding Force kn / (lbs) Unclamp Pressure Blow Out D DN D1 H HA LK M T K / (20) / (56) 72 psi (5 bar) Yes M K.3 17 / (3800) 55 / (12350) 66 psi (4.5 bar) Yes M All linear dimensions in (mm) Note: The installation clamping modules have high holding and pull-in forces with very small insatallation dimensions. Pneumatic pressure is needed for unclamping ( min 4.5 bar/ 66 psi). The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines or dangers of leakage. The pneumatic design has 1 connection for unclamping and 1 optional connection for blowout. Clamping Modules with Sensors Net Weight (kgs) Size Pull-in Locking Force up to kn / (lbs) Holding Force kn / (lbs) DA D DN H HA K LK M MH7 R Net Weight (kgs) (20) (56) G1/ (3800) 55 (12350) G1/ Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

53 ZERO POINT Surface/Mounted Clamping Modules (K5) Hydraulic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") For mounting on machine tables, clamping profiles, columns and towers, measuring machines, assembly stations. Stainless Steel Pull-In/Locking Holding Force Size Force up to kn / (lbs) kn / (lbs) ØB ØD ØDB ØDN HA K R g K5 5 / (1100) 13 / (2900) G1/8 300 All linear dimensions in (mm) Note: Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 7psi, max. 60 bar / 870psi). The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping Pneumatic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") For mounting on machine tables, clamping profiles, columns and towers, measuring machines, assembly stations. QUICK CHANGE FIXTURING» ZERO POINT Hardened Stainless Steel Pull-In/Locking Holding Force Size Force up to kn / (lbs) kn / (lbs) ØB ØD ØDB ØDN HA K R g K5 1.5 / (330) 13 / (2900) G1/8 300 All linear dimensions in (mm) Note: Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. Phone: Fax: workholding@jergensinc.com 57

54 ZERO POINT Surface/Mounted Clamping Modules (K10, K, K40) Hydraulic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") For mounting on machine tables, clamping profiles, columns and towers, measuring machines,assembly stations in connection with clamping bracket on page 59. QUICK CHANGE FIXTURING» ZERO POINT Hardened Stainless Steel Pull-In/Locking Holding Force Size Force up to kn / (lbs) kn / (lbs) Blow out ØD ØDB ØDN HA K R Kg K10 10 / (20) / (56) Yes G1/ K / (4500) 55 / (12350) Yes G1/ K40 40 / (9000) 105 / (23600) Yes G1/ All linear dimensions in (mm) Note: Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 7psi, max. 60 bar / 870psi). The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. Further more, there are no cumbersome lines and no danger of leakage. The contact surface is the upper surface of the housing. The hydraulic design has 1 connection: 1 x unclamping Pneumatic Unlocking Cover and piston hardened. Repeatability < mm (0.0002") For mounting on machine tables, clamping profiles, columns and towers, measuring machines,assembly stations in connection with clamping bracket on page 59. Hardened Stainless Steel Pull-In/Locking Holding Force Size Force up to kn / (lbs) kn / (lbs) Blow out ØD ØDB ØDN HA K R Kg K10 8 / (1800) / (56) Yes G1/ K 17 / (3800) 55 / (12350) Yes G1/ K40 30 / (6700) 105 / (23600) Yes G1/ All linear dimensions in (mm) Note: Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 58 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

55 ZERO POINT Clamping Bracket for Surface/Mounted Clamping Modules Black Nitrided Clamping flanges are used to fasten raised/mounted clamping modules on the machine table. See pages Special clamping flanges for various T-slot tables Clamping flange and housing manufactured as a single piece Stainless Steel Pieces Size Per Module ØD ØDB H ØLK M g All linear dimensions in (mm) Flange Type Installation Modules with Centering and Cover Rings Features: Oil supply by pipes or manifolds Integrated centering Provided as assembled unit Benefits: Simple design and manufacturing of adaptor plate Weight saving due to less thickness for adaptor plate Easy to adapt to existing mounting angles and cubes QUICK CHANGE FIXTURING» ZERO POINT Installation comparison Standard Clamping Module Cover Ring Flange Type Module Oil Oil Installation Module Centering Ring Oil Supply by Pipes Base Plate Oil Supply by Manifold No seal face needed centering only Sealing face O-ring Phone: Fax: workholding@jergensinc.com 59

56 ZERO POINT Flange Type Installation Modules with Centering and Cover Rings Hydraulic Release Cover and piston hardened. Repeatability < mm (0.0002") QUICK CHANGE FIXTURING» ZERO POINT Hardened Stainless Steel Pull-In/Locking Holding Force Size force up to kn / (lbs) kn / (lbs) Blow out ØDA ØDN ØD1 HA K ØLK M R T Kg K10 10 / (20) / (56) Yes M5 G1/ K / (4500) 55 / (12350) Yes M6 G1/ K40 40 / (9000) 105 / (23600) Yes M8 G1/ All linear dimensions in (mm) Note: Combines features of the Threaded Module and Raised/Mounted module. Especially designed when installation space is limited and base plate or angle plate has relatively thin dimensions. The positioning of the module is simple and accurate when using the precision flange diameter. Hydraulic supply is possible by manifolds or pipes/ hoses. Hydraulic supply and pressure is only needed for unclamping (min. 50 bar / 7psi, max. 60 bar / 870psi). The module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The hydraulic design has 1 connection: 1 x unclamping Pneumatic Release Cover and piston hardened. Repeatability < mm (0.0002") Hardened Stainless Steel Pull-In/Locking Holding Force Size force up to kn / (lbs) kn / (lbs) Blow out ØDA ØDN ØD1 HA K ØLK M R T Kg K10 8 / (1800) / (56) M5 G1/ K 17 / (3800) 55 / (12350) M6 G1/ K40 30 / (6700) 105 / (23600) M6 G1/ All linear dimensions in (mm) Note: Combines features of the Threaded Module and Raised/Mounted module. Especially designed when installation space is limited and base plate or angle plate has relatively thin dimensions. The positioning of the module is simple and accurate when using the precision flange diameter. Pneumatic supply is possible by manifolds or pipes/hoses. Pneumatic pressure is needed for unclamping ( min 8 bar/ 116 psi, max 12 bar/ 175 psi). For clamping process pneumatic pressure of min 5 bar / 75 psi, max 6 bar / 90 psi is required briefly in order to achieve defined pull-in force. The installation clamping module is mechanically locked in the clamped position. The unique mechanical locking system results in virtually no vibration even with extensive machining forces. The pneumatic design has 2 connections: 1 x unclamping / 1 x clamping. 60 Jergens, Inc S. Waterloo Road Cleveland, Ohio USA

57 ZERO POINT Manual ZPS Ideal when Pneumatic and Hydraulic connections are not available The manual ZPS modules provide locating and clamping with single bolt actuation. The indexing slots on the face of the modules allow workpieces to be indexed in 90 increments. Indexing slot plugs are available for applications where only specified slots are needed. to Mechanical clamping and unclamping Quenched and tempered steel Repeatability 0.01 mm ( in.) Single Hex Drive Actuation Flexible Mounting & Placement Two Sizes Available K10 & K Eliminates Need for Air or Hydraulic Connection Size Pull-in / Locking Force kn / (lbs) Holding Force kn / (lbs) Tightening Torque Nm / (ft. lbs) D D1 ±.01 D2 DN E1 G H ±.01 H1 H2 H3 K F6 L R S1 SW Weight (Kgs) 5508 K10 6 (1349) (56) 30 (22.1) ,5 M K 10 (2248) 55 (12364) 30 (22.1) ,0 M , , QUICK CHANGE FIXTURING» ZERO POINT Phone: Fax: workholding@jergensinc.com 61