ZX420-TC Facing & Contouring Head Service Manual
Contents
1. f 2 x JIL 7 St Matas eae St j Fa TIS il N a Fig 1 02 camlocs in their open position and aligned with camloc studs 3 Wind out the inner spindle of the machine so that it protrudes from the bonnet face 4 Make sure that the ZX420 head taper and the machines inner spindle taper are thoroughly clean 5 Locate the shank of the ZX420 head into the taper of the machines inner spindle and clamp it into the spindle using the machines pull stud or draw bar arrangement See fig 1 03 INNER SPINDLE WOUND FORWARD AND ZX420 HEAD TAPER CLAMPED INTO SPINDLE Fig 1 03 Locating and clamping the ZX420 head into the inner spindle 6 Slowly wind back the inner spindle locating the ZX420 head into the bonnet until the mating faces are just clear or touching each other 7 Clamp the ZX420 head into the bonnet by depressing the camlocs then using an allen key turn the camlocs into their locked position A As GA MEN 8 Remove the sling that was used to2. ADJUSTING SCREWS DETAIL 31 Fig 2 03 Gib strip adjustment 2 The actuator should centralize the slide in the main body 3 Tighten the adjusting screws detai 37 until the gib strips grip the cross slide 4 Carefully slacken the adjusting screws detail 31 until minimum clearance is achieved See fig 2 03 11 Dismantling amp Assembly 1 4 Remove contouring head from the machine reverse procedure as described in chapter one installation of head Remove any tooling fitted to the cross slide making sure to carefully mark the tooling position on the cross slide for accurate re assembly Remove five caphead screws detail 107 from each keeper plate detail 1 on the front of the contouring head both left hand and right hand keeper plates Make careful note of which keeper plate if fitted to which side of the body to ensure correct re assembly CEO c O fh Fig 1 Whilst pressing the plunger detail 30 actuate the shank detail 16 fully forwards thus pushing the cross slide and attached toolslide details 4 amp 5 forwards also to enable their removal from the head The cross slide and attached toolslide can now be pulled off the actuator detail 7 in a diagonally upwards direction away from the main body A gt Soo CS ae 4 Fig 3 12 5 Remove four caphead screws detail 106 securing the adaptor nose detail
3. 0058 2 542 14 4 20 ZX420 CON FACING amp CONTOURING HEAD SERVICE MANUAL Torque Settings The values are based on black finish allov screws ZX 420 Con Torque Detail Thread 65 Pullstud M24 or 1 UNC Keeper plate cap head Screw Slipper key cap head Screw Tool slide cap head screw The above table is intended for general guidance only In practice the actual torque tightening values can vary on whether the screws are lubricated or not Common sense should prevail in the application of the above values Another method of determining the correct torque is to tighten the screw with an Allen key hexagon wrench to finger tight and then a further 30 past this position Cogsdill Nuneaton will not take any responsibility for miss use of this information which leads to damage of the ZX420 head tooling or personal injury 21 ZX420 CON FACING amp CONTOURING HEAD SERVICE MANUAL Chapter General Assembly Drawing amp Parts List e General assembly drawing of ZX420 TC head ZX420 TC GA e Parts list for to be used in conjunction with the above drawing e Standard tooling for the ZX420 TC head 22
4. 14 to the main body detail 6 Now pull the adaptor nose off approximately 12 to 20mm this will give access to the coolant connector block detail 18 6 Accessing through the 12 to 20mm gap between the main body detail 6 and adaptor nose detail 14 actuate the shank backwards until the two caphead screws detail 117 securing the coolant block detail 18 to the actuator detail 7 can be seen through the gap Loosen these two caphead screws detail 117 but do not remove them Fig 6 7 The adaptor nose detail 14 can now be carefully pulled off the back of the main body detail 6 Make sure to pull the adaptor nose off squarely or damage to the plunger detail 30 and coolant connector block detail 18 will occur Fig 7 13 9 10 11 12 13 The plunger detail 30 and spring detail 125 scated behind the plunger can now be pulled out the back of the head At this point the spring cap detail 29 on the side of the head can be unscrewed and removed This will allow removal of the spring detail 134 locking pin detail 28 and ball bearing detail 124 The actuator detail 7 can now be pulled out of the back of the head Taking care not to damage the plunger detail 30 and coolant connector block detail 18 Once the actuator is removed check the seals on the attached coolant connector block details 101 102 amp 104 for wear or damage replace as required
5. Check actuator keys detail 9 for wear or damage If required remove the keys from the actuator detail 7 by removing the caphead screws detail 15 amp 115 Make note of which key fitted to which actuator slot prior to removal Also note position the caphead screw detail 15 as this is also a lube access point to the keys Assembly is the reverse of steps 1 10 Important on step 6 do not fully tighten caphead screws detail 117 securing the coolant connector block detail 18 to the actuator detail 7 until the coolant connector block detail 18 is fully engaged and self centred in the hole in the main body detail 6 Once assembled adjust the gib strips as detailed in chapter two gib strip adjustment 14 Recommended Spares To minimise downtime of your ZX420 head we recommend you carry spare parts Below is a list of the main spare items that may need replacement through normal wear and tear The spare parts can be fitted by you the customer e Actuator ZX420 10 e Toolslide ZX 420 05 e Slipper keys ZX420 TC 20 e O Ring Set Note In the event of the ZX420 head being damaged we strongly advise customers to return it to Cogsdill Nuneaton for evaluation and repair 15 Lubrication Recommendations The ZX 420 head requires regular maintenance whilst being used and should be cleaned free from swarf and any other foreign matter To ensure the ZX420 con remains in good working order it is recommend that the interna
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7. Hi COGSDILL NUNEATON LTD Precision Engineers ZX420 TC Facing amp Contouring Head Service Manual PRECISION ENGINEERS ZX420 TC Facing amp Contouring Head Service Manual Cogsdill Nuneaton Ltd Tenlons Road Nuneaton England Phone 44 0 2476 383792 Fax 44 0 2476 344433 Email sales cogsdill co uk Table of Contents Customer Order Details Introduction CHAPTER 1 Installation of Head CHAPTER 2 Camloc Adjustment Gib Strip Adjustment CHAPTER 3 Dismantling amp Assembly CHAPTER 4 Recommended Spares CHAPTER 5 Lubrication Recommendations CHAPTER 6 Torque Settings CHAPTER 7 Recommended Spares 10 11 12 15 16 21 22 Customer Order Details Customer When contacting Cogsdill Nuneaton Quote No for information about your order please have this sheet to hand Works Order No Sales Order Processing No Additional Notes and Related Tooling Introduction spindles such as horizontal boring machines with C N C controls The combination of the spindle feed z axis and the workpiece w axis enables most profiles to be accurately machined The independent spindle feed z axis is utilised to actuate the feed out mechanism in the facing head Different makes of horizontal boring machine or machining centre will have different home positions for their inner spindle Shank gauge line to the spindle nose face Cogsdill Nuneaton s facing heads are indivi
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11. dually set to suit cach customer s machines if our standard home position will not fit C ogsdill Nuneaton s Facing heads are designed to work on machines with live Use the Cogsdill Nuneaton facing and contouring heads to machine large castings or components that are awkward for holding or rotating for conventional machining External turning grooving taper boring radius forming chamfering recessing threading can all be finished in one set up without removing the workpiece from the machine tool table Cogsdill Nuneaton s development of quality tooling and pursuit for continuous improvement in our product lines has now resulted in a proven rugged design for it s facing heads All moving parts are precision ground and heat treated to ensure lasting accuracy with next to no backlash Oilways are built into internal slide mechanisms and lubrication is through easily accessible grease nipples Cross slides and actuators may be coated with a friction reducer to reduce actuation pressures resulting in improved machining capabilities and reduced wear to critical parts upon request When you the customer feel it necessary to design and manufacture your own tooling please feel free to consult us about your intention We can provide any information to you that you might need Our aim is to serve and satisfy you the customer please take advantage of this offer Suitable for Horizontal Boring Machines with Size 5 6 amp 7 Inch Spind
12. erland Kl ber Lubrication AG SCHWEIZ Thurgauerstrasse 39 CH 8050 Zurich Tel 01 308 69 69 Fax 01 308 69 44 Thailand TEXMAC Co Ltd Kl ber Division Texmac Building 912 Stinakarin Road Suanluang Suanluang Bangkok 10250 G P 0 Box 1594 Bangkok 10501 Thailand Tel 02 3218730 42 Telex 87917 texmac th Fax 02 3227893 Turkey Kl ber Lubrication YAGLAMA R NLERI SAN VE TIC A S Korukent Al Blok D 2 80600 Levent Istanbul Tel 0212 273 14 49 275 05 50 Fax 0212 267 23 67 United Kingdom Kl ber Lubrication Great Britain Ltd Hough Mills Northowram Halifax HX3 7BN Tel 01422 205115 Fax 01422 206073 Email sales uk kluber com United States of America Kl ber Lubrication North America L P 54 Wentworth Avenue Londonderry N H 03053 7437 Tel 603 434 7704 Fax 603 434 8046 Summit Industrial Products Inc 9010 County Road 2120 Tyler Texas 75707 POB 131359 Tyler Texas 75713 Tel 903 534 8021 Fax 903 581 4376 Uruguay Marx Representaciones Ltda Lieja 6962 P O Box 18948 Distrito No 9 C P 11500 Montevideo Tel 02 60 06 81 Fax 02 60 04 82 Vietnam Hantexmac Enterprice 340K Hoang Van Thu Street Ward 4 Tan Bihn District HO CHI MINH CITY VIETNAM Tel 0084 8 8850485 8850486 8850487 Fax 0084 8 8457 391 Venezuela Sutexma SA Dr Paul a Chorro 31 Edif Blohm Apartado 2018 Caracas 1010 A Tel 02 541 36 08 541 30 43 Telex 29179 Fax
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15. l working parts are well greased at regular intervals via the external grease nipples found on the outside of the body If the head is to be stored for a long time after the completion of a machining operation we recommend that the ZX420 head is dismantled and the working and moving parts are checked for wear or damage and then well greased and lubricated before re assembling for storage If the ZX420 head is used in a humid or hostile climate it should be sprayed with a proprietary rust inhibitor The above procedure will avoid corrosion and ensure that the ZX420 head remains in good working order Grease Nipples Fig 4 01 Location of external grease nipples 16 Operational reliabilty and trouble free service of high performance machinery and tooling depends on the correct selection and use of high quality specialised lubricants 1 It is recommend that a water resistant paste Kl ber Altemp Q NB 50 be used in this type of tool The paste should be applied to all moving parts or surfaces when the tool is dismantled for cleaning and maintenance or when the tool is stored for an extended period of time 2 To lubricate the ZX420 TC head during use it is recommended that a low soap grease Calcuim Cup No 2 should be applied via the greae nipples as a general guideline every 200 300 operating hours or as deemed necessary in practice The lubrication frequency can vary depending upon the working environment working speed coolant
16. les LENGTH EXCLUDING TOOLING A sur E TL MACHINE SPINDLE TRAVEL C DIAMETER RANGE Installation of Head 1 Using an eyebolt and ensuring both the bonnet and spindle nose location diameters are thoroughly clean carefullv lift the bonnet and locate it onto the spindle nose of the machine Secure the bonnet in position with the four socket head cap screws See fig 1 01 SPINDLE NOSE EYE BOLT l a N A BO NN ET Y Sy H N INNER SPINDLE SOCKET HEAD CAP SCREWS N N gt J N j ee R we N y DI H y IH seed PT x N J gt ER H 1 asek ssd WA IN Fig 1 01 Fitting the bonnet to the spindle nose 2 Before commencing to load the ZX 420 head onto the machine ensure all top tooling and slide adaptors are removed from the slide Check that the camlocs in the bonnet are in their open position The camlocs are spring loaded and will click into their open position when turned with an allen key Using a crane and with the ZX420 carefully slung lift into it in to a load position fully making sure the camloc studs are in line with their respective holes See fig 1 02 ENSURE ALL FOU ARE LINE WITH CAM
17. lift the ZX420 head 11 The ZX420 head is now ready for use See fig 1 04 9 Set inner spindle into its HOME position 10 Fit required tooling Lock 1 ee OR TOUCHING CLEAR JST Fig 1 04 Locating and clamping the ZX 420 onto the machine Do not exceed the slide stroke of IMPORTANT Camloc Adjustment In the locked position the indicator mark on thr camloc should be in between the il two lines indicated by the arrow and lock mar ked on the bonnet a mn f ALN I 7 X _ KA J N J Ssl 4 ae u wee a wm uw Figure 2 01 camloc stud in locked position 2 If the camloc does not lock i e the indicator mark does not fall within the lock position then the camloc stud needs to be adjusted CAMLOC STUD i en a IAL CAP HEAD SCREW Figure 2 02 Adjustment of camloc stud 3 To adjust remove the cap head screw that retains the camloc stud and screw in or out to suit Replace and tighten the cap head screw after adjustment 10 Gib Strip Adjustment 1 Slacken the four adjusting screws detail 31 ADJUSTING SCREWS DETAIL 31 j GIB STRIP DETAIL 3 GIB STRIP DETAIL 3 4 aN ID E ETET KEEPER STRIP REMOVED THIS SIDE
18. used machine used number of head actuations and distance stroked by the tool 3 A lube gun Ref part No CN D24 is available from Cogsdill Nuneaton to make routine maintainance easy To attain long term maintenance free operation of Cogsdill tooling it is recommended that the toolslides and sliding parts be lubricated with Kl ber Altemp Lubrications special lubricating paste 17 Altemp Q NB 50 The benefits of this tribologically developed lubricant are Long term lubrication product for Boundary friction conditions gt Enables precise positional accuracy and repeatability gt Prevents fretting corrosion gt Provides unparalleled resistance to water based coolants gt Resists centrifuging at high rotational speeds gt No workplace contamination Apply Altemp Q NB 50 paste to all sliding surfaces on assembly of the head and thereafter by high pressure lever type grease gun Frequent relubrication with Altemp Q NB 50 is not generally required depending on service conditions As a guideline we recommend re application every 200 300 operating hours or as deemed necessary in practice Mixing of lubricants should be avoided and could result in operational performance deficit 18 Kl ber Lubrication Branches Worldwide Argentina Kl ber Lubrication Argentina SA Martin J Haedo 4301 63 1602 Florida Prov Buenos Aires Tel 54 11 4709 1400 0236 4505 3686 1055 Fax 54 11 709 5394 Australia Kl ber Lubric
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