Cogsdill ZX Seat Pocket tool Service Manual
Contents
1. 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 0058 2 542 14 43 Korea Republic of Kl ber Lubrication Korea Ltd Seoul Head Office Suite 802 Samhwan Camus Bldg 17 3 Yoido Dong Youngdungpo ku Seoul Tel 02 782 5151 Fax 02 784 9900 KLK SEOUL Daegu Factory 1132 Jungri dong Seo Ku Daegu Republic of Korea Tel 053 555 51 51 Fax 053 555 51 55 Malaysia Kl ber LUBRICATION MALAYSIAO SDN BHD 37 amp 37 1 Jalan Tanjung SD 13 2 Bandar Sri Damansara 52200 Kuala Lumpur Tel 03 632 8958 Fax 03 632 8940 Mexico Kl ber Lubrication Mexicana S A de C V Boleo 62 Col Maza Del Cuauhtemoc 06270 Mexico D F Tel 05 702 00 48 Fax 05 702 10 21 Morocco Anciens Establissements R Geissmann amp Fils Zankat Ach Charif El Idrissi Casablanca Tel 02 25 12 15 25 12 64 Telex 23 842 Fax 02 25 35 90 Netherlands Kl ber Lubrication Benelux N V Energlestraat 5 NI 1411 AN Naarden Postbus 111 NI 1400 AC Bussum Tel 035 695 14 64 Fax 032. 0 COGSDILL NUNEATON LTD Precision Engineers ZX SEAT POCKET TOOL SERVICE MANUAL PRECISION ENGINEERS ZX Seat Pocket Tool Service Manual Cogsdill Nuneaton Ltd Tenlons Road Nuneaton England Phone 44 0 24 76383792 Fax 44 0 24 76344433 Email sales cogsdill co uk wwwv cogsdill co UuK ZX SEAT POCKET TOOL SERVICE MANUAL 12 15 17 19 21 22 23 27 Table of Contents Customer Order Details Introduction CHAPTER 1 Mounting the Seat Pocket Tool onto the machine CHAPTER 2 Positioning of Collet Assembly CHAPTER 3 Removing Collet Assembly CHAPTER 4 Removing the Toolblock Housing Assembly CHAPTER 5 Extension Sleeve Removal amp Re fitting CHAPTER 6 Changing the Toolslide CHAPTER 7 Dismantling Assembly of Collet Assembly CHAPTER 8 Maintenance CHAPTER 9 Recommended Spares CHAPTER 10 Lubrication CHAPTER 11 General Arrangement Drawings When contacting Cogsdill Nuneaton for information about your order please have this sheet to hand ZX SEAT POCKET TOOL SERVICE MANUAL C M Customer Order Details Customer Quote No Works Order No Sales Order Processing No Drawing Number Additional Notes and Related Tooling ZX SEAT POCKET TOOL SERVICE MANUAL Introduction ZX SEAT POCKET TOOL SERVICE MANUAL ZX SEAT POCKET TOOL SERVICE MANUAL Cartridge Assembly with Insert Mounted in ZX Seat P
3. 12 4 Remove the cover screw detail 109 to gain access to the push rod 5 Load the Allen Key through the cover screw hole into the taper lock screw detail 14 and undo until the screw bottoms out Wind back one quarter tutn to avoid damage to the extension sleeve bore 6 Pull off the tool block housing assembly The tool block housing should be held across the toolslide during removal to restrict actuator movement d Reverse the above procedure for re assembly Tighten the taper lock screws with a torque wrench to 28 NM 13 14 zai z NN rom EN mii ODN D ZZ ZS x M VIF REPETI 410 3001 100 SSOHOv IOH AJA 3 0 3 ALLL 0 VEG IR m L n iz FILLE Ke 2 1 LS te iu 8 395 3001 3307 1 dod HSMd 80 III i IIIIII wa wa dda VU m NM gt LE KEN a E EE p MIYOS 3 0 9 5 4901 M3dvl 3 0 Od SERVICE MANUAL ZX SEAT POCKET TOOL ZX SEAT POCKET TOOL SERVICE MANUAL Extension Sleeve Assembly Assembly amp Removal 1 Load seat pocket tool into a vice gripping the stub sleeve next to the section to be removed alternatively load into the machine spindle 2 Move the shank into the home position The toolslide should be in the central position in the tool block housing
4. 5 695 12 99 New Zealand Via Australia Norway Kl ber Lubrication Skandinavian A S Filial Norge Postboks 72 N 1483 Skytta Tel 47 67 06 78 40 Fax 47 67 06 78 50 Pakistan Industrial Contracting Trading Company 16 Gulshan Terrace P O Box No 549 M A Jinnah Road Karachi 74200 Tel 021 26 25 188 26 29 029 Telex 27479 aktiv pk Fax 021 216312745 Peru RAUL FATULE SA Av Elmer Faucett No 272 2 piso Lima 32 Peru Tel 01 445 10 206 Fax 01 445 13 624 Phillipines Republic of the Diversified Holdings Inc Rm 300 DHI Bldg 2 Lapu Lapu cor Victoria St Magallanes Village Makati Metro Manila Tel 02 8338566 68 8342781 86 Telex 22322 MTA PH Fax 02 834 27 86 Poland TOP LUBRICANTS INDUSTRIAL ul Skoczowska 19 61 345 Poznan Starolcka Tel Fax 061 8 73 98 05 Portugal Paulo C Barbosa Lda Rua Antonio Silva Marinho 211 249 P 4100 Porto Tel 02 619 7170 619 7175 F 02 619 71 79 Singapore Republic of Kluber Lubrication South East Asia Pte Ltd 25 International Business Park 04 103 G German Centre Singapore 609916 Tel 0065 562 9460 Fax 0066 562 9469 Marine Teknik Pt Ltd Blk 196 Pandan Loop 05 17 Pantech Industrial Complex Singapore 128384 Tel 0065 779 8366 Fax 0065 779 8266 ZX SEAT POCKET TOOL SERVICE MANUAL General Arrangement Drawings 27
5. 5 Remove the 3 taper lock screws detail 12 4 Remove the cover screw detail 109 to gain access to the push rod 5 Load the Allen Key through the cover screw hole into the taper lock screw detail 14 and undo until the screw bottoms out Wind back one quarter tutn to avoid damage to the extension sleeve bore 6 Pull off the tool extension assembly 4 Remove toolblock housing assembly as previously described in chapter 4 7 Reverse the above procedure for re assembly Tighten the taper lock screws with a torque wrench to 28 NM 15 16 dr SN z2 ZE CE 1 NN 22 IIIIII LLILILLLLLLELLLLLLLLLLLLLLLLLLLLLLLL 2 AURA D bon ZZ 4 NT LILLI A 277 ZA zr TSG M 8 1352 NOISN3LX3 130 RE n SSSA ZZ RE ET LLLLLLLLL 2 LLLLLLLLLLLL LLL LLL LLL La LER CL LM KL Se M3495 MOOT 1 JOHN 4 60 EUER LL e er LIL BNSC un TS rKKAELZ Og MINIS WJAOO SAM3HOS 4901 2320 1 1 0 b Old SERVICE MANUAL ZX SEAT POCKET TOOL ZX SEAT POCKET TOOL SERVICE MANUAL Changing the Toolslide Mount the Seat Pocket Tool into the machine spindle See Chapter 1 1 Remove the pilot shaft assembly detail 2 by unscrewing the 3 cone point screws detail 117 from the pilot shaft see Fig 5 2 Remove the end cap detail 3 by unscrewing the 5 cap head screws
6. 62 45 27 05 30 Belgium Kl ber Lubrication Benelux DSA NV Rue Cardinal Mercier 100 B 7711 Dottignies Tel 056 48 33 11 Telex 57059 Fax 056 48 62 52 Bolivia Quimiza Ltda Casilla 4667 av Ecuador 2416 La Paz Bolivia Tel 02 35 06 56 35 05 78 Fax 02 39 13 57 Brazil Kl ber Lubrication Lubrificantes Especials Ltda amp Cia Rue S o Paolo 345 Distrito Industrial de Alphaville 06465 902 Barueri SA Paulo Tel 011 7295 5511 Telex 11 39209 Fax 011 421 5150 Bulgaria BULEMS Bd Tzarigradsko Shosse 64 Block 11 Eingang B App 72 Sofia 1784 Bulgarien Tel 02 74 56 89 77 93 76 Telex 067 23066 Fax 02 76 24 29 Canada North American Headquarters Kl ber Lubrication North America L P 54 Wentworth Avenue Londonderry N H 03053 7437 Tel 603 434 7704 Fax 603 434 8046 Canadian Office Ontario Tel 905 628 5595 Fax 905 628 5402 Chile Kl ber Lubrication Lubricantes Especiales y Cia Ezequiel Fernandez 575 Comuna Nunoa Santiago Chile Tel 02 204 22 02 204 21 28 Fax 02 274 77 10 China Republic of LUBTEK Co Ltd 5FI 4 Lane 235 Pao Chiao Road Hsin Tien 23115 Taipei Hsien Taiwan R O C Tel 02 917 36 93 917 45 59 Fax 02 911 42 13 China people s Rep of Via Hong Kong ZX SEAT POCKET TOOL SERVICE MANUAL Slovenia PETROL d d Dunajska 50 1527 Ljubljana Tel 061 131 21 55 Fax 061 319 857 South Aflic
7. Alexandria office P O Box 114 Elsaray 21411 Alexandria Tel 03 587 3301 Fax 03 586 3514 El Salvador J M Escobar P O Box 107 San Salvador EL Salvador CA Tel Fax 503 2 98 34 72 Finland Kl ber Lubrication Skandinavian AIS Filial Finland Martinkylantie 67 FIN 01720 Vantaa Tel 9 854 56 10 Fax 9 854 56 130 France Kl ber Lubrication Francre SA 10 16 Allee E Ducretet F 26000 Valence Tel 04 75 44 84 36 Fax 04 75 40 89 10 Germany Kl ber Lubrication M nchen KG Geisenhausenerstrasse 7 D 81379 M nchen Postfach 70 10 47 D 81310 Munchen Tel 089 78 76 0 Telex 523131 Fax 089 78 76 333 Beratungs und Verkaufsb ros in Berlin Frankfurt Hannover Krefeld N rnburg Stuttgart 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 Lubrication A division of Freudenberg Australia Pty Ltd 1st Floor 3 Brand Drive PO Box 4 Thomastown VIC 3074 Tel 03 9464 7577 Fax 03 9464 7588 Sydney Branch Office 14 Daniel Street P O Box 164 Botany N S W 2019 Sydney Tel 02 666 5744 Telex 26121 lesco Fax 02 3169490 Austria Kl ber Lubrication Austria Ges m b H Franz Wolfram Scherer Strasse 32 Postfach 84 A 5028 Salzburg Kasern Tel 0662 45 27 05 0 Telex 633326 Fax 06
8. a Republic of Kl ber Lubrication Ply Ltd P O Box 11461 Ranhart Alberton 1457 Tel 011 908 2457 2458 2459 Fax 011 8647373 Spain Kl ber Lubrication GmbH Iberica S en C Carratera Nacional 154 KM 22 E 08150 Parets del Valles Barcelona Tel 03 573 07 11 573 06 66 573 06 67 Telex 93659 klub e Fax 03 573 07 54 Sweden Kl ber Lubrication Skandinavien A S Filial Sverige Box 601 S 19426 Uppland Vasby Tel 08 59 09 86 00 Fax 08 59 09 86 01 Switzerland 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 Srinakarin 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 URUNLERI SAN VE TIC AS Korukent A1 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
9. detail 104 3 Actuate the machine spindle forward approximately 1 500 the toolslide detail 5 will push forward enabling its removal 4 Replace with new toolslide ensuring that all items are clean and free from swarf making sure that the toolslide is the right way round and properly located in the keyway in the actuator detail 10 5 Actuate the machine spindle and move to the home position 6 Replace the end cap detail 3 ensuring that the location faces are free from swarf Ta Tighten up the 5 cap head screws detail 104 8 Replace the pilot shaft detail 2 9 Tighten up the 3 cone point screws detail 117 17 18 SpTS Co 2AOTUSY sppurds aumnqoeur 7 despus po pnd pue SAIS peaude sowy pupeo jo qmd pue 49158 pesydes 3AOUISY NR SS SSH Whar WLLL tt S Il MMMM peso vi NZ ACER RRA DIN tia OOO RTA NS len os NN TT ASSESSEER ER IT SSMS EE CITT a ipm LLLI LL ee CLA ni SIIIISSIIIHIISEH THE S TUE LU as SN RSC a SERVICE MANUAL ZX SEAT POCKET TOOL ZX SEAT POCKET TOOL SERVICE MANUAL Dismantling and assembly of Collet Assemblies Manual Collet Dismantling L Unscrew the adjusting nut detail 2 and remove it along with the thrust washer detail 5 2 Slide the collet see detail 6 of the pilot b
10. ki Plant 955 4 Am Ohishi Isohara Isoharamachi Kitaibaraki City Ibaraki 319 15 Japan Tel 0293 42 7320 Fax 0293 42 6784 CIS Commonwealth of Independent States STOELCK AUSSENHANDEL AG Hotel Mezhdunarodnaya 2 App 438 Krasnopresnenskaya Nab 12 Moskau 123610 Tel 253 15 57 Fax 255 05 04 Telex 411432 Comm su Colombia Hanseatica Ltd Bogota Atn Thomas Beller Calle 17 No 69B 06 A A 14467 Santafe de Bogota D C Colombia Tel 01 292 53 54 292 21 53 Fax 01 411 88 63 Costa Rica RESOCO SA Apartado 5559 1000 San Jose COSTA RICA Tel 506 232 8433 Telex 2102 reso Fax 506 232 8898 Croatia Republic of INA INDUSTRIJA NAFTE d d MAZIVA ZAGREB Radnicka Cesta 175 10000 Zagreb Tel 01 45 78 627 Fax 01 45 78 629 Cyprus Lebanon TRCI Ltd 122 Limassol Avenue P O Box 4371 Nicosia Cyprus Tel 2 427 980 Telex 2 5737 Fax 2 423 021 Czech Republic Benzina a s obchodni zalezitosti Tridvorska ul 280 00 Kolin Tel 0321 26535 Fax 0321 20404 Denmark Kl ber Lubricatio Skandinavien A S Skjemvej 70 DK 7500 Holstebro Tel 97 42 46 20 42 42 77 Fax 97 41 38 58 Ecuador Empress Tecnica Comercial C A Eteco Av Amazonas 6017 y Rio Coca P O Box 17 17 589 Quito Tel 02 268 600 Fax 02 469 115 Egypt SAPO SA Salem for Agencies Export and Import P 0 Box 5567 Heliopolis West 11771 Cairo Tel 02 2909727 2909737 Fax 02 2916578
11. ocket Tool ZX SEAT POCKET TOOL SERVICE MANUAL Mounting Tool onto Machine 12 Before the Seat Pocket Tool is installed into the machine spindle ensure all locating faces are free from swarf chips and foreign matter 2 Advance the machine spindle forward through the cam loc bonnet 3 Mount the Seat Pocket Tool into the spindle and actuate the pull stud clamp 4 Retract the spindle slowly until the Seat Pocket Tool flange is within 1 0mm of bonnet face 5 Check with the home position on C N C controls 6 Retract the spindle to its home position T Tighten the two camlocs in the camloc bonnet 8 Before machining commences check tip height measure the tool block housing diameter and divide by a factor of 2 for radial dimension from centre 9 Measure the amount which the insert edge protrudes from the tool block housing 10 Add this figure to the tool block housing Radial dimension to get the tip height Multiply by 2 for diameter ZX SEAT POCKET TOOL SERVICE MANUAL Positioning of Collet Assembly Manual Collet 1 Load the collet onto the Collet Spanner see Fig 1 2 Insert the collet into position in the valve block component ensuring that sufficient clearance has been allowed to clear the end cap on the Seat Pocket Tool when machining the seat pocket see Fig 2 3 Holding the Handle on the end of the Collet Spanner stationary tighten the collet by turning the Collet Spanner Tommy Bar
12. ody detail 1 3 Mount the pilot body detail 1 into a bench vice using soft jaws with the seal housing detail 4 facing upwards 4 Using circlip pliers remove circlip detail 103 from its groove 5 Remove the seal housing along with one seal details 4 amp 100 6 Remove the bearings detail 101 and seal detail 9 19 ZX SEAT POCKET TOOL SERVICE MANUAL Manual Collet Assembly Before assembling ensure that seal surfaces are clean and free from swarf and imperfections Replace any worn or damaged seals or bearings 1 Mount the pilot body detail 1 in a bench vice using soft jaws with the largest diameter upward 2 Replace the seal see detail 100 bearings detail 101 and seal housing detail 4 3 Replace circlip detail 103 using circlip pliers to put circlip into its groove in the pilot body bore detail 1 4 Remove from vice 5 Replace the collet detail 6 6 Replace the adjustment nut detail 2 and thrust washer detail 5 ZX SEAT POCKET TOOL SERVICE MANUAL Maintenance Cogsdill Nuneaton Limited s Seat Pocket Tools require regular maintenance whilst being used The tools should be cleaned free of swarf or other foreign matter after each machining operation To ensure the Seat Pocket Tool remains in good working order it is recommended that the wotking parts e g the actuator detail 10 and tool slide detail 5 are well oiled or greased This will av
13. oid corrosion from coolants etc and ensure that the tool is in good working order when next used 21 ZX SEAT POCKET TOOL SERVICE MANUAL Recommended Spares Below is a list of recommended spares which could need replacements due to normal wear Collet Tool slides Cartridges End cap Actuator Front amp Rear Retaining plates and tear ZX SEAT POCKET TOOL SERVICE MANUAL Lubrication Chapter Recommendations Operational reliability 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 recommended 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 disassembled for cleaning and maintenance or when the tool is stored for extended petiod of time 2 To lubricate the heads during use it is recommended that a water resistant paste Kl ber Altemp Q NB 50 should be applied 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 used machine used number of head actuations and distance stroked by the tool 3 A lube gun is available from Cogsdill to make routine maintenance easy Ref Part No CN D24 To attain long term maintenance free operation of Cogsdill t
14. ooling it is recommended that the tools be lubricated with Kl ber Lubrication s special lubricating paste 23 ZX SEAT POCKET TOOL SERVICE MANUAL 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 24 ZX SEAT POCKET TOOL SERVICE MANUAL Greece E Scazikis L Marangos SA P 0 Box 154 57022 Sindos Industrial Area of Thessaloniki Tel 31 797640 Telex 412095 roul gr Fax 31 798890 and 8 Serronstr 10441 Athens Tel 01 52 25 310 Telex 225 116 Fax 01 52 23 412 Guatemala Nativo Trading Ltda Apartado Postal 2212 3a Callo 1 69 Zone 1 Ciudad de Guatemala CA 01001 Tel 02 514273 Telex 9255 Fax 02 536846 Hong Kong Kl ber Lubrica
15. s clockwise 4 Remove the Collet Spanner by turning the Handle in either direction until the drive dowel can pass through the drive collar 10 Tod 709 3 8 ONIQVO LOWd 131103 IN3NOdWOO LINS OL avag 1 3 SERVICE MANUAL ZX SEAT POCKET TOOL m T O r z 1 E 991 i RES SSS ZX SEAT POCKET TOOL SERVICE MANUAL Removing Collet Assembly Manual Collet 1 Load the collet spanner down the component bore and into the collet pilot assembly Turn the collet spanner handle to find the drive dowel slot then turn the collet spanner tommy bars to find the drive collar slot 25 Hold the collet spanner handle stationary and turn the collet spanner tommy bars anti clockwise to undo the collet assembly 3 Lightly tap the end of the collet spanner to release the collet from the component bore 4 Pull out the collet assembly with the collet spanner 12 ZX SEAT POCKET TOOL SERVICE MANUAL Tool block Housing Assembly Assembly amp Removal 1 Load seat pocket tool into a vice gripping the extension next to the section to be removed alternatively load into the machine spindle 2 Move the shank into the home position The toolslide should be in the central position in the tool block housing 3 Remove the 3 taper lock screws detail
16. tion Hang Kong China Ltd Unit 18 21 1 F Advanced Technology Centre F S S T A 148 Choi Yuen Road Sheung Shui New Territories Hong Kong Tel 0852 2692 01 91 2692 03 29 Fax 0852 2693 4304 Telex 33234 KLINT HX India AJAY METACHEM LTD Sangli Bank Bldg 4th FI 296 Perin Nariman Str behind Reserve Bank Building Fort Mumbai 400 001 Tel 022 2662017 2662022 2665637 Telex 118 6458 ajay in Fax 022 2660530 Pune Office 72 76 Mundhwa Pune 411036 India Tel 0212 672030 672250 Telex 145 7381 ajay in Fax 0212 672837 Kl ber Lubrication India PVT Ltd 504 Navbharat Estates Zakaria Bunder Road Sewri West Mumbai 400 015 Tel 022 416 6019 Fax 022 414 7319 Indonesia Republic of PT A Darmawan JI Hegarmanah 63 Bandung 40141 Tel 022 230100 Telex 28238 darmawan bd Fax 022 433080 Tran Faratek Ltd Technical amp Trading Consultants North Vali Asr Ave before Vanak Sq No 1262 Apt No 5 P O Box 11365 5883 Tehran Tel 021 879 6325 877 39 87 Telex 222576 acti ir Fax 021 877 46 80 Italy Kl ber Lubrication Italia S a S Via Monferrato 57 Sesto Ulteriano 1 20098 S Guiliano Milanese Casella Postale 13 104 I 20141 Milano Tel 02 98 213 1 Telex 316090 Fax 02 98281595 Japan NOK Kl ber Co Ltd Seiwa Building 1 12 15 Shiba Daimon Minato Ku Tokyo 105 Japan Tel 03 3434 1734 Fax 03 5472 6073 NOK Kl ber Co Ltd Kitaibara
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