ZX200-TC Facing & Contouring Head Service Manual
Contents
1. FIGURE 1 03 Load head to spindle and clamp in place via pullstud or drawbar 5 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Slowly wind back the spindle locating facing head into bonnet until location faces are just clear or touching each other Clamp facing head in position by pushing down on the camlocs and turning them into the lock position Set inner spindle of machine to its home position The head is now ready for use FIGURE 1 04 Wind back machine spindle and secure head in position by turning Camlocs to lock position ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Camloc Adjustment In the locked position the indicator mark on the Camloc should be in between the two lines indicated by the arrow and lock marked on the Bonnet FIGURE 1 05 Camloc Pin in locked position 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 To adjust remove the caphead screw that retains the Camloc Stud and screw in or out to suit replace the caphead screw after adjustment Camloc Stud FIGURE 1 06 Camloc Stud can be adjusted to ensure Camloc locks up 7 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter Maintenance Operational reliabilty and trouble free service of high performance machinery and tooling depends on the correct selection and use of high quality specialised lubricants2. 1 It is recommend that a water resistant paste Kliiber 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 ZX200 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 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 FIGURE 2 02 Lubrication Points on Main Body FIGURE 2 01 Lubrication Points on Main Body Cross slide ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter Dismantling of Facing Head Remove facing head from machine spindle reverse instructions of Chapter 1 and remove any tooling fitted to cross slide Ensure prior to dis mantling that items are suitably marked to ensure accurate re assembly Due to the close manufacturing tolerances problems may occur if this method is not adhered to Step 1 Remove adaptor nose detail 17 from main body detail 6 by removing four caphead screws detail 106 and pulling off back of b
3. Now move shank to home position ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL 10 Re fit locking ball details 112 115 117 118 to hole in main body detail 6 The ball detail 118 will seat in a groove in actuator diameter detail 7 when the shank is set to home position 11 Refit adaptor nose detail 17 to main body detail 6 and secure in position with four caphead screws detail 106 12 Actuate head to home position and check head moves freely across full range of stroke ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Adjustment of Facing Head If adjustment through wear is needed on the slideblocks the following procedure should be followed Step 1 Dismantle the Contouring and Facing head as described previously Do not remove slideblocks Replace worn keys in actuator if necessary Remove one slideblock from cross slide and check both slideblocks for any wear replace if necessary Assemble facing head to procedure previously stated and check actuator can move freely without play between slideblocks The spring plungers should ensure this Check actuator and cross slide move freely in body If actuator slideblocks or tenon keys are worn and spares are ordered individually not in a set it may be necessary to grind the datum faced marked once the sides of the slideblocks are set in position See figure 3 01 It is recommended that units are returned for ser
4. 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 individually set to suit each customer s machines if our standard home position will not fit 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 work piece 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 abo
5. Hi COGSDILL NUNEATON LID Precision Engineers ZX200 TC Facing amp Contouring Head Service Manual PRECISION ENGINEERS ZX200 TC Facing amp Contouring Head Service Manual Cogsdill Nuneaton Ltd Tenlons Road Nuneaton England Phone 44 0 24 76383792 Fax 44 0 24 76344433 Email sales cogsdill co uk ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Table of Contents Customer Order Details 1 Introduction CHAPTER 1 Installation of Head 4 Camloc Adjustment 7 CHAPTER 2 General Maintenance 8 CHAPTER 3 Dismantling of Facing Head 9 Assembly of Facing Head 12 Adjustment of Facing Head 16 CHAPTER 4 Recommended Spares 17 Repair and Overhaul Procedure 18 CHAPTER 5 Torque Settings 19 CHAPTER 6 Trouble Shooting 20 CHAPTER 7 General Arrangement Drawings 21 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL i Customer Order Details Customer When contacting Quote No Cogsdill Nuneaton for information about your order Works Order No please have this sheet to hand Sales Order Processing No Additional Notes and Related Tooling ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Introduction ogsdill Nuneaton s Facing heads are designed to work on machines with live spindles such as horizontal boring machines with C N C controls The combination of the spindle feed z axis and the work piece w axis enables most profiles to be accurately machined
6. at the actuator moves free off the machine e Check concentricity of drawbar e Check drawbar has not been over tightened and has caused damaged to the actuator blade e Check that the head has been assembled correctly e Check that the retaining screws are not over tight and have not distorted the body e Check if using a bonnet face that it is flat parallel and free from any surface imperfections e Check all greaseways are clear and not blocked 2 Inconsistency in component sizing e Check for radial pay in actuator re adjust slideblocks against actuator blade Check for wear on keys and key slots in slideblocks replace as required e Insufficient lubrication being used try lubricating regularly e Check for out of balance situation when head is stroked e Check clearance between cross slide and keeper plates On no condition force the actuator for extra movement but contact Cogsdill Nuneaton Ltd for advice 20 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter General Arrangement Drawings General Arrangement drawing of ZX200 TC e Standard tooling available for ZX200 TC 21
7. embled to each other Use assembly drawing found in chapter 7 when following these assembly steps Step 1 Make sure all slideblocks are fitted with spring plungers detail 123 which on assembly close slideblocks details 3 amp 4 around actuator detail 7 to produce a precision fit 2 Fit cross slide detail 2 and slideblocks details 3 amp 4 together Locate slideblocks in position on the cross slide with slipper slot facing towards the centre of the cross slide and fix slideblocks in position with two special caphead screws detail 5 per slideblock Do not fully tighten yet 3 Locate keys details 10 amp 11 in position on actuator bar detail 7 and secure by two countersunk head screws detail 111 4 Inspect o ring detail 104 and quad ring detail 101 amp 102 for damage Replace if necessary If coolant pipe detail 13 has been removed from actuator detail 7 re fit now with o ring detail 104 fitted underneath coolant pipe Secure coolant pipe in place with two caphead screws detail 110 but leave caphead screws loose at this stage ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Position actuator bar detail 7 into rear of main body detail 6 with spade end towards the front of the head and vertical with cross slide cavity and coolant pipe located in hole in main body It is helpful to hold the body in a soft jawed vice to ensure the location diameter is protected Offer the cross slide assemb
8. ly with attached slideblocks onto the actuator and slide the unit down the actuator keys until the spring plungers detail 123 rest on the keeper plate location face Using the keeper plates detail 1 depress the spring plungers simultaneously and push down to the home position Damage to the spring plungers will occur if this procedure is not followed Replace keeper plates detail 1 and tighten up eight caphead screws detail 107 through keeper plates Check actuator detail 7 moves freely forward amp backwards then fully tighten two caphead screws detail 110 securing coolant pipe detail 13 to the actuator detail 7 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL 8 The spring plungers will push the slideblocks onto the actuator blade and therefore the slideblocks can now be fully tightened by means of four access holes in the top face of the cross slide detail 2 Using an Allen key turn the four special caphead screws detail 5 anti clockwise to tighten The following procedure should be adhered to Lightly nip the four special screws detail 5 in an anti clockwise direction moving the actuator in and out of the head to actuate the slide Continue to tighten the four special screws and moving the actuator until the screws are fully tightened Do not over tighten special screws as damage to the head will result 9 Replace shank detail 9 and secure in position with two taper lock screws detail 8
9. ody 2 Remove locking ball details 112 115 117 118 3 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL 4 Unscrew eight caphead screws detail 107 and remove two keeper plates detail 1 5 Pull away cross slide detail 2 and attached slideblocks details 3 amp 4 from body detail 6 the actuator bar detail 7 can now be removed by pulling out the back of the head with attached coolant pipe detail 13 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL To remove slideblocks details 3 amp 4 from cross slide detail 2 unscrew four caphead screws detail 5 from slideblocks In removing slideblocks identify their position with the cross slide If necessary clamp the slideblock in a soft jawed vice and very gently tap the cross slide free from the slideblocks The keys details 10 amp 11 can now be removed by unscrewing the two countersunk head screws detail 111 The Coolant pipe detail 13 can now be removed from the actuator detail 7 if required by removing two caphead screws detail 110 Care must be taken not to mis place the o ting detail 104 located underneath the coolant pipe Inspect o ring detail 104 and quad ring detail 101 amp 102 for damage Replace if necessary 11 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Assembly of Facing Head Ensure all parts are thoroughly cleaned and well lubricated before assembly Make sure all parts are correctly ass
10. ut 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 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Suitable for Horizontal Boring Machines with Size 4 5 amp 6 Inch Spindles LENGTH EXCLUDING TOOLING 15 ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter Installation of Head 1 Locate Bonnet onto spindle nose of machine ensuring both bonnet and spindle location faces are free from swarf chips and other foreign matter Secure in position with four socket head screws Camlock ka Spindle Nose Inner Spindle FIGURE 1 01 Loading Bonnet to Machine Spindle AT ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL 2 Before commencing to load the Contouring and Facing head onto the machine spindle nose Check that the camlocs in the bonnet are in their open position The camlocs are spring loaded and will pop up above the bonnet diameter approximately 2 00mm 079 when they are in the open position FA Yo FIGURE 1 02 3 Wind out Inner spindle of machine so that it protrudes the bonnet face 4 Load Contouring and Facing head into the spindle of the machine and clamp in position via drawbar or pullstud ZX200 TC Facing Head 5i p L
11. vice if repair facilities are not available matched actuators and slideblocks can be supplied to save down time ZX200 TC FACING 8 CONTOURING HEAD SERVICE MANUAL Chapter Recommended Spares 1 Slideblock Detail 3 2 Slideblock Detail 4 3 Actuator Detail 7 4 Key Detail 10 5 Key Detail 11 6 O ring set for head ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Repair and Overhaul Procedure Cogsdill can offer the following set maintenance and overhaul service to ensure guaranteed and trouble free operation Fit this service into your preventative maintenance schedule Stage 1 Over size keys up to 005 Inches e Slideblocks re ground Grease all over e Plus any minor adjustments to slideblocks and keeper plates e All o rings screws and plungers to be replaced 2 Over size keys up to 010 Inches e Slideblocks re ground e Hard Chrome and re grind actuator bore e Re grind actuator shaft Grease all over e Plus any minor adjustments to slideblocks and keeper plates e All o rings screws and plungers to be replaced 3 Over size keys up to 015 Inches e Replace slideblocks e Replace Keys e Grind actuator bore back to original size e Re grind actuator shaft e Re fit new actuator e Grease all over e Plus any minor adjustments to slideblocks and keeper plates e All o rings screws and plungers to be replaced Note In the event of the Contouring and Facing Head being damaged we strongly ad
12. vise customers to return the heads to Cogsdill Nuneaton Ltd for repair ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter Torque Settings All values are based upon plain black finish screws The above table is intended for general guidance only In practice the actual torque tightening value s 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 clamping pressure is to tighten with an Allen key hexagon wrench to finger tight and then a further 30 degrees past this position Cogsdill Nuneaton will not take any responsibility for miss use of this information which leads to damage or injury of head tooling or personal ZX200 TC FACING amp CONTOURING HEAD SERVICE MANUAL Chapter Trouble Shooting Inevitably problems occur with any tool Some of these are due to lack of experience with this type of tooling and others due to wear Some of these problems can be quickly overcome in your factory and others will necessitate returning the tool to Cogsdill Nuneaton Ltd for overhaul and repair To help you to determine which course of action is required we have listed a few of these points and subsequent checks to help you If you require further assistance please ask us for help 1 Difficulty in moving actuator when assembled to machine spindle or excessive pressure required moving actuator Check th
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