X-ml-5001: Ml-5000 Repair Parts Catalog

Transcript

REPAIR PARTS CATALOG FOR SUNNEN® POWER STROKED HONING MACHINE MODEL: ML5000 “SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN® PRODUCTS COMPANY.” SUNNEN® PRODUCTS COMPANY 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 3147812100 X-ML-5001D Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment. INTRODUCTION Illustrations show all major components in exploded detail. Item numbers on each illustration are keyed to the corresponding parts list, providing a descriptive identification of each part. The parts lists include assemblies as well as detail parts. An item listed without a part number can be obtained as a component of the complete assembly of which it is a part. Standard hardware items are listed with complete descriptions, such as Item 29 below. These may be purchased at your local hardware store, but it is important to replace an item with one having the same dimensions as the original. In some places brand names and part numbers are shown. These may change depending upon availability. Sunnen Products Company reserves the right to make changes, without notice, to materials, specifications, colors, designs and accessories included with units. HOW TO ORDER When ordering replacement parts be sure to include the following information to ensure prompt shipment of correct parts: 1. The part number and description of each part desired, obtained from this parts catalog. 2. The quantity of each part desired. 3. The voltage, frequency and phase, when ordering electrical parts. 4. The model and serial number of the machine, obtained from the name plate, where there is any question concerning a part. HOW TO USE THIS PARTS LIST Step 1. – Locate desired part on illustration. Note item number. Step 2. – Locate item number in the parts list. Step 3. – If the item has a part number listed, order by part number and the description. A part number in light face type indicates that it is a component of the last preceding part number in bold face type. Step 4. – If no number is listed, order the part number of the unit of which the desired part is a component. ORDER ONLY BY PART NUMBER AND DESCRIPTION – NOT by item number. NOTE: In this manual, parts may be followed by “(For CE Machines)” or “(For NonCE Machines)” to denote domestic machines from exported machines. The CE version is constructed to meet the requirements of the European market, and is available to any customer. 1 Step 1. 4 2 3 15 17 14 ITEM NO. Step 2. Step 3. Step 4. ORDER BY PART NUMBER QTY. DESCRIPTION 1 2 3 4 MVH4499A PHSM405 PHW354 MVH4422 1 3 3 1 ....Spindle Cap includes ......Screw (M6 x 1 x 16 SHCS) ......Washer (M6) ....Inner Spindle Nose 14 15 16 17 PEM870A PEM871 PEM872 PHSM600 1 1 1 1 ....Cable Carrier includes ......Cable Carrier Bracket ......Cable Carrier Bracket ....Screw (M3 x 0,5 x 5mm FHCS) iii GENERAL INFORMATION The Sunnen® equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care and maintenance this equipment will give years of service. READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT. IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with the planning and installation of your SUNNEN® equipment. Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time. Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance of your equipment. Troubleshooting information can also be found within the Instructions. If you cannot find what you need, call for technical support. Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in the literature packaged with your equipment. Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the following information available: • Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it. • Have Model Number and Serial Number printed on your equipment Specification Nameplate. • Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data. For Troubleshooting, additional information may be required: • Power distribution information (type delta, wye, power factor correction; other major switching devices used, voltage fluctuations) • Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding). • Use of any optional devices/equipment between the Drive & motor (output chokes, etc.). For fast service on your orders call: Sunnen Automotive Customer Service toll free at: 18007722878 Sunnen Industrial Customer Service toll free at: 18003253670 Customers outside the USA, contact your local authorized Sunnen Distributor. Additional information available at: http://www.sunnen.com or email: [email protected] NOTE: Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding. ESD PREVENTION REVIEW Let's review the basics of a sound static control system and its effective implementation. First, in the three step plan: 1. Always ground yourself when handling sensitive components or assemblies. 2. Always use a conductive or shielded container during storage or transportation. These materials create a Faraday cage which will isolate the contents from static charges. 3. Open ESD safe containers only at a static safe work station. At the static safe work station, follow these procedures before beginning any work: A. Put on your wrist strap or foot grounding devices. B. Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of static charges. C. Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics. D. Antistatic bubble wrap has been included for use at the machine when an ESD safe workstation is not available. You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you: GROUND ISOLATE NEUTRALIZE iv SUNNEN® LIMITED PRODUCT WARRANTY SUNNEN® Products Company and its subsidiaries (SPC) warrant that all new SPC honing machines, gaging equipment, tooling, and related equipment will be free of defects in material and/or workmanship for a period of one year from the date of original shipment from SPC. Upon prompt notification of a defect during the oneyear period, SPC will repair, replace, or refund the purchase price, with respect to parts that prove to be defective (as defined above). Any equipment or tooling which is found to be defective from improper use will be returned at the customer's cost or repaired (if possible) at customer's request. Customer shall be charged current rates for all such repair. Prior to returning any SPC product, an authorization (RMA#) and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer. Warranty Limitations and Exclusions This Warranty does not apply to the following: • Normal maintenance items subject to wear and tear: (belts, fuses, filters, etc). • Damages resulting from but not limited to: › Shipment to the customer (for items delivered to customer or customer's agent F.O.B., Shipping Point) › Incorrect installation including improper lifting, dropping and/or placement › Incorrect electric power (beyond +/ 10% of rated voltage) including intermittent or random voltage spikes or drops › Incorrect air supply volume and/or pressure and/or contaminated air supply › Electromagnetic or radio frequency interference from surrounding equipment (EMI, RFI) › Storm, lightning, flood or fire damage › Failure to perform regular maintenance as outlined in SPC manuals › Improper machine setup or operation causing a crash to occur › Misapplication of the equipment › Use of nonSPC machines, tooling, abrasive, fixturing, coolant, repair parts, or filtration › Incorrect software installation and/or misuse › Nonauthorized customer installed electronics and/or software › Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES. SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND, EXPRESS OR IMPLIED, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER. SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS. SPC SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO: LOSS OF USE, REVENUE, OR PROFIT. SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES. REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER, SPC's LIABILITY, IF ANY, FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS, AND BUYER'S SOLE AND EXCLUSIVE REMEDY THEREFORE, SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE. Shipping Damages Except in the case of F.O.B., Buyer's destination shipments, SPC will not be liable for any settlement claims for obvious and/or concealed shipping damages. The customer bears the responsibility to unpack all shipments immediately and inspect for damage. When obvious and/or concealed damage is found, the customer must immediately notify the carrier's agent to make an inspection and file a claim. The customer should retain the shipping container and packing material. SUNNEN® SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you, as user and licensee (Licensee), and Sunnen® Products Company (SPC) with respect to preprogrammed software (Software) provided by SPC for use on SPC Equipment. By using the Software, you, as Licensee, agree to become bound by the terms of this Agreement. In consideration of payment of the license fee (License Fee) which is part of the price evidenced by your receipt (Receipt), SPC grants to you as Licensee a nonexclusive right, without right to sublicense, to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software. SPC reserves all rights including rights not otherwise expressly granted, and retain title and ownership to the Software including all subsequent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied on removable media (floppy disk), you, as Licensee, may copy the Software only for back up purposes; or you may request that SPC copy the Software for you for the same purposes. All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement. The Software and accompanying written materials (including the user's manual, if any) are provided in an "as is" condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct, indirect, consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use. It is recognized that some states do not allow the exclusion or limitation of liability for consequential or accidental damages and to the extent this is true, the above limitations may not apply. Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement. SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement. v SAFETY INSTRUCTIONS READ FIRST The ML2000, like any machine tool, may be dangerous if used improperly. As a result of our commitment to continual safety improvement, many new safety features have been incorporated into this machine. However, these features cannot protect the operator from all hazards of misuse or abuse of the product. Please read all warnings and instructions before attempting to use this machine. DO NOT turn power on until all guards and covers are securely in place. DO NOT remove or defeat any safety device. Depressing foot pedal with power “ON” can start spindle and stroker motion. Use foot pedal ONLY to start a honing cycle after workpiece is securely fixtured and located on honing tool. Begin each new setup by depressing Emergency Stop button to clear all previous spindle and stroker speed settings. NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing ML2000.1 Always wear eye protection when operating ML2000. DO NOT attempt any repair or maintenance procedure beyond those described in this book. Contact your Sunnen® Service Representative for repairs not covered in this book. Manual stroked honing and truing should only be performed by operators trained to use safe manual honing practices. The key for switch to disable stroker and allow manual honing should be kept by a supervisor or skilled honing operator to prevent unauthorized manual honing. Much of the safety of the honing operation is dependent on how workpiece is fixtured. Several standard fixturing components are available but each is limited to certain types of applications. “Homemade” fixtures are also not uncommon and can be quite effective if designed and used properly. Sometimes it is necessary to clamp workpieces lightly when honing with special fixtures to minimize bore distortion. Likewise, tooling for small diameter honing is inherently fragile. Therefore, Always start a new setup with speeds and feed forces that are much lower than recommended to test stability of tooling and fixturing. After that, speeds and feed forces may be increased slowly to recommended values. If specially built automation components are added to this system, be sure that safety is not compromised. If necessary, obtain special enlarged work area safety system from Sunnen Products Co. Indicates CE version ONLY. 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous. vi CONTENTS PAGE Introduction .......................................................................................................... How To Order ...................................................................................................... How To Use This Parts List ................................................................................. General Information ............................................................................................. ESD Prevention Review ...................................................................................... Limited Product Warranty .................................................................................... Sunnen Software License Agreement .................................................................. General Safety Instructions .................................................................................. Contents ............................................................................................................... SECTION I BASIC MACHINE A Side View ........................................................................................................ B Upper Stroker .................................................................................................. C Lower Stroker ................................................................................................. D Feed Unit ........................................................................................................ E Front View ....................................................................................................... F Expand/Retract System .................................................................................. G Motor Assembly (MLU-2015) .......................................................................... H Save Saver Idler Assembly (MLU2000 ........................................................... I Spindle ............................................................................................................ J Cam Assembly ................................................................................................ K Outside Stroker ............................................................................................... L Front Panel (Inside) ......................................................................................... M Front Panel (Outside) ...................................................................................... N Universal Honing Fixture ................................................................................. O Foot Pedal ....................................................................................................... P Runout Indicator & Torque Bar ........................................................................ Q Coolant System (without Cycle Start) ............................................................. R Coolant System (with Cycle Start) .................................................................. S Operator Station Enclosure (MLU-4380) ........................................................ iii iii iii iv iv v v vi 1 2 4 6 8 11 12 14 15 16 19 20 22 25 26 28 29 30 33 37 SECTION II ELECTRICAL COMPONENTS T Operator Control Panel ................................................................................... 39 U Control Panel .................................................................................................. 40 V Control Panel .................................................................................................. 44 SECTION III OPTIONAL ITEMS W Automatic Size Control .................................................................................. 48 X Transformer Kit ................................................................................................ 50 “SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN® PRODUCTS COMPANY.” © Copyright 2007 by Sunnen® Products Company • Printed in U.S.A. Page 1 SECTION I BASIC MACHINE 3 1 4 5 10 7 16 9 8 22 12 23 18 20 17 13 24 19 6 14 25 2 11 21 25 28 29 26 30 27 31 FIGURE A – SIDE VIEW PARTS LIST COVERING FIGURE “A” ITEM NO. 1 2 3 4 5 6 7 8 9 10 10 11 11 12 13 ORDER BY PART NUMBER ------------------EC4010 EC4317 EC4015 EC4476 EC4023 EC4024 N/S indicates Not Shown Page 2 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Upper Stroker (See Fig. B) ....Lower Stroker (See Fig. C) ....Feed Unit (See Fig. D) ....Expand / Retract System (See Fig. F) ....Cam Assembly (See Fig. J) ....Spindle (See Fig. I) ....Outside Stroker (See Fig. K) ....Front Panel, Inside (See Fig. L) ....Universal Honing Fixture (See Fig. N) ....Right Beam Cover Assembly ....Right Beam Cover Assembly (CE Machines ONLY) ....Left Beam Cover Assembly ....Left Beam Cover Assembly (CE Machines ONLY) ....Right Hood Rest ....Left Hood Rest (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “A” ITEM NO. N/S 14 15 N/S N/S N/S 16 17 18 N/S N/S N/S 19 20 N/S N/S N/S N/S N/S N/S 21 22 23 24 25 26 27 28 29 N/S 30 31 N/S N/S N/S N/S N/S N/S N/S ORDER BY PART NUMBER PHNM434 PHSM401 EC4022 EC4021 PHSM966 PHWM509 EC4051A EC4052A EC4110 PHSM495 PHWM407 PHWM501 EC4140 EC4146 PHSM964 PHWM509 PHWM530 PHSM402 PHWM519 PHNM407 PFC103A PPP439A PPP477 PPP478 PPP190 EC5505 PHSM574 PPP–440A PFC–102A PHNM425 PFC101A PPP441 78156A 78157A 78158A 78159A 78160A 78161A 78162A N/S indicates Not Shown DESCRIPTION QTY. 4 6 1 1 2 2 1 1 1 4 4 4 1 1 2 2 2 2 2 2 1 1 1 1 1 1 2 1 2 2 6 2 * * * * * * * ....Insert Nut (M5) ....Screw (M5 x 0,8 x 12 SHCS) ....Left Corner Block ....Right Corner Block ....Screw (M6 x 1,0 x 25 SHCS) ....Lockwasher (M6) ....Right Hood Prop ....Left Hood Prop ....Machine Cover Frame ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Rear Panel Assembly ....Guide Plate ....Screw (M6 x 1,0 x 35 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Screw (M5 x 0,8 x 18 SHCS) ....Washer (M5) ....Nut (M5) ....Filter Regulator ....Elbow ....Adapter ....Street Elbow ....Hose Barb ....Solenoid Valve Manifold ....Screw (M4 x 0,7 x 30 SHCS) ....Straight Fitting ....Blanking Plate Assembly ....Nut (M4) ....Solenoid Valve ....Exhaust Muffler ....Tubing (4 mm O.D. White) ....Tubing (4 mm O.D. Black) ....Tubing (4 mm O.D. Red) ....Tubing (4 mm O.D. Blue) ....Tubing (4 mm O.D. Yellow) ....Tubing (4 mm O.D. Orange) ....Tubing (4 mm O.D. Green) * Sold by the foot only. Page 3 SECTION I BASIC MACHINE 50 42 48 45 44 32 38 49 36 26 51 33 43 47 37 46 34 35 31 39 41 8 40 20 30 23 22 23 22 24 9 21 2 10 9 29 28 8 25 27 3 11 4 5 1 6 7 FIGURE B – UPPER STROKER PARTS LIST COVERING FIGURE “B” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 20 21 ORDER BY PART NUMBER EC1526 PHSM498 PHWM407 PHWM501 EC1560 EC1564 PHSM539 PHSM495 PHWM407 PHWM501 PMO710A EC1530A PHSM498 N/S indicates Not Shown Page 4 QTY. 1 4 4 4 1 1 1 8 8 4 1 1 3 DESCRIPTION ....Rear Frame Member ....Screw (M8 x 1,25 x 30 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Stroker Motor Bracket Assembly ....Wedge ....Screw (M8 x 1,25 x 50 HHCS) ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Stroker Motor ....Crank Assembly ....Screw (M8 x 1,25 x 30 HHCS) (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “B” ITEM NO. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 N/S N/S ORDER BY PART NUMBER PHWM407 PHWM501 PHSM582 EC1537 EC1536 PHSM498 PHWM407 PHWM501 PHSM595 PHNM443A PES663A ML4730A ML4731A ML4732A ML4733A ML4734A ECA7558 EC4376 EC1566A PHSM538 EC1551A PHKM102A PHSM495 PHNM401 ECA7559 PDB320A EC1552 PHSM495 PHWM407 EC1553 ML4316 ML4742 QTY. 5 5 2 1 1 4 4 4 1 1 6 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 DESCRIPTION ....Lockwasher (M8) ....Washer (M8) ....Screw (M8 x 1,25 x 50 HHCS) ....Left Frame Member ....Right Frame Member ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Screw (M10 x 1,5 x 45 HHCS) ....Nut ....Proximity Switch, NC (Pkg. of 1) ....Proximity Switch Cable Adaptor, Stroke Length #1 ....Proximity Switch Cable Adaptor, Stroke Length #2 ....Proximity Switch Cable Adaptor, Stroke Length #3 ....Proximity Switch Cable Adaptor, Stroke Pulley #1 ....Proximity Switch Cable Adaptor, Stroke Pulley #2 ....Proximity Switch Bracket ....Proximity Sensors Support ....Stroker Motor Pulley with ......Setscrew (M6 x 1,0 x 8 FPSS) ....Stroker Pulley ....Key ....Screw (M8 x 1,25 x 20 HHCS) ....Nut (M8) ....Stroker Pulley Target ....Belt ....Wedge ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (Special) ....P.S.C. Sensor Bracket ....PSC Sensor Cable N/S indicates Not Shown Page 5 SECTION I BASIC MACHINE FIGURE C – LOWER STROKER PARTS LIST COVERING FIGURE “C” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 ORDER BY PART NUMBER EC1512 PHSM498 PHWM407 PHWM501 EC1595 PBR196A PHM783A PPPM411 PHSM966 PHWM509 PHWM530 EC1850 EC1670 N/S indicates Not Shown Page 6 QTY. 1 4 4 4 1 1 2 1 2 2 2 1 1 DESCRIPTION ....Front Stroker Frame ....Screw (M8 x 1,25 x 30 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Front Pillow Block ....Ball Bushing ....Seal (Pkg. of 1) ....Grease Fitting ....Screw (M6 x 1,0 x 25 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Stroker Drive Shaft Assembly ....Rear Pillow Block (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “C” ITEM NO. 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 ORDER BY PART NUMBER PHSM495 PHWM407 PHWM501 PBR196A PHM783A PPPM411 EC1660A EC1656 PBR216A PBR214A EC1658 EC1657 PSP530A EC1659 PHNM419 PHNM408 PHSM495 PHWM407 PHWM501 EC1646 PBR214A EC1647 PPPM411 EC1648 EC4769 PHNM408 EC4768 PHM212A EC1641 EC1639A PHPM535 EC1642 PHSM964 PDB206A EC1636 EC1637 PHSM962 EC1653 EC4771 PHM373A PSP527A PHNM419 PHNM408 QTY. 2 2 2 1 2 1 1 2 2 1 1 1 2 1 1 1 2 2 2 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 2 4 1 1 1 1 1 1 DESCRIPTION ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Ball Bushing ....Seal (Pkg. of 1) ....Grease Fitting ....Cross Beam Assembly ....Yoke Link ....Bearing (Pkg. of 1) ....Roller ....Pin ....Roller Yoke ....Disc Spring (Pkg. of 2) ....Yoke Guide ....Nut (M10) ....Nut, Jam (M10) ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Cross Beam Pivot Assembly with ......Roller ......Pin ......Grease Fitting ....Short Rod ....Long Rod ....Nut ....Pulley Shaft ....Timing Pulley ....Pulley Bracket ....Idler Pulley ....Dowel Pin (8 Dia. x 20 M6) ....Tensioning Block ....Screw (M6 x 1,0 x 35 SHCS) ....Timing Belt ....Belt Connector ....Belt Clamp ....Screw (M3 x 0,5 x 12 SHCS) ....Guide Block ....Spacer ....Hand Lever ....Disc Spring ....Nut (M10) ....Nut, Jam (M10) N/S indicates Not Shown Page 7 SECTION I BASIC MACHINE 63 65 62 64 41 38 61 41 40 39 75 72 73 93 47 29 15 18 11 17 14 22 19 28 30 23 37 34 12 26 31 21 32 33 83 80 82 76 87 84 58 20 81 81 67 60 48 13 50 85 86 49 79 88 27 18 35 36 68 59 77 71 70 78 92 16 25 100 74 69 94 46 98 99 95 66 42 44 45 97 96 65 10 24 19 34 7 9 17 6 8 2 55 1 89 56 53 4 90 91 5 3 57 54 55 52 50 51 FIGURE D – FEED UNIT PARTS LIST COVERING FIGURE “D” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER EC2555 PHSM495 PHWM407 EC2571 PHSM548 PHSM963 EC2849 PHSM401 PHWM519 PHNM434 EC2687 PHSM402 PHSM597 PHNM401 EC2692A EC2691A N/S indicates Not Shown Page 8 QTY. 1 4 4 1 1 1 1 2 2 2 1 2 1 1 1 1 DESCRIPTION ....Feed Unit Frame ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Retraction Stop ....Setscrew (M8 x 1,25 x 16 FPSS) ....Screw (M5 x 0,8 x 20 SHCS) ....Damper Spring Bracket ....Screw (M5 x 0,8 x 12 SHCS) ....Washer (M5) ....Insert Nut ....Overtravel Stop Bar ....Screw (M5 x 0,8 x 16 SHCS) ....Setscrew (M8 x 1,25 x 25 FPSS) ....Nut (M8) ....Left Acuator Bracket ....Right Actuator Bracket (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “D” ITEM NO. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 N/S N/S 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 ORDER BY PART NUMBER PHSM405 PHWM509 PHWM518 PHSM495 PHWM407 PHWM501 EC2500 EC2580 EC2583 EC2578 PBR517 PHPM534 PSP222 EC2579 PSP327 EC4491 PHNM435 EC2582 EC4467 PHNM434 PHSM963 EC2584 PHNM434 PHWM519 PFC–108A PFC–104A EC2651 EC2649 EC2648 EC2674 EC2619A EC2673 PHR361 PPPM411 EC2670 EC2684A PHR361 EC2680 EC2683A PHPM538 PBR–216A EC2686 EC2675 EC4407 EC2610A EC2638 PBR212A EC2640 EC2803 PHSM405 N/S indicates Not Shown QTY. 4 4 4 4 4 4 1 1 1 1 1 1 1 1 2 1 2 1 1 2 3 2 2 1 1 2 1 2 2 1 1 1 2 4 1 1 2 1 1 1 1 2 1 1 1 2 4 1 1 3 DESCRIPTION ....Screw (M6 x 1,0 x 16 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Indicator Assembly includes ......Indicator Frame Assembly ......Pin ......Indicator Finger ......Ball ......Dowel Pin ......Spring ......Spacer ......Spring (Pkg. of 2) ......Split Bushing ......Nut, Jam (M27 x 3,0) ......LVDT ......Clip ......Nut, Insert (M5 x 1,8) ....Screw (M5 x 0,8 x 20 SHCS) ....Spacer ....Insert Nut ....Washer (M5) ....Air Cylinder ....Flow Control Valve (Pkg. of 1) ....Actuator Rod End ....Counterbalance Pivot Pin ....Counterbalance Pivot Block ....Spring Support ....Feed Spring ....Counterbalance Pivot Pin ....Retaining Ring ....Grease Fitting ....Right Frame Section ....Main Pivot Pin ....Retaining Ring ....Main Lever ....Indicator Point ....Dowel Pin (10 Dia. x 30) ....Roller Bearing ....Spacer ....Left Frame Section ....Disassembly Warning Label ....Spring Link ....Control Link ....Roller Bearing (Pkg. of 2) ....Right Input Link ....Input Link Bracket ....Screw (M6 x 1,0 x 16 SHCS) (Parts continued on next page) Page 9 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “D” ITEM NO. 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95a 95b 96 97a 97b N/S 98 99 100a 100b ORDER BY PART NUMBER PHSM405 PHWM509 PHNM407 EC–2661A PHR363 EC2656 EC2659 PHSM516 EC2657A EC2658A PHSM573 PHWM516 EC2636 PHM479A EC1787A EC2645 EC2678 PHSM463 EC2676 EC2677 PHSM588 PBR–212A EC2637 PHWM501 PHRM303 PHSM495 PHWM407 PNP327 EC2652A PHWM406 PHSM431 --PHSM667 CRG868 ML4727 PES669 CBL332 ML4741 PEM983 MLA4859 PHWM528 PHNM402 N/S indicates Not Shown Page 10 QTY. 2 2 1 1 1 1 2 4 2 2 2 2 1 2 2 1 2 4 2 2 4 2 1 2 2 4 4 1 2 4 4 Ref. 2 2 1 1 1 1 1 1 4 4 DESCRIPTION ....Screw (M6 x 1,0 x 16 SHCS) ....Lockwasher (M6) ....Nut (M6) ....Input Link Pivot Pin ....Retaining Ring ....Input Link Frame ....Washer Plate ....Screw (M5 x 0,8 x 25 SHCS) ....Stop Block (Pkg. of 1) with ......Compression Pad (Pkg. of 2) ....Screw (M4 x 0,7 x 20 SHCS) ....Washer (M4) ....Linkage Yoke ....Ball Plunger (Pkg. of 1) ....Pad (Pkg. of 1) ....Left Input Link ....Flexible Coupling ....Setscrew (M6 x 1,0 x 10 CPSS) ....Force Adjustment Screw ....Stop Collar ....Setscrew (M5 x 0,8 x 6 CPSS) ....Roller Bearing (Pkg. of 2) ....Spring Link Pivot Pin ....Washer (M8) ....Retaining Ring ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Warning Label (Used on “CE” Machines only) ....Control Link Retainer (Pkg. of 1) ....Lockwasher ....Screw (M5 x 0,8 x 10 BHCS) ....Anti-Glaze Unit includes ......Screw ......Washer ......Prox. Mounting Plate ......Module Prox. Switch ......DC Prox. Cable ......CTC Upper Limit ......Mounting Collar ......Anti-Glaze Prox. Switch Bracket ......Washer ......Nut SECTION I BASIC MACHINE 5 14 13 17 1 8 7 12 6 11 9 15 16 4 3 10 2 FIGURE E – FRONT VIEW PARTS LIST COVERING FIGURE “E” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 N/S 13 14 N/S 15 16 N/S N/S 17 N/S ORDER BY PART NUMBER ----------EC4408 EC4420 PHM536 ML4470 EC4485 EC6510A EC6519A EC6518A EC4255A EC4250A PHM484A EC4291A PHM788A PHSM966 EC4292 EC4325 EC4335 QTY. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 DESCRIPTION ....Front Panel (See Fig. L & M) ....Foot Pedal (See Fig. O) ....Coolant System (See Fig. Q & R) ....Control Panel (See Fig. U) ....Operator Station Enclosure (See Fig. S) ....Side Shelf Mat ....Oil Tray ....Ball Knob ....Operator Station Support ....Gage Tray Assembly (Optional) ....Side Tray Assembly (Optional) includes ......Side Tray Mat ......Spacer (Pkg. of 2) ....Left Hood Assembly ....Right Hood Assembly ....Latch (Pkg. of 1) ....Spindle Splash Guard ....Knob ....Screw ....Spacer ....Left Guard Assembly (CE Machines ONLY) ....Right Guard Assembly (CE Machines ONLY) N/S indicates Not Shown Page 11 SECTION I BASIC MACHINE 39 56 38 40 41 35 37 43 42 36 12 27 21 22 18 19 20 34 16 17 53 23 31 29 52 15 14 26 20 19 13 28 25 1 9 11 51 33 24 54 46 2 3 45 44 4 32 30 31 10 50 47 49 5 55 6 48 7 8 FIGURE F – EXPAND/RETRACT SYSTEM PARTS LIST COVERING FIGURE “F” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 ORDER BY PART NUMBER EC2810 PHSM966 PHWM518 PHWM509 EC2842A PHWM518 PHRM308 PSP328A EC2885 EC2948 PHSM520 PHWM516 PHNM402 N/S indicates Not Shown Page 12 QTY. 1 4 4 4 1 1 1 1 1 1 2 2 2 DESCRIPTION ....Cam Assembly (See Fig. J) ....Screw (M6 x 1,0 x 25 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Damper Spring Link ....Washer ....Retaining Ring ....Spring ....Cable Hook Assembly includes ......Proximity Switch Bracket ......Screw (M4 x 0,7 x 10 SHCS) ......Washer (M4) ......Nut (M4) (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “F” ITEM NO. 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 ORDER BY PART NUMBER EC2880 EC2906A PHNM402 EC2874A EC2875 EC2848 PHWM518 PHNM407 PHSM401 PHWM519 PHNM434 EC2957A EC2956A EC2894A EC2897A PHRM305 EC2898A EC2887A PHRM305 EC2896A PHM475A EC2890 PFC109A PPP439A PFC104A EC2549 EC2892A PHNM420 PHR363 PHSM495 PHWM407 PEM983 PHWM528 PHNM402 ML4727 PHSM520 PHWM516 PHWM528 PHNM402 PES669 ML4735 PES670 ML4736 MLU2015 QTY. 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 2 1 1 2 1 2 1 1 1 1 1 1 1 1 2 2 2 4 4 2 4 4 4 4 1 1 1 1 1 DESCRIPTION ......Cable Hook Assembly ......Cable Assembly ......Nut (M4) ......Cable Spring ......Spring Retainer Assembly ......Cable Bracket ......Washer (M6) ....Nut (M6) ....Screw (M5 x 0,8 x 12 SHCS) ....Washer (M5) ....Insert Nut ....Counter Balance Spring ....Spring Connector Link ....Link ....Pin with ......Retaining Ring ....TRiCoupling ....Pin with ......Retaining Ring ....Chain ....Chain Connector (Pkg. of 2) ....Rod End Assembly ....Air Cylinder ....Elbow ....Flow Control Valve ....Retraction Cylinder Bracket ....Retraction Cylinder Pivot Pin ....Nut (M16) ....Retaining Ring ....Screw (M8 x 1,25 x 20 HHcs) ....Lockwasher (M8) ....Mounting Collar ....Washer (M4) ....Nut (M4) ....Proximity Mounting Plate ....Screw (M4 x 0,7 x 10 SHCS) ....Washer (M4) ....Washer (M4) ....Nut (M4) ....Modular Proximity Switch, NO ....Foot Pedal #1 Proximity Cable ....Modular Proximity Switch, NC ....Foot Pedal #2 Proximity Cable ....Cycle Time Control Motor Assembly (See Fig. G) N/S indicates Not Shown Page 13 SECTION I BASIC MACHINE FIGURE G – CYCLE TIME CONTROL MOTOR ASSEMBLY PARTS LIST COVERING FIGURE “G” ITEM NO. 1 2 3 4 6 5 7 8 10 11 12 13 14 15 Page 14 ORDER BY PART NUMBER MLU2015 PMO166 MLA4854 PHW342 PHS614 PHS683 MLU2022 MLU2011 PHSM1089 PHNM407 PHSM622 MLU2018 PHSM623 MLU4856 PHS508 QTY. Ref. 1 1 4 2 2 1 1 2 2 2 1 1 1 3 DESCRIPTION ....Cycle Time Contrl Motor Assembly includes ......DC Gearmotor - Extended Shaft ......Motor Bracket ......Flatwasher (#10) ......Screw (#10-32 x 1/2 BHCS) ......Screw (#10-32 x 5/8 BHCS) ......Torque Arm ......Motor Mounting Plate ......Screw (M6 x 1,0 x 16 HHCS) ......Nut, Hex (M6 X 1,0) ......Screw (M6 x 1,0 x 12 HHCS) ......Electric Clutch ......Screw (M4 x 0,7 x 8 BHCS) ......Anti-Glaze Drive Gear ......Screw (#6-32 x 7/8 SHCS) SECTION I BASIC MACHINE FIGURE H – CYCLE TIME CONTROL IDLER ASSEMBLY PARTS LIST COVERING FIGURE “H” ITEM NO. 1 2 3 4 5 6 7 8 9 ORDER BY PART NUMBER MLU2000 MLU2003 PBR135 MLU2006 MLU2001 MLU2002 MLU2009 PHSM490 PHWM517 PHNM402 QTY. Ref. 1 2 1 1 1 1 2 2 2 DESCRIPTION ....Cycle Time Control Idler Assembly includes ......Pinion Bracket ......Bearing ......Anti-Glaze Pinion Gear ......Anti-Glaze Driven Shaft ......Anti-Glaze Driven Sprocket ......Pinion Support Bracket ......Screw (M4 x 0,7 x 12 SHCS) ......Lockwasher (M4) ......Nut, Hex (M4 x 0,7) Page 15 SECTION I BASIC MACHINE 76 80 78 77 76 79 20 70 82 81 84 85 83 49 44 57 50 52 51 69 68 66 64 65 67 61 55 63 34 36 31 73 71 33 27 29 38 42 35 41 46 47 45 48 19 75 23 18 72 62 58 43 56 74 22 21 58 59 60 37 30 24 32 25 28 9 39 53 40 26 1 17 54 16 11 12 15 13 14 86 10 FIGURE I – SPINDLE PARTS LIST COVERING FIGURE “I” ITEM NO. 1 2 9 N/S 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ORDER BY PART NUMBER PMO967A PHSM556 PEC127 PEM251 ML2510A PHSM498 PHWM407 PHWM532 EC1564 PHSM539 EC2114A PHSM538 EC2010A PHK112A PHSM405 EC2041 EC2040 PHSM551A PHR116 N/S indicates Not Shown Page 16 QTY. 1 4 1 1 1 4 4 4 1 1 1 1 1 1 4 1 1 8 1 DESCRIPTION ....Spindle Motor ....Screw ....Cord Grip ....Rubber Spacer ....Spindle Motor Base ....Screw (M8 x 1,25 x 30 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Wedge ....Screw (M8 x 1,25 x 50 HHCS) ....Motor Pulley with ......Setscrew (M6 x 1,0 x 8 FPSS) ....Spindle Assembly ....Key ....Screw (M6 x 1,0 x 16 SHCS) ....Spindle Nose Washer ....Spindle Nose ....Setscrew (M8 x 0,75 x 16 FPSS) (Pkg. of 8) ....Retaining Ring (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “I” ITEM NO. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 ORDER BY PART NUMBER EC2046A EC2044 PHSM549 PHPM501 EC2501A EC2070A PHSM538 PDB340A EC2511A EC2516 PHSM520 PBR211A EC2512 PHSM556 EC2532 EC2515 EC2520 EC2525A EC2541 PHSM966 PHWM509 PHWM518 EC2536A EC2538A EC2537 EC2542 PHM122A PBR215 PHM213A PHSM495 PHWM407 PBR213A EC2693 PHSM599 PHWM518 PHWM509 PHNM407 PDB207A PHM213A PBR215 EC2799 PHSM607 PHWM509 PHWM518 EC2796 EC2797 PHSM402 EC2768 EC2773A N/S indicates Not Shown QTY. 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 2 1 3 3 1 2 1 2 1 1 1 1 1 1 2 2 2 2 1 1 1 1 DESCRIPTION ....Drive Plate ....Inner Spindle Nose ....Setscrew (M12 x 1,75 x 16 FPSS) ....Dowel Pin (4 Dia. x 12) ....Wedge Hook ....Spindle Pulley with ......Setscrew (M6 x 1,0 x 8 FPSS) ....Belt ....Feed Rod ....Cover Plate ....Screw (M4 x 0,7 x 10 SHCS) ....Bearing (Pkg. of 2) ....Shoulder Washer ....Screw (M10 x 1,5 x 25 FHCS) ....Torque Bracket ....Guide Feed Rod Unit includes ......Feed Rod Guide Assembly ......Guide Feed Rod Assmebly ......Bracket ......Screw (M6 x 1,0 x 25 SHCS) ......Lockwasher (M6) ......Washer (M6) ......Feed Screw ......Feed Screw Gear ......Retractor Yoke ......Intermediate Shaft ......Gear ......Bearing ......Timing Pulley ....Screw (M8 x 1,25 x 20 HHCS) ....Lockwasher (M8) ....Roller ....Spacer ....Screw (M6 x 1,0 x 60 SHCS) ....Washer (M6) ....Lockwasher (M6) ....Nut (M6) ....Timing Belt ....Timing Pulley ....Bearing ....Shaft Support Bracket ....Screw (M6 x 1,0 x 30 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Drag Spring Clamp ....Drag Spring ....Screw (M5 x 0,8 x 16 SHCS) ....Pulley Shaft ....Drag Wheel (Parts continued on next page) Page 17 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “I” ITEM NO. 73 74 75 76 77 78 79 80 81 82 83 84 85 86 ORDER BY PART NUMBER EC2772 PHSM538 EC2771 EC2696 PBR213A PHPM539 EC2698 PHSM598 PHWM407 PHWM401 EC2697 PHSM597 PHNM401 PHSM556 N/S indicates Not Shown Page 18 QTY. 1 1 1 2 1 1 1 3 3 3 1 1 1 4 DESCRIPTION ....Clamp Collar ....Setscrew (M6 x 1 x 8 FPSS) ....Feed Shaft ....Feed Control Arm ....Roller ....Dowel Pin (6 Dia. x 24) ....Control Arm Spacer ....Screw (M8 x 1,25 x 35 HHCS) ....Lockwasher (M8) ....Nut (M8) ....Control Arm Extension ....Setscrew (M8 x 1,25 x 25 FPSS) ....Nut (M8) ....Screw SECTION I BASIC MACHINE FIGURE J – CAM ASSEMBLY PARTS LIST COVERING FIGURE “J” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ORDER BY PART NUMBER EC2810A EC2856 PBR218A EC2835A PHSM507 EC2820 EC2823 PHSM401 EC2834 PHSM573 EC2844 PHSM540 EC2858A PHRM307 EC2830A EC2826 PHSM401 EC2846 PBR220A PHR362 EC2840A EC2847 EC2871 EC2826 PHSM401 PHSM490 QTY. 1 1 2 1 1 1 1 2 1 1 1 3 1 1 1 1 1 1 2 1 1 1 1 1 1 3 DESCRIPTION ....Cam Assembly includes ......Cam Housing ......Bearing (Pkg. of 2) ......Sping Lever Assembly ......Screw (M5 x 0,8 x 30 SHCS) ......Damper Lever Assembly ......Dog Block ......Screw (M5 x 0,8 x 12 SHCS) ......Dog Collar ......Screw (M4 x 0,7 x 20 SHCS) ......End Plate ......Screw (M4 x 0,7 x 10 FHCS) ......Camshaft ......Retaining Ring ......Cable Lever Assembly ......Dog Block ......Screw (M5 x 0,8 x 12 SHCS) ......Housing ......Bearing (Pkg. of 2) ......Retaining Ring ......Auto Lever Assembly ......Shim Cover ......Eccentric Cam ......Dog Block ......Screw (M5 x 0,8 x 12 SHCS) ......Screw (M4 x 0,7 x 12 SHCS) N/S indicates Not Shown Page 19 SECTION I BASIC MACHINE FIGURE K – OUTSIDE STROKER PARTS LIST COVERING FIGURE “K” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ORDER BY PART NUMBER EC1172 EC1594A EC1822 PHSM402 PHSM966 PHWM518 PPPM417A PFC115A PEM695A PEC139A PEC140A EC1853 EC1858A EC1855A PSP225A EC1859A PHSM437 PHWM528 EC1817 PHSM507 PHWM406 EC1671 EC1850A EC1866 N/S indicates Not Shown Page 20 QTY. 1 1 2 1 6 6 2 2 1 1 1 2 1 1 1 1 2 2 1 3 3 1 1 2 DESCRIPTION ....Spindle Frame ....Seal ....Collar ....Screw (M5 x 0,8 x 16 SHCS) ....Screw (M6 x 1,0 x 25 SHCS) ....Washer (M6) ....Bulkhead Union (Pkg. of 1) ....Flow Control Valve (Pkg. of 1) ....Female Receptacle ....Clamp ....Plug ....Latch Plate ....Front Latch Finger ....Latch Wedge Assembly ....Spring ....Rear Latch Finger ....Screw (M4 x 0,7 x 25 SHCS) ....Lockwasher (M4) ....Spacer ....Screw (M5 x 0,8 x 30 SHCS) ....Lockwasher (M5) ....Rear Pillow Block ....Stroker Drive Shaft Assembly ....Lifter Arm (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “I” ITEM NO. 25 26 27 28 29 30 31 32 33 34 ` 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 ORDER BY PART NUMBER PBR228A PHWM531 EC1867 PHPM548 PHSM598 PHWM407 PHWM501 EC1871A EC1869 PBR228A PHSM534 PHWM530 EC1872 PHSM963 PHWM406 EC1861 PHSM965 PHWM407 PHSM625 PFC118A PPP439A EC1862 PHNM401 EC1876A EC1880A EC1781 EC1890A EC1885A PHM494A PHSM966 EC1782 EC1787A PHSM422 PSP228A EC1784 EC1788A PBR199A PBR197A PBR198A PHSM963 EC1786 PHNM437A MLU1825 EC1815A PHSM966 PHWM509 PHWM518 EC1811 PFC117A PPPM423A QTY. 2 3 1 1 2 2 2 1 1 2 2 2 1 4 4 1 2 2 2 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 3 1 1 1 2 8 8 8 2 1 1 DESCRIPTION ....Bushing (Pkg. of 2) ....Washer ....Lifter Pivot Block with ......Dowel Pin (36 x 10) ....Screw (M8 x 1,25 x 35 HHCS) ....Lockwasher (M8) ....Washer (M8) ....Roller ....Roller Shaft ....Bushing (Pkg. of 2) ....Screw (M6 x 1,0 x 20 SHCS) ....Lockwasher (M6) ....Lifter Bar ....Screw (M5 x 0,8 x 20 SHCS) ....Lockwasher (M5) ....Unlatch Cylinder Base ....Screw (M8 x 1.25 x 20 HHCS) ....Lockwasher (M8) ....Screw (M5 x 0,8 x 50 SHCS) ....Air Cylinder ....Elbow (Pkg. of 1) ....Rod End ....Nut, Hex (M8 x 1,25) ....Stop Collar Nut (Pkg. of 1) ....Stroker Extension Tube ....Carriage Position Screw ....Bottom Clamp Block Assembly ....Top Clamp Block Assembly ....Hand Lever ....Screw (M6 x 1,0 x 25 SHCS) ....Carriage Position Handwheel ....Pad ....Setscrew (M5 x 0,8 x 12 CPSS) ....Wave Spring ....Collar ....Bearing/Spring Locator Plate ....Thrust Bearing Washer (Pkg. of 2) ....Center Thrust Bearing Washer ....Thrust Bearing Roller Assembly (Pkg. of 2) ....Screw (M5 x 0,8 x 20 SHCS) ....Bearing Locator Plate ....Bearing Nut ....Stroker Carriage ....Pillow Block Assembly (Pkg. of 1) ....Screw (M6 x 1,0 x 25 SHCS) ....Lockwasher (M6) ....Washer (M6) ....Ball Bushing Shaft ....Regulator ....Elbow N/S indicates Not Shown Page 21 SECTION I BASIC MACHINE 1 79 78 74 76 85 82 70 75 81 77 6 70 73 82 28 68 69 71 73 72 71 66 64 69 72 22 32 64 21 65 30 47 44 59 18 53 60 57 48 46 38 54 39 49 37 14 51 13 50 12 FIGURE L – FRONT PANEL (INSIDE) Page 22 36 43 42 45 58 15 35 41 56 17 34 11 52 55 16 9 33 62 19 29 3 61 20 10 27 26 31 25 2 63 4 7 8 84 83 68 23 5 81 76 77 24 80 82 67 40 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “L” ITEM NO. 1 1 2 3 4 5 6 7 8 9 10 N/S N/S 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 ORDER BY PART NUMBER EC4765 EC4765CE PHSM535 PHWM530 ML2756 PHSM401 PHWM529 PED1057A PEM701 PES379A PEC179 PEM252 PEM302 EC2920A EC2925 CRG939A EC2927 EC2926 KKN912 KKN905 EC2935A EC2936 EC2937A EC2939 PSP223 EC2930 PHSM421 PHSM421 EC2931 PHSM421 EC2991A EC2914 EC2913 PHSM424 PHWM518 PHRM308 EC2782 PHSM963 PHWM519 PFC113A PFC114A PPPM422 PPP479A EC2776 EC2774 PHPM514 EC2777 PHNM408 N/S indicates Not Shown QTY. 1 1 4 4 1 6 4 1 2 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 2 2 1 1 2 2 1 1 5 1 1 1 2 1 4 DESCRIPTION ....Front Panel Assembly ....Front Panel Assembly (CE Machines ONLY) ....Screw (M6 x 1,0 x 12 SHCS) ....Washer (M6 Fender) ....Indicator Electrical Enclosure ....Screw (M5 x 0,8 x 12 SHCS) ....Washer (M5) ....LVDT Circuit Board ....12 Pole Plug ....Contact Block (Pkg. of 1) ....Strain Relief Connector with ......Sealing "O" Ring w/ Retainer ......Lock Nut ....Damper Assembly includes ......Cylinder Cap ......"O" Ring ......Damper Weight ......Spacer Tube ......Cylinder ......Piston ......Piston Pivot ......Piston Nut ......Metering Screw ......Spring Cup ......Spring ......Stop Collar ......Setscrew (M4 x 0,7 x 5 FPSS) ....Setscrew (M4 x 0,7 x 5 FPSS) ....Feed Regulator Dial ....Setscrew (M4 x 0,7 x 5 FPSS) ....Coiled Tape ....Feed Regulator Screw ....Standoff ....Screw (M6 x 1,0 x 20 HHCS) ....Washer (M6) ....Retaining Ring ....Rack Support ....Screw (M5 x 0,8 x 20 SHCS) ....Washer (M5) ....Valve ....Valve Adapter ....Elbow ....Union "Y" Fitting ....Link ....Clevis ....Spring Pin ....Compensator Screw ....Nut, Jam (M10) (Parts continued on next page) Page 23 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “L” ITEM NO. 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 N/S 67 N/S 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 ORDER BY PART NUMBER PHR363 EC2766 EC2792 EC2787 EC2788 PHSM574 EC2781 EC2783 PHSM573 EC2784A EC2786 PBR223A EC2772 PHSM538 EC2771 EC2791 PHSM613 PFC110A PEC116A PHSM401 EC2731 EC2736 EC2732 EC2737 EC2727 EC2728 PHSM550 PHM121 EC2735A PHSM588 EC2739 PHM120 PHM119 EC2741 PHSM401 PHWM529 PES659 PES644 PEM961 PEM671 PEM1066 MLU2000 N/S indicates Not Shown Page 24 QTY. 1 1 1 1 2 2 1 1 2 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 2 6 2 2 2 1 2 2 2 1 1 2 2 3 1 1 1 DESCRIPTION ....Retaining Ring ....Feed Dial Shaft ....Compensator Rack ....Spring Opening Plate ....Standoff ....Screw (M4 x 0,7 x 30 SHCS) ....Compensator Gear ....Spring Housing ....Screw (M4 x 0,7 x 20 SHCS) ....Torsion Spring ....Clutch Housing ....Roller Clutch ....Clamp Collar ....Setscrew (M6 x 1,0 x 8 FPSS) ....Feed Shaft ....Rack Rod End ....Screw (M4 x 0,7 x 16 SHCS) ....Air Cylinder ....Flow Control Valve (Pkg. of 1) ....Screw (M5 x 0,8 x 12 SHCS) ....Finishing Force Dial ....Finishing Dial Face ....Roughing Force Dial ....Roughing Dial Face ....Feed Force Input Shaft ....Output Gear (Pkg. of 1) ....Screw (M3 x 0,5 x 8 SHCS) ....Pinion (Pkg. of 1) ....Coupling Assembly (Pkg. of 1) ....Setscrew (M5 x 0,8 x 6 CPSS) ....Gear Cluster Bracket ....Gear (Pkg. of 1) ....Gear (Pkg. of 1) ....Intermediate Gear Shaft ....Screw (M5 x 0,8 x 12 SHCS) ....Washer (M5) ....Key Switch, 2 Position (CE Machines w/Spindle Reverse) ....Contact, N.O., Screw Term. (CE Machines w/Spindle Reverse) ....Mounting Collar (CE Machines w/Spindle Reverse) ....Green LED Light Block (CE Machines w/Spindle Reverse) ....Green Pilot Light Head (CE Machines w/Spindle Reverse) ....Cycle Time Control Idler Assembly (See Fig. H) SECTION I BASIC MACHINE 17 14 R 16 ML-5000 PRECISION HONING MACHINE PATENTED 13 22 X L X AK AN-600 AL BAL JAK JK BL BLR L K KR LR P20 P28 R28 Y YY A B A B mm D2 170 160 140 120 A 100 12 19 IN 6.6 6.0 5.0 80 3.0 70 8 2.5 60 11 9 7 6 21 4.0 90 50 2.0 18 20 15 45 40 1.5 35 30 (A > B) X0 5 25 1.0 3 4 L = 0.95 X A A 20 L .5 (B > A) 10 10 3 B 15 .4 6 .25 L = 0.95 X B A .3 L B ML-2996CE / IL-1148 2 1 FIGURE M – FRONT PANEL (OUTSIDE) PARTS LIST COVERING FIGURE “M” ITEM NO. 1 1 2 3 N/S 4 5 5 6 7 8 9 10 10 N/S 11 12 13 14 N/S N/S 15 15 16 N/S 17 18 19 N/S 20 21 22 ORDER BY PART NUMBER MLU2724EN MLU2724CE PFC112A EC2918 PHSM609 EC2763 EC2764 EC2764M EC2761 EC2762 EC2769A PHSM608 ML2751A ML2751MA ML2754A PES378A EC2726 EC3782 PED32 PES3786 PES456A MLU2996EN MLU2996CE EC2994 PHSM609 EC2762 EC2992A PHSM604 PHNM400 PHM373 PNP331 --- QTY. 1 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 DESCRIPTION ....Front Panel Overlay (English Version) ....Front Panel Overlay (CE Icon Version) ....Push Button ....Knob ....Setscrew (M4 x 0,7 x 6 CPSS) ....Feed Dial Disc ....Feed Dial Face (Inch) ....Feed Dial Face (Metric) ....Feed Knob ....Knob Handle ....Index Piece ....Screw (M3 x 0,5 x 12 FHCS) ....Honing Indicator (Inch) ....Honing Indicator (Metric) ....Gasket (For Indicator) ....4Position Selector Switch ....Force Knob ....Sparkout LED Cable ....Potentiometer Operator ....Sparkout Potentiometer Cable includes ......Potentiometer ....Stroker Overlay (English Version) ....Stroker Overlay (CE Icon Version) ....Stroke Length Handwheel ....Setscrew (M4 x 0,7 x 6 CPSS) ....Knob Handle ....Index Piece ....Screw (M3 x 0,5 x 12 FHCS) ....Nut (M3) ....Hand Lever ....Label, Safety Glasses ....Key Switch, 2 Position (CE Machines w/Spindle Reverse) N/S indicates Not Shown Page 25 SECTION I BASIC MACHINE 36 55 56 47 52 54 53 6 40 39 38 5 1 57 4 16 3 17 35 20 41 10 24 30 11 9 12 22 21 26 18 31 51 8 19 28 37 2 7 23 46 50 49 27 25 13 31 42 43 45 14 29 33 15 34 44 32 41 FIGURE N – UNIVERSAL HONING FIXTURE PARTS LIST COVERING FIGURE “N” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ORDER BY PART NUMBER EC6100A EC6117A EC6126A EC6127A EC6132A KKN613C PHSM616 EC6133A PBR224A PHSM964 PHWM509 PSP330A EC6131A PHSM534 EC6134A PHSM615A EC6141A EC6142A PHSM534 PHWM509 N/S indicates Not Shown Page 26 QTY. 1 1 1 1 4 2 1 2 2 2 2 1 1 4 2 2 1 1 1 1 DESCRIPTION ....Universal Honing Fixture includes ......Gate ......Right Finger ......Left Finger ......Spacer (Pkg. of 2) ......Carbide Tip (Pkg. of 2) with ........Screw (M4 x 0,7 x 8 FHCS) ......Roller Spacer (Pkg. of 1) ......Bearing (Pkg. of 1) ......Screw (M6 x 1,0 x 35 SHCS) ......Lockwasher (M6) ......Spring ......Finger Frame ......Screw (M6 x 1,0 x 20 SHCS) ......Knurled Nut (Pkg. of 2) ......Screw (M6 x 1,0 x 40 SHCS) (Pkg. of 2) ......Block ......Pin ......Screw (M6 x 1,0 x 20 SHCS) ......Lockwasher (M6) (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “N” ITEM NO. 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 ORDER BY PART NUMBER PHWM534A EC6143A EC1767A PHM372A PBR224A PHSM405 PHWM518 PHRM308 EC6139A EC6136A EC6137A EC6138A PHSM425 PHWM509 PHWM518 EC6105A PHSM661 EC6108A EC6109A PHSM607 PHSM405 EC6122A PHSM607 EC6118A PHSM512 EC6119A PHPM546A EC6116A PBR225A PHSM534 PHWM518 EC6111A PHSM607 EC6121A EC6123A KKN613A PHSM616 PHSM966 QTY. 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 6 1 1 1 2 2 2 1 2 1 1 1 2 2 2 2 2 1 4 4 4 4 DESCRIPTION ......Washer (Special) ......Arm ......Cam Lever ......Knob ......Bearing ......Screw (M6 x 1,0 x 16 SHCS) ......Washer (M6) ......Retaining Ring ......Spacer ......Lever ......Bushing ......Washer (Special) (Pkg. of 1) ......Screw (M6 x 1,0 x 40 SHCS) ......Lockwasher (M6) ......Washer (M6) ......Fixture Support Bar (Pkg. of 1) ......Screw ......Torque Finger Base ......Torque Finger ......Screw (M6 x 1,0 x 30 SHCS) ......Screw (M6 x 1,0 x 16 SHCS) ......Stop Collar (Pkg. of 1) ......Screw (M6 x 1,0 x 30 SHCS) ......Latch Block ......Screw (M6 x 1,0 x 20 SHCS) ......Gate Latch ......Groove Pin ......Gate Hinge ......Bushing (Pkg. of 2) ......Screw (M6 x 1 x 20 SHCS) ......Washer (M6) ......Stop Collar (Pkg. of 1) ......Screw (M6 x 1,0 x 30 SHCS) ......Stop Pin ......Finger (Pkg. of 1) ......Carbide Tip (Pkg. of 1) ......Screw (M4 x 0,7 x 8 FHCS) ......Screw N/S indicates Not Shown Page 27 SECTION I BASIC MACHINE 28 25 27 26 19 22 20 24 34 12 11 23 18 13 9 8 14 9 10 7 16 5 6 2 15 2 31 4 32 33 3 20 21 16 17 1 29 30 FIGURE O – FOOT PEDAL PARTS LIST COVERING FIGURE “O” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 N/S 28 29 30 31 32 33 34 ORDER BY PART NUMBER EC2980 EC2984 PHSM535 PHWM518 EC2985A EC2973 PHNM402 EC2885 PHNM407 EC2979 PHSM535 PHWM518 PHNM436 EC2974 PHSM405 PHWM518 PHNM407 EC2970 PHSM964 PHWM518 PHNM407 EC4422 PHWM518 PHRM308 EC2978 PHSM510 PHWM518 PHNM436 EC4406 EC4490 EC–2966A PNP326A EC121A PEC104A PHM538 N/S indicates Not Shown Page 28 QTY. 1 2 4 4 1 1 1 1 2 1 2 2 2 1 2 4 2 1 2 4 2 1 1 1 1 4 4 2 1 1 2 1 1 2 1 DESCRIPTION ....Foot Pedal Base Assembly ....Pedal Pivot Block ....Screw (M6 x 1,0 x 12 SHCS) ....Washer (M6) ....Pedal Assembly ....Cable End ....Nut (M4) ....Cable Assembly ....Nut (M6) ....Conduit Bracket ....Screw (M6 x 1,0 x 12 SHCS) ....Washer (M6) ....Insert Nut (M6) ....Pedal Stop ....Screw (M6 x 1,0 x 16 SHCS) ....Washer (M6) ....Nut (M6) ....Latch Block Assembly ....Screw (M6 x 1,0 x 35 SHCS) ....Washer (M6) ....Nut (M6) ....Safety Latch with ......Washer (M6) ......Retaining Ring ....Foot Pedal Cover ....Screw (M6 x 1,0 x 12 BHCS) ....Washer (M6) ....Insert Nut (M6) ....Caution Label ....Safety Cover Assembly ....Bumper Strip (Pkg. of 2) ....Foot Pedal Label (Used on “CE” Machines only) ....Conduit with ......Conduit Fitting (Pkg. of 2) ....Hand Retractable Spring Plunger SECTION I BASIC MACHINE 6 4 10 11 7 3 5 9 2 8 1 12 FIGURE P – RUNOUT INDICATOR & TORQUE BAR PARTS LIST COVERING FIGURE “P” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 ORDER BY PART NUMBER EC6550A --EC6551 CGM4007 CGM4009A EC6552 PHPM447 PHSM614 EC6031A CGM4241A PHSM619 PHWM518 ML6190 QTY. 1 1 1 1 1 1 1 1 1 1 2 2 1 DESCRIPTION ....Runout Indicator Assembly includes ......Runout Indicator (Not Sold Separately) ......Indicator Clamp ......Pivot Rod ......Cone ......Cam ......Spring Pin ......Shoulder Screw (8 Dia. x 25 w/ M6 Thd.) ....Manual Torque Bar ....Torque Bar Base ....Screw ....Washer (M6) ....Torque Arm N/S indicates Not Shown Page 29 SECTION I BASIC MACHINE 39 38 40 43 46 44 45 41 42 49 51 47 71 55 64 70 62 56 50 74 72 57 26 53 65 73 81 58 52 77 38 59 54 76 75 22 53 22 88 31 89 14 33 22 83 15 27 32 80 86 2 26 28 36 96 85 26 24 82 90 34 23 97 84 79 78 87 35 1 22 25 30 22 91 63 68 66 69 37 48 52 58 60 61 67 21 91 12 95 94 10 29 92 11 16 8 9 19 93 18 20 3 13 6 5 4 8 17 7 FIGURE Q – COOLANT SYSTEM PARTS LIST COVERING FIGURE “Q” ITEM NO. 1 2 3 N/S N/S N/S N/S 4 5 6 7 8 9 10 11 12 N/S ORDER BY PART NUMBER ML3495DS EC4750 EC3844 EC3981 PHSM432 EC3980 PHSM495 PHWM501 PHM449 PHSM441 PHWM501 PHSM673 PHWM501 PHWM407 PHNM407 EC3813 CK578 PHSM674 N/S indicates Not Shown Page 30 QTY. 1 1 2 2 8 2 8 8 4 12 8 4 16 8 8 2 2 2 DESCRIPTION ....Coolant System (230 Volt, 60 Hz) includes ......Reservoir assembly ......Corner Plug ......Caster Cover with ........Screw ......Caster Extension ........Screw (M8 x 1,25 x 20 HHCS) ........Washer (M8) ......Swivel Caster ......Screw (M8 x 1,25 x 12 BHCS) ......Washer (M8) ......Screw (M8 x 1,25 x 40 BHCS) ......Washer (M8) ......Washer ......Nut ......Bumper Bracket ......Rubber Bumper ......Screw (M5 x 0,8 x 20 LHCS) (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “Q” ITEM NO. N/S 13 14 15 16 17 18 19 20 21 N/S N/S N/S N/S N/S N/S N/S N/S 22 23 24 25 26 27 28 29 30 31 32 33 34 35 N/S N/S 36 37 N/S 38 39 40 N/S 41 41 42 43 44 45 46 47 48 N/S N/S N/S N/S N/S 49 50 51 52 ORDER BY PART NUMBER PHNM441 PPP130 PNP101 KN231 EC3496 PF224 CH376 KN172 KN568 EC3498 EC34971 EC34972 EC34973 EC34974 PHSM515 PHWM501 PHWM407 PHNM401 PPPM446 PPPM544 PPPM434 EC3480 PPPM416 PPPM435 PPPM419 PF317 PPP461 EC3476 PHSM495 PHWM407 PHWM501 PPPM425 PHW328 KN370 PPPM514 EC3440 PPPM414 PF246 PF243 PF244 PF247 PF1054 PF1104 EC3620 EC3625 EC3630 PHSM598 PHWM407 PF162 PHM494 PHWM518 PHNM453 PHSM534 PHWM509 PHNM407 EC3486 PHS1061 PPP533 PPP161 N/S indicates Not Shown QTY. 2 1 1 4 1 4 4 8 8 1 1 1 1 1 4 4 4 4 6 1 1 1 4 2 1 1 1 2 2 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 3 1 2 3 2 1 2 1 2 DESCRIPTION ......Nut (M5) ......Pipe Plug ......Electrical Specification Plate ......Drive Screw ......Pump Base ......Vibration Isolator ......Spacer ......Nut (5/16 x 18) ......Washer (5/16) ......Motorized Moyno Pump includes ........Stator ........Joint ........Seal ........Abrasion Resistant Seal ......Screw (M8 x 1,25 x 25 SHCS) ......Washer (M8) ......Washer (M8) ......Nut (M8) ......Elbow ......Hose Assembly ......Hose Assembly ......Pressure Relief Valve ......Nipple ......Hose Assembly ......Intake Hose Assembly ......Intake Strainer ......Hose Clamp ......Tray Retainer ......Screw (M8 x 1,25 x 20 HHCS) ......Washer (M8) ......Lock washer (M8) ......Bulkhead Union ......Washer ......Washer ......Flexible Tubing ......Filter Canister ......Bushing ......Drain Valve ......Cover ......Gasket ......Spring Hold Down ......Filter Element (5 Micron) (Pkg of 4) ......Filter Element (10 Micron) (Pkg of 4) ......Clamp Assembly ......Clamp Yoke Assembly ......Tee Handle Assembly ......Screw (M8 x 1,25 x 35 HHCS) ......Lock Washer (M8) ......Mounting Bracket, Front Half ......Hand Lever ......Washer (M6) ......Nut (M6) ......Screw (M6 x 1,0 x 20 SHCS) ......Lock Washer (M6) ......Nut (M6) ......Output Connection Block ......Screw (1/4 x 20UNC x ½ HHCS) ......Relief Valve ......Reducer Bushing (Parts continued on next page) Page 31 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “Q” ITEM NO. 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 N/S 73 74 75 N/S 76 77 78 N/S 79 N/S 80 81 N/S N/S N/S 82 83 84 85 86 87 88 89 90 91 N/S N/S 92 93 N/S 94 95 96 97 N/S N/S N/S N/S ORDER BY PART NUMBER MB2368 79710 PFC165 PPPM404 78156 PHM558 79717 PHM790 PHM791 PHM792 PHSM613 PHWM516 79714 EC3817 PHSM964 PHM788 PHM789 PHM530 PHM403 PHM435 PHM483 EC3838 EC3833 EC3831 PHSM506 EC3835 EC3834 EC3842 EC3843 PHRM303 AG275 EC4745 EC4370 PHWM518 PHWM509 PHNM407 EC4424 EC4343 EC3811 EC3741 PHSM495 EC3680 EC3812 EC3477 EC3470 PEC220 PEM252 PHN125 EC3321 PEM981 PEM461 PPP130 PHSM438 EC4305 EC4307 EC4710 PES654 PNP476 PNP477 N/S indicates Not Shown Page 32 DESCRIPTION QTY. 2 * 1 1 * 2 * 2 5 3 2 2 * 4 4 4 4 4 * 2 2 2 2 2 4 1 1 1 1 2 4 1 1 8 8 8 4 2 1 2 4 1 1 1 1 2 2 2 1 1 1 1 4 1 2 2 2 1 1 ......Hose Barb ......Tubing (1/2 I.D. x 11/16 O.D. Tygon) ......Pneumatic Valve ......Male Connector ......Tubing (5.32 O.D. Nylon, Natural Color) ......Hose Clamp ......Tubing (1/2 I.D. x 11/16 O.D. Tygon) ......LocLine Elbow ......LocLine Shut Off Valve ......LocLine Tee ......Screw (M4 x 0,7 x 12 SHCS) ......Washer (M4) ......Tubing (3/8 I.D. x ½ O.D. Tygon) ......Coolant Nozzel Base ......Screw ......Knob ......Adapter ......Check Valve ......LocLine Hose ......Nozzle, 1/8 Black ......Nozzle, ¼ Orange ......Splash Gate Bumper ......Retaining Nut ......Spring Retaining Nut ......Screw (M5 x 0,8 x 8 SHCS) ......Splash Gate Assembly ......Splash Gate Pivot ......Right Torsion Spring ......Left Torsion Spring ......Retaining Ring ......Washer ......Drip Tray Assembly ......Left Hand Rest (w/o Light Curtain) ......Washer ......Washer ......Nut ......Hand Rest Strip ......Hand Rest Gasket ......Drip Tray Liner ......Nut Plate ......Screw (M8 x 1,25 x 20 HHCS) ......Reservoir Cover Assembly ......Reservoir Liner ......Hose Clip ......Sediment Tray Assembly ......Strain Relief Connector ......Sealing O-Ring w/Retainer ......Locknut ......Cart Motor Cable ......Housing ......10 Position Male Insert ......Plug ......Screw (M5 x 0,8 x 12 STS) ......Right Hand Rest (w/o Light Curtain) ......Pushbutton Cover ......Pushbutton Cap ......Pushbutton ......Sunburst Logo ......Sunnen Name Logo * Sold by the foot only. SECTION I BASIC MACHINE 91 39 38 47 68 69 71 64 62 72 57 53 73 22 96 31 97 14 22 85 15 27 32 80 94 2 26 23 28 24 36 100 81 93 26 1 22 25 30 22 21 99 104 101 12 105 10 29 11 16 18 102 20 3 8 9 19 108 83 98 34 33 82 84 92 79 78 95 35 107 77 38 59 110 111 112 106 89 76 75 22 53 109 74 58 52 54 87 65 56 26 63 66 70 55 50 86 60 61 58 67 37 48 52 88 45 41 42 51 90 46 44 49 88 40 43 13 6 5 4 8 17 103 7 FIGURE R – COOLANT SYSTEM PARTS LIST COVERING FIGURE “R” ITEM NO. 1 2 3 N/S N/S N/S N/S 4 5 6 7 8 ORDER BY PART NUMBER ML3495CD ML3495CE EC4750 EC3844 EC3981 PHSM432 EC3980 PHSM495 PHWM501 PHM449 PHSM441 PHWM501 PHSM673 PHWM501 N/S indicates Not Shown QTY. 1 1 1 2 2 8 2 8 8 4 12 8 4 16 DESCRIPTION ....Coolant System (220 Volt, 50 Hz / 230 Volt, 60 Hz) includes ....Coolant System (400 Volt, 50 Hz / 460 Volt, 60 Hz) includes ......Reservoir assembly ......Corner Plug ......Caster Cover ......Screw (M5 x 0,8 x 12 BHCS) ......Caster Extension ......Screw (M8 x 1,25 x 20 HHCS) ......Washer (M8) ......Swivel Caster ......Screw (M8 x 1,25 x 12 BHCS) ......Washer (M8) ......Screw (M8 x 1,25 x 40 BHCS) ......Washer (M8) (Parts continued on next page) Page 33 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “R” ITEM NO. 9 10 11 12 N/S N/S 13 14 15 16 17 18 19 20 21 N/S N/S N/S N/S N/S N/S N/S N/S 22 23 24 25 26 27 28 29 30 31 32 33 34 35 N/S N/S 36 37 N/S 38 39 40 N/S 41 41 42 43 44 45 46 47 48 ORDER BY PART NUMBER PHWM407 PHNM407 EC3813 CK578 PHSM674 PHNM441 PPP130 PNP101 KN231 EC3496 PF224 CH376 KN172 KN568 EC3498 EC34971 EC34972 EC34973 EC34974 PHSM515 PHWM501 PHWM407 PHNM401 PPPM446 PPPM544 PPPM434 EC3480 PPPM416 PPPM435 PPPM419 PF317 PPP461 EC3476 PHSM495 PHWM407 PHWM501 PPPM425 PHW328 KN370 PPPM514 EC3440 PPPM414 PF246 PF243 PF244 PF247 PF1054 PF1104 EC3620 EC3625 EC3630 PHSM598 PHWM407 PF162 PHM494 N/S indicates Not Shown Page 34 QTY. 8 8 2 2 2 2 1 1 4 1 4 4 8 8 1 1 1 1 1 4 4 4 4 6 1 1 1 4 2 1 1 1 2 2 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ......Washer ......Nut ......Bumper Bracket ......Rubber Bumper ......Screw (M5 x 0,8 x 20 LHCS) ......Nut (M5) ......Pipe Plug ......Electrical Specification Plate ......Drive Screw ......Pump Base ......Vibration Isolator ......Spacer ......Nut (5/16 x 18) ......Washer (5/16) ......Motorized Moyno Pump includes ........Stator ........Joint ........Seal ........Abrasion Resistant Seal ......Screw (M8 x 1,25 x 25 SHCS) ......Washer (M8) ......Washer (M8) ......Nut (M8) ......Elbow ......Hose Assembly ......Hose Assembly ......Pressure Relief Valve ......Nipple ......Hose Assembly ......Intake Hose Assembly ......Intake Strainer ......Hose Clamp ......Tray Retainer ......Screw (M8 x 1,25 x 20 HHCS) ......Washer (M8) ......Lock washer (M8) ......Bulkhead Union ......Washer ......Washer ......Flexible Tubing ......Filter Canister ......Bushing ......Drain Valve ......Cover ......Gasket ......Spring Hold Down ......Filter Element (5 Micron) (Pkg of 4) ......Filter Element (10 Micron) (Pkg of 4) ......Clamp Assembly ......Clamp Yoke Assembly ......Tee Handle Assembly ......Screw (M8 x 1,25 x 35 HHCS) ......Lock Washer (M8) ......Mounting Bracket, Front Half ......Hand Lever (Parts continued on next page) SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “R” ITEM NO. N/S N/S N/S N/S N/S 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 N/S 73 74 75 N/S 76 77 78 N/S 79 N/S 80 81 81 82 83 N/S N/S N/S 84 85 86 87 88 ORDER BY PART NUMBER PHWM518 PHNM453 PHSM534 PHWM509 PHNM407 EC3486 PHS1061 PPP533 PPP161 MB2368 79710 PFC165 PPPM404 78156 PHM558 79717 PHM790 PHM791 PHM792 PHSM613 PHWM516 79714 EC3817 PHSM964 PHM788 PHM789 PHM530 PHM403 PHM435 PHM483 EC3838 EC3833 EC3831 PHSM506 EC3835 EC3834 EC3842 EC3843 PHRM303 AG275 EC4745 EC4350 EC4425 EC4370 EC4360 EC4307 EC4710 PES654 PHWM406 PHNM405 EC4424 EC4343 EC4415 EC4375 EC4338 N/S indicates Not Shown QTY. 3 1 2 3 2 1 2 1 2 2 * 1 1 * 2 * 2 5 3 2 2 * 4 4 4 4 4 * 2 2 2 2 2 4 1 1 1 1 2 4 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 DESCRIPTION ......Washer (M6) ......Nut (M6) ......Screw (M6 x 1,0 x 20 SHCS) ......Lock Washer (M6) ......Nut (M6) ......Output Connection Block ......Screw (1/4 x 20UNC x ½ HHCS) ......Relief Valve ......Reducer Bushing ......Hose Barb ......Tubing (1/2 I.D. x 11/16 O.D. Tygon) ......Pneumatic Valve ......Male Connector ......Tubing (5.32 O.D. Nylon, Natural Color) ......Hose Clamp ......Tubing (1/2 I.D. x 11/16 O.D. Tygon) ......LocLine Elbow ......LocLine Shut Off Valve ......LocLine Tee ......Screw (M4 x 0,7 x 12 SHCS) ......Washer (M4) ......Tubing (3/8 I.D. x ½ O.D. Tygon) ......Coolant Nozzel Base ......Screw (M6 x 1,0 x 35 SHCS) ......Knob ......Adapter ......Check Valve ......LocLine Hose ......Nozzle, 1/8 Black ......Nozzle, ¼ Orange ......Splash Gate Bumper ......Retaining Nut ......Spring Retaining Nut ......Screw (M5 x 0,8 x 8 SHCS) ......Splash Gate Assembly ......Splash Gate Pivot ......Right Torsion Spring ......Left Torsion Spring ......Retaining Ring ......Washer ......Drip Tray Assembly ......Left Hand Rest with Pushbutton only includes ......Left Hand Rest with Pushbutton and Light Curtain includes ........Left Hand Rest (w/o Light Curtain) ........Left Hand Rest (w/Light Curtain) ........Pushbutton Cover ........Pushbutton Cap ........Pushbutton ........Washer ........Nut ........Hand Rest Strip ........Hand Rest Gasket ........Left Light Curtain ........Left Light Curtain Guard includes ..........Extension Panel (Parts continued on next page) Page 35 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “R” ITEM NO. N/S N/S N/S 89 89 82 83 N/S N/S N/S 84 85 90 91 88 N/S N/S N/S 92 93 94 95 96 97 98 99 100 101 N/S N/S 102 103 104 104 105 106 106 N/S N/S N/S N/S 107 N/S 108 N/S N/S 109 110 111 112 N/S N/S ORDER BY PART NUMBER PHWM518 PHWM509 PHNM407 EC4365 EC4450 EC4305 EC4455 EC4307 EC4710 PES654 PHWM406 PHNM405 EC4424 EC4343 EC4445 EC4355 EC4338 PHWM518 PHWM509 PHNM407 EC3811 EC3741 PHSM495 EC3680 EC3812 EC3477 EC3470 EC3041 PHSM438 PEC220 PEM252 PHN125 EC3321 PEC180 PEM823 PEM823 PEM681 PEC179 PEC179 PEM252 PEM252 PHN125 PHN125 PEM460 PEM461 PHSM440 PHWM528 PHNM402 ML4729 ML4728 EC3816 EC3814 PNP476 PNP477 N/S indicates Not Shown Page 36 DESCRIPTION QTY. 4 4 4 1 1 1 1 1 1 1 2 2 2 1 1 1 1 4 4 4 1 2 4 1 1 1 1 1 4 1 1 1 1 1 4 2 1 2 4 2 4 2 4 1 1 4 4 4 1 1 1 1 1 1 ......Washer ......Washer ......Nut ......Right Hand Rest w/Pushbutton only includes ......Right Hand Rest w/Pushbutton and Light Curtain includes ........Right Hand Rest (w/o Light Curtain) ........Right Hand Rest (w/Light Curtain) ........Pushbutton Cover ........Pushbutton Cap ........Pushbutton ........Washer ........Nut ........Hand Rest Strip ........Hand Rest Gasket ........Right Light Curtain ........Right Light Curtain Guard includes ..........Extension Panel ......Washer ......Washer ......Nut ......Drip Tray Liner ......Nut Plate ......Screw (M8 x 1,25 x 20 HHCS) ......Reservoir Cover Assembly ......Reservoir Liner ......Hose Clip ......Sediment Tray Assembly ......Junction Box ......Screw (M5 x 0,8 x 12 PHS) ......Strain Relief Connector ......Sealing ORing with Retainer ......Locknut ......Cart Motor Cable ......Strain Relief Connector ......Knockout Plug, 22,5 mm (Systems w/o Light Curtain) ......Knockout Plug, 22.5 mm (Systems w/Light Curtain) ......Knockout Plug (27,8 mm) ......Strain Relief Connector (Systems w/o Light Curtain) ......Strain Relief Connector (Systems w/Light Curtain) ......Sealing ORing with Retainer (Systems w/o Light Curtain) ......Sealing ORing with Retainer (Systems w/Light Curtain) ......Locknut (Systems w/o Light Curtain) ......Locknut (Systems w/Light Curtain) ......Panel Mounting Base ......10 Position Male Insert ......Screw (M4 x 0,7 x 12 PHS) ......Washer ......Nut ......Right Start Button Cable ......Left Start Button Cable ......MGSS Cable ......MGSE Cable ......Sunburst Logo ......Sunnen Name Logo * Sold by the foot only. SECTION I BASIC MACHINE FIGURE S – OPERATOR STATION ENCLOSURE PARTS LIST COVERING FIGURE “S” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER MLU4380 PHWM510 89019 PHWM516 PHSM505 PHWM528 PHNM402 EC4420 PHM536 PHWM519 PHWM510 PHNM405 PEM1018 PHWM518 PHWM509 PHNM407 --- QTY. Ref. 1 1 7 7 1 7 1 2 1 1 1 1 1 1 1 1 DESCRIPTION ....Operator Station Enclosure includes ......Lockwasher (M5) ......Weather Stripping ......Flatwasher (M4) ......Screw (M4 x 0,7 x 12mm BHCS) ......Lockwasher (M4) ......Nut, Hex (M4 x 0,7) ......Operator Enclosure Oil Tray ......Metric Phenolic Ball Knob, Black ......Flatwasher (M5) ......Lockwasher (M5) ......Nut, Hex (M5 x 0,8) ......Cushioned Clamp ......Flatwasher (M6) ......Lockwasher (M6) ......Nut ......Operator Control Panel (See Fig. T) N/S indicates Not Shown Page 37 NOTES Page 38 SECTION II ELECTRICAL COMPONENTS 1 20 15 16 11 R ML-5000 PRECISION HONING MACHINE PATENTED SPINDLE SPEED 18 2 AFTER ROUGH TO FINISH DIAMETER 17 OFF DURING EXTRA STROKES ONLY 4 19 L mm STROKER SIZE CONTROL ZERO SHUT OFF UNLATCH MANUAL AUTO RPM 6 2500 .25 .3 2000 .4 1500 .5 .6 20 25 30 40 50 60 .8 800 1.0 600 500 400 1.5 2.0 300 100 FEED RETRACT CYCLE START USE CAUTION WHEN STARTING NEW SETUP CYCLE STOP STROKER JOG DOWN .8 400 1.0 40 250 50 200 60 150 80 100 100 80 150 170 4.0 IN 500 25 300 OPERATING SPEED MAY NOT BE SUITABLE FOR ALL APPLICATIONS ASC PROBE UP 9 200 SPM 20 30 WARNING 2.5 3.0 80 EXPAND 12 1000 L mm IN 3000 8 10 15 ASC 10 14 STROKER SPEED EXTRA STROKES FINISHING FEED FORCE 60 1.5 2.0 2.5 3.0 4.0 5.0 6.0 6.5 COOLANT CONSTANT POWER ON 13 CYCLE ONLY 3 POWER OFF ML-1484CE / IL-1147 8 7 6 5 FIGURE T – OPERATOR CONTROL PANEL PARTS LIST COVERING FIGURE “T” ITEM NO. 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 N/S N/S N/S ORDER BY PART NUMBER QTY. --MLU1484ENA MLU1484CEA PES653A PES651A PES652A PES656A PEM967 PEM968 PEM966 PES654 PES655 PED2202A PEM972A PES647A PES646A PED2203A CBL275A PEM961A PEM962A PEM963A PED2151 PEM702A PEM895A PHSM745 Ref. 1 1 3 4 2 1 1 2 1 4 1 1 1 3 18 1 1 15 15 15 1 8 1 21 DESCRIPTION ....Operator Control Panel includes ......Console Overlay (English) ......Console Overlay (Icon CE Machines ONLY) ......3 Position Selector, Return to Center (Pkg. of 1) ......2 Position Selector, Maintained (Pkg. of 1) ......3 Position Selector, Maintained (Pkg. of 1) ......White Pushbutton, Illuminated ......Blue Pushbutton Cap, Flush ......Red Pushbutton Cap, Extended ......Green Pushbutton Cap, Flush ......Pushbutton Head w/o Cap ......Red Mushroom Operator, Latching ......Operator Station Control Board ......Light Block, Integral LED, White ......Contact Block, NC (Pkg. of 1) ......Contact Block, NO (Pkg. of 1) ......Operator Station Display Board ......Operator Station Display Board Ribbon Cable ......Selector/Operator Mounting Collar, Die Cast (Pkg. of 1) ......Selector/Operator Adapting Pillar, Plastic (Pkg. of 1)) ......PCB Socket (Pkg. of 1) ......PLC Display ......6 Position Terminal Block Connector (Pkg. of 1) ......9 Position Terminal Block Connector ......Screw (M3 x 16 Plastic Grip) N/S indicates Not Shown Page 39 Page 40 60 61-62 63 64 65 66 67-68 69 70 1-2 3 58-59 4 5 6-7-8 9 57 71 72 10 11 FIGURE U – SUB PANEL ASSEMBLY (LOW VOLTAGE) 56 54-55 73-74 12 13 53 51-52 15 14 16 49-50 47-48 20 19 17-18 21 32 31 46 45 42-43-44 41 40 39 38 36-37 34-35 33 30 29 28 27 26 25 24 23 22 LOW VOLTAGE DEVICE D-230V 1OL PES734 1.6-2.5A 1FU-1, 1FU-2, 1FU-3 PEF158 30A 2FU-1, 2FU-2 PEF23 1.5A 3FU PEF160 4.0A 4FU-1, 4FU-2, 4FU-3 PEF175 15.0A 5FU PEF176 1A SLO 6FU PEF127 2A SECTION II ELECTRICAL COMPONENTS SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “U” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 26 26 26 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 ORDER BY PART NUMBER ML4750-L EC3004 PHSM583 PED2155 PED2153 PED2154 PES638 PEM927 PEM928 PET184 PEM675 PES750 PES714 PES710 PET545 PNP299 PES297 PEF23 PEM755 PEM260 DRB0500 WCA0710 PEM153 PEM788 WDA0710 WDA0145 PES734 PEF158 PEF23 PEF160 PEF175 PEF176 PEF127 WCA0145 PEM489 PES741 WDA0505 PES299 PEM473 DRB0425 PEM621 PEM6211 WCA0450 WDA0450 PED983 PEM496 WCA0505 PEM473 PES638 PEM927 N/S indicates Not Shown DESCRIPTION QTY. 1 4 4 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 6 1 2 * 3 2 2 3 3 3 3 3 3 3 2 1 1 1 1 1 1 1 1 1 1 1 19 1 * 3 3 ....Sub Panel Assembly (Low Voltage) includes ......Spacer ......Screw (M4 x 0,7 x 25mm PHST) ......Power Supply, 24V ......AC/DC Relay ......PLC I/O Module, 24V ......Miniature Relay ......Base, Miniature Relay ......EMC Suppressor, Miniature Relay ......Terminal Block End Cap ......Fuseholder (See Chart) ......Aux. Contact ......Contactor, 24VDC Coil (32A) ......Contactor, 24VDC Coil (9A) ......Ground Terminal ......Decal, Electical ......Non-Fused Disconnect Switch ......Fuse ......Fuseholder, Ultrasafe Class CC ......Ground Terminal ......Din Rail ......Wiring Duct Cover (1in.) ......Label, Wire ......Fuse Cover ......Wiring Duct (1in.) ......Wiring Duct (1in.) ......Fuse (See Chart) ......Fuse (30A) (See Chart) ......Fuse (1.5A) (See Chart) ......Fuse (4A) (See Chart) ......Fuse (15A) (See Chart) ......Fuse (1A) (See Chart) ......Fuse (2A) (See Chart) ......Wiring Duct Cover ......Fuse Block, Class J ......Auxiliary Contact ......Wiring Duct B&E ......Control Relay, 24V ......End Stop ......Din Rail ......Time Meter, SO# ......Time Meter Din Rail Adapter ......Wiring Duct Cover (1in.) ......Wiring Duct (1in.) ......Line Filter (36A, 3Ph)(CD Panel ONLY) ......Duct Mounting Clip ......Wiring Duct Cover B&E ......End Stop ......Miniature Relay ......Base, Miniature Relay * Quantity varies, depending on features. Page 41 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “U” (cont’d) ITEM NO. 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 ORDER BY PART NUMBER PEM928 ML4724 ML4751 WDA0265 WCA0265 PED2092 ML4905 WDA0340 WCA0340 PHSM440 PED2094 ML4900 EC3758 WCB0485 PES580 CBL257 MLA4000 WDB0505 WCB0505 PHSM438 PEM246 ML4723 PES581 PES299 CBL257 WCB0715 WDB0715 PET919 PEM473 PEF175 PEM755 N/S indicates Not Shown Page 42 DESCRIPTION QTY. 3 1 1 1 1 1 1 1 1 37 1 1 1 1 2 2 1 1 1 19 9 1 2 1 1 1 1 2 1 3 3 ......EMC Suppressor, Miniature Relay ......Terminal Block, TB33 ......Panel ......Wiring Duct (1in.) ......Wiring Duct Cover (1in.) ......Stroker Drive ......Programmed Stroker Drive (230V) ......Wiring Duct ......Wiring Duct Cover ......Screw (M4 x 0,7 x 12mm PHTC) ......Spindle Drive ......Programmed Spindle Drive (230V) ......Wiring Duct ......Wiring Duct Cover (2in.) ......Control Relay, 24V (CD Panel ONLY) ......Diode Assembly (CD Panel ONLY) ......Terminal Block, TB34 (MLA Panel ONLY) ......Wiring Duct (2in.) ......Wiring Duct Cover (2in.) ......Screw (M5 x 0,8 x 12mm PHTC) ......Wire Duct Clip ......Terminal Block, TB30 ......Aux. Contact (CD Panel ONLY) ......Control Relay, 24V (CD Panel ONLY) ......Diode Assembly (CD Panel ONLY) ......Wiring Duct Cover (2in.) ......Wiring Duct (2in.) ......Terminal Block, Multiclamp ......End Stop ......Fuse ......Fuseholder, Ultrasafe Class CC * Quantity varies, depending on features. SECTION II ELECTRICAL COMPONENTS NOTES Page 43 Page 44 58 59-60 61 62 63 64 65-66 67 68 1 2 56-57 3 4 55 5-6-7 9 54 69 8 11 52-53 70-71 10 FIGURE V – SUB PANEL ASSEMBLY (HIGH VOLTAGE) 51 49-50 12 14 13 47-48 45-46 18 17 15-16 19 30 29 40-41-42 43 44 39 38 37 36 34-35 32-33 31 28 27 26 25 24 23 22 21 20 HIGH VOLTAGE DEVICE G-4000V 1OL PES733 1.0-1.6A 1FU-1, 1FU-2, 1FU-3 PEF129 20A 2FU-1, 2FU-2, 2FU-3 PEF24 6.0A 3FU PEF160 4.0A 4FU-1, 4FU-2, 4FU-3 PEF136 8.0A 5FU PEF176 1A SLO 6FU PEF127 2A SECTION II ELECTRICAL COMPONENTS SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “V” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 24 24 24 24 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 ORDER BY PART NUMBER ML4750-H PED2156 DRB0125 PED2153 PED2154 PES638 PEM927 PEM928 PEM675 PES750 PES714 PES710 PET545 PNP299 PES297 PEF24 PEM755 PEM260 DRB0500 WCA0710 PEM153 PEM788 WDA0710 WDA0145 PES733 PEF129 PEF24 PEF160 PEF136 PEF176 PESF127 WCA0145 PEM489 PES741 WDA0505 PES299 PEM473 DRB0425 PEM621 PEM6211 WCA0450 WDA0450 PED2145 PEM496 WCA0505 PEM473 PES638 PEM927 PEM928 ML4724 N/S indicates Not Shown DESCRIPTION QTY. 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 3 3 6 1 2 * 3 2 2 3 3 3 3 3 3 3 2 1 1 1 1 1 1 1 1 1 1 1 19 1 * 3 3 3 1 ....Sub Panel Assembly (High Voltage) includes ......Power Supply, 24V (400V Supply) ......Din Rail ......AC/DC Relay (Not Required on CGW1AGX Panel) ......PLC I/O Module, 24V (Not Required on CGW1AGX Panel) ......Miniature Relay ......Base, Miniature Relay ......EMC Suppressor, Miniature Relay ......Fuseholder (See Chart) ......Aux. Contact ......Contactor, 24VDC Coil (32A) ......Contactor, 24VDC Coil (9A) ......Ground Terminal ......Decal, Electical ......Non-Fused Disconnect Switch ......Fuse ......Fuseholder, Ultrasafe Class CC ......Ground Terminal ......Din Rail ......Wiring Duct Cover (1in.) ......Label, Wire ......Fuse Cover ......Wiring Duct (1in.) ......Wiring Duct (1in.) ......Fuse (See Chart) ......Fuse (20A) (See Chart) ......Fuse (6A) (See Chart) ......Fuse (4A) (See Chart) ......Fuse (8A) (See Chart) ......Fuse (1A) (See Chart) ......Fuse (2A) (See Chart) ......Wiring Duct Cover ......Fuse Block, Class J ......Auxiliary Contact ......Wiring Duct B&E ......Control Relay, 24V ......End Stop ......Din Rail ......Time Meter, SO# ......Time Meter Din Rail Adapter ......Wiring Duct Cover (1in.) ......Wiring Duct (1in.) ......RFI/EMI Line Filter, 550V/25A (CE Panel ONLY) ......Duct Mounting Clip ......Wiring Duct Cover ......End Stop ......Miniature Relay ......Base, Miniature Relay ......EMC Suppressor, Miniature Relay ......Terminal Block, TB33 * Quantity varies, depending on features. Page 45 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “V” (cont’d) ITEM NO. 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 ORDER BY PART NUMBER ML4751 WDA0265 WCA0265 PED3009 ML4915 WDA0340 WCA0340 PHSM440 PED3013 ML4910 EC3758 WCB0485 PES580 CBL257 MLA4000 WDB0505 WCB0505 PHSM438 PEM246 ML4723 PES581 PES299 CBL257 WCB0715 WDB0715 PEM473 PEF136 PEM755 N/S indicates Not Shown Page 46 DESCRIPTION QTY. 1 1 1 1 1 1 1 37 1 1 1 1 2 2 1 1 1 21 9 1 2 1 1 1 1 1 3 3 ......Panel ......Wiring Duct (1in.) ......Wiring Duct Cover (1in.) ......Variable Freq. Drive (2Hp, 460V) ......Programmed Stroker Drive (400V) ......Wiring Duct ......Wiring Duct Cover ......Screw (M4 x 0,7 x 12mm PHTC) ......Variable Freq. Drive (5Hp, 460V) ......Programmed Spindle Drive (400V) ......Wiring Duct ......Wiring Duct Cover (2in.) ......Control Relay, 24V (CE Panel ONLY) ......Diode Assembly (CE Panel ONLY) ......Terminal Block, TB34 (MLA Panel ONLY) ......Wiring Duct (2in.) ......Wiring Duct Cover (2in.) ......Screw (M5 x 0,8 x 12mm PHTC) ......Wire Duct Clip ......Terminal Block, TB30 ......Aux. Contact (CE Panel ONLY) ......Control Relay, 24V (CE Panel ONLY) ......Diode Assembly (CE Panel ONLY) ......Wiring Duct Cover (2in.) ......Wiring Duct (2in.) ......End Stop ......Fuse ......Fuseholder, Ultrasafe Class CC * Quantity varies, depending on features. SECTION II ELECTRICAL COMPONENTS NOTES Page 47 SECTION III OPTIONAL ITEMS FIGURE W – AUTOMATIC SIZE CONTROL PARTS LIST COVERING FIGURE “W” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER EC4500A EC4634 EC4632 PHSM607 PHWM518 EC4628 EC4629A PHSM965 PHSM405 EC4631A EC4641A PHSM588 EC4643A EC4644A PHSM434 PHWM519 EC4623A N/S indicates Not Shown Page 48 QTY. 1 1 1 2 2 1 1 1 1 1 1 4 1 1 1 1 1 DESCRIPTION ....Automatic Size Control includes ......Base ......Clamp Block ......Screw (M6 x 1,0 x 30 SHCS) ......Washer (M6) ......Pivot Block ......Clamp Pin ......Screw (M8 x 1,25 x 20 SHCS) ......Screw (M6 x 1,0 x 16 SHCS) ......Pivot Bushing ......Guide Rod ......Setscrew (M5 x 0,8 x 6 CPSS) ......Arm ......Bumper ......Screw (M5 x 0,8 x 16 BHCS) ......Washer (M5) ......Shaft (Parts continued on next page) SECTION III OPTIONAL ITEMS PARTS LIST COVERING FIGURE “W” ITEM NO. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 N/S 59 60 61 62 63 ORDER BY PART NUMBER PBR200A EC4626A PHSM966 PHSM518 EC4624 PHSM514 EC4638A EC4637 PHSM609 EC4654 EC4656 PHSM609 EC4639A PHRM303 EC4652 PHSM609 PFC111A EC4636 PHM482A PHM481A PHM480A PHNM401 PPP439A EC4651A 78157A 78156A EC4600A EC4646 PHWM375 EC4603 EC4604 EC4606 PHSM509 PHSM611 PSP121A EC4612A EC4613 EC4611 EC4612 PHWM375 PHRM100 EC4609A PES461A PEM710A EC7174A EC4658A --EC4618 PHSM965 N/S indicates Not Shown DESCRIPTION QTY. 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 2 2 2 1 2 1 * * 1 1 1 1 1 1 1 3 1 1 1 3 1 1 1 1 1 * 1 1 1 Ref. Ref. ......Bushing (Pkg. of 2) ......Angle Plate ......Screw (M6 x 1,0 x 25 SHCS) ......Washer (M6) ......End Plate ......Screw (M8 x 1,25 x 20 FHCS) ......Adjustment Rod ......Stop Collar ......Setscrew (M4 x 0,7 x 6 CPSS) ......Lock Knob ......Fine Position Knob ......Setscrew (M4 x 0,7 x 6 CPSS) ......Clamp Rod ......Retaining Ring ......Clamp Knob ......Setscrew (M4 x 0,7 x 6 CPSS) ......Air Cylinder ......Cylinder End ......Ball Socket (Pkg. of 2) ......Clip (Pkg. of 2) ......Ball Stud (Pkg. of 2) ......Nut (M8) ......Elbow (Pkg. of 1) ......Cylinder Rod Cover ......Tubing (4 O.D. Black) ......Tubing (4 O.D. White) ......Probe Assembly includes ........Clamp Knob ........Washer ........Plunger Housing ........Sleeve ........Washer ........Screw (M6 x 1,0 x 10 SHCS) ........Setscrew (M4 x 0,7 x 8 FPSS) ........Spring ......Collar Assembly includes ........Plunger (Not Sold Separately) ........Spiral Spring (Not Sold Separately) ........Collar (Not Sold Separately) ......Shim Washer (Not Sold Separately) ......Retaining Ring ......Boot ......Proximity Sensor (see Fig. 3-E, item 20) ......Cable Wrap ......Probe Extension ......Stop Clamp ......Set Screw (M6 x 1 x 8 Brass Tip) ....Rail ....Screw * Sold by the foot only. Page 49 SECTION III OPTIONAL ITEMS 3 2 4 1 7 6 5 7 6 FIGURE X – TRANSFORMER KIT PARTS LIST COVERING FIGURE “X” ITEM NO. 1 2 3 4 5 6 7 ORDER BY PART NUMBER PEM1083A PEM1083 PHWM531 PHWM521 PHSM447 PHWM501 PHWM407 PHSM965 N/S indicates Not Shown Page 50 QTY. Ref. 1 1 1 1 2 2 2 DESCRIPTION ....Transformer Kit includes ......Transformer (15Kva) ......Flatwasher (M10) ......Lockwasher (M10) ......Screw (M10 x 1,5 x 20 SHCS) ......Flatwasher (M8) ......Lockwasher (M8) ......Screw (M8 x 1,25 x 20 SHCS) 5 NOTES Page 51 NOTES Page 52 Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow the instructions for the operation of the equipment. FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART INCH FRACTION DECIMAL MILLIMETER INCH FRACTION DECIMAL MILLIMETER INCH FRACTION DECIMAL MILLIMETER .... .003937 0,1000 9/32 .281250 7,1438 21/32 .656250 16,6688 .... .007874 0,2000 19/64 .296875 7,5406 .... .669291 17,0000 .... .011811 0,3000 5/16 .312500 7,9375 43/64 .671875 17,0656 1/64 .015625 0,3969 .... .314961 8,0000 11/16 .687500 17,4625 .... .015748 0,4000 21/64 .328125 8,3344 45/64 .703125 17,8594 .... .019685 0,5000 11/32 .343750 8,7313 .... .708661 18,0000 .... .023622 0,6000 .... .354331 9,0000 23/32 .718750 18,2563 .... .027559 0,7000 23/64 .359375 9,1281 47/64 .734375 18,6531 1/32 .031250 0,7938 3/8 .375000 9,5250 .... .748031 19,0000 .... .031496 0,8000 25/64 .390625 9,9219 3/4 .750000 19,0500 .... .035433 0,9000 .... .393701 10,0000 49/64 .765625 19,4469 .... .039370 1,0000 13/32 .406250 10,3188 25/32 .781250 19,8438 3/64 .046875 1,1906 27/64 .421875 10,7156 .... .787402 20,0000 1/16 .062500 1,5875 .... .433071 11,0000 51/64 .796875 20,2406 5/64 .078125 1,9844 7/16 .437500 11,1125 13/16 .812500 20,6375 .... .078740 2,0000 29/64 .453125 11,5094 .... .826772 21,0000 3/32 .093750 2,3813 15/32 .468750 11,9063 53/64 .828125 21,0344 7/64 .109375 2,7781 .... .472441 12,0000 27/32 .843750 21,4313 .... .118110 3,0000 31/64 .484375 12,3031 55/64 .859375 21,8281 1/8 .125000 3,1750 1/2 .500000 12,7000 .... .866142 22,0000 9/64 .140625 3,5719 .... .511811 13,0000 7/8 .875000 22,2250 5/32 .156250 3,9688 33/64 .515625 13,0969 57/64 .890625 22,6219 .... .157480 4,0000 17/32 .531250 13,4938 .... .905512 23,0000 11/64 .171875 4,3656 35/64 .546875 13,8906 29/32 .906250 23,0188 3/16 .187500 4,7625 .... .551181 14,0000 59/64 .921875 23,4156 .... .196850 5,0000 9/16 .562500 14,2875 15/16 .937500 23,8125 13/64 .203125 5,1594 37/64 .578125 14,6844 .... .944882 24,0000 7/32 .218750 5,5563 .... .590551 15,0000 61/64 .953125 24,2094 15/64 .234375 5,9531 19/32 .593750 15,0813 31/32 .968750 24,6063 .... .236220 6,0000 39/64 .609375 15,4781 .... .984252 25,0000 1/4 .250000 6,3500 5/8 .625000 15,8750 63/64 .984375 25,0031 17/64 .265625 6,7469 .... .629921 16,0000 1 1.000000 25,4000 .... .275591 7,0000 41/64 .640625 16,2719 1-1/16 1.062500 26,9880 FORMULAS: MULTIPLY INCHES (in) FEET (ft) x x BY 25.4 0.3048 = = TO GET MILLIMETERS (mm) METERS (m) MULTIPLY MILLIMETERS (mm) METERS (m) “SUNNEN® AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.” Sunnen® reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding. PRINTED IN U.S.A. 1208 SUNNEN PRODUCTS COMPANY 7910 Manchester Road, St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. Toll-Free Sales and Service:1-800-325-3670 International Division Fax: 314-781-6128 http://www.sunnen.com e-mail: [email protected] x x BY 0.03937 3.281 = = TO GET INCHES (in) FEET (ft) SWITZERLAND – SUNNEN AG Phone: ++ 41 71 649 33 33 Fax: ++ 41 71 649 34 34 www.sunnen.ch e-mail: [email protected] ITALY - SUNNEN ITALIA S.R.L. Phone: 39 02 383 417 1 Fax: 39 02 383 417 50 www.sunnenitalia.com e-mail: [email protected] FRANCE – SUNNEN SAS Phone: +33 01 69 30 0000 Fax: +33 01 69 30 1111 www.sunnen.fr e-mail: [email protected] BELGIUM – SUNNEN BENELUX BVBA Phone: +32 38 80 28 00 Fax: +32 38 44 39 01 www.sunnen.be e-mail: [email protected] UK – SUNNEN PRODUCTS LTD. Phone: ++ 44 1442 39 39 39 Fax: ++ 44 1442 39 12 12 www.sunnen.co.uk e-mail: [email protected] POLAND – SUNNEN POLSKA SP. Z O.O. Phone: +48 22 814 34 29 Fax: +48 22 814 34 28 www.sunnen.pl e-mail: [email protected] RUSSIA – SUNNEN RUS Phone: +7 495 258 43 43 Fax: +7 495 258 91 75 www.sunnen.ru e-mail: [email protected] CZECH REPUBLIC – SUNNEN S.R.O. Phone: +420 383 376 317 Fax: +420 383 376 316 www.sunnen.cz e-mail: [email protected] CHINA – SHANGHAI SUNNEN MECHANICAL CO., LTD. Phone: 86 21 5813 3322 Fax: 86 21 5813 2299 www.sunnensh.com e-mail: [email protected] ©COPYRIGHT SUNNEN® PRODUCTS COMPANY 2012, ALL RIGHTS RESERVED