X-ml-5006: Ml-5000 Repair Parts Catalog (sn1125

Transcript

REPAIR PARTS CATALOG FOR SUNNEN® POWER STROKED HONING MACHINE MODEL: ML-5000 THIS CATALOG COVERS THE ABOVE MODEL BEGINNING WITH SERIAL NO. 1125 - 1142 “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: 314-781-2100 X-ML-5006B 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 Non-CE 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 MVH-4499A PHSM-405 PHW-354 MVH-4422 1 3 3 1 ....Spindle Cap includes ......Screw (M6 x 1 x 16 SHCS) ......Washer (M6) ....Inner Spindle Nose 14 15 16 17 PEM-870A PEM-871 PEM872 PHSM-600 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: 1-800-772-2878 Sunnen Industrial Customer Service toll free at: 1-800-325-3670 Customers outside the USA, contact your local authorized Sunnen Distributor. Additional information available at: http://www.sunnen.com or e-mail: [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. Anti-static 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 one-year 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 non-SPC machines, tooling, abrasive, fixturing, coolant, repair parts, or filtration › Incorrect software installation and/or misuse › Non-authorized 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 non-exclusive right, without right to sub-license, 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 ML-5000, 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 ML-5000.1 Always wear eye protection when operating ML-5000. 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 ........................................................................................................ Overall - Basic Machine (ML5000)................................................................ SECTION I BASIC MACHINE-TOP 1-A Upper Stroker (ML5000-100) ........................................................................ 1-B Lower Stroker (ML5000-110/-120) ................................................................ 1-C Feed Unit (ML5000-160/-170/-180/-190) ..................................................... 1-D Expand/Retract System (ML5000-210) ........................................................ 1-E Spindle (ML5000-130/-150) ......................................................................... 1-F Cam Assembly (ML5000-200) ..................................................................... 1-G Outside Stroker (ML5000-140/-280) ............................................................ 1-H Hood Assembly (ML5000-290) .................................................................... 1-I Front Panel (ML5000-230/-240/-250) ........................................................... 1-J Universal Honing Fixture .............................................................................. 1-K Runout Indicator & Torque Bar ..................................................................... 1-L Front Pillow Block Assembly (EC1595) ....................................................... 1-M Rear Pillow Block Assembly (EC1670) ........................................................ 1-N Stroker Driveshaft Assembly (ML)(ML1850) ................................................ 1-O Stroker Driveshaft Assembly (MLA)(MLA4865) ........................................... 1-P Cable Hook Assembly (EC2885) ................................................................. 1-Q Guide Feed Rod (EC2515) .......................................................................... 1-R Pillow Block Assembly (EC1815) ................................................................. 1-S Manifold Assembly (ML5505) ....................................................................... 1-T Damper Assembly (EC2920) ...................................................................... 1-U Cycle Timer Control Motor Assembly (MLU2015) ....................................... 1-V Stone Saver Idler Assembly (MLU2000) ...................................................... SECTION II BASIC MACHINE-BOTTOM 2-A Foot Pedal Assembly (ML2900) ................................................................... 2-B Machine Base Assembly (ML5000-010) ...................................................... 2-C Tray Assembly (ML5000-220) ...................................................................... 2-D Deck Assembly (ML5000-020) ..................................................................... 2-E CE Guard Module ........................................................................................ 2-F Left Guard Pane Assembly (ML3340) .......................................................... 2-G Right Guard Pane Assembly (ML3360) ....................................................... 2-H Coolant System (ML3495-10/-20/-30) .......................................................... 2-I CE Light Curtain (ML3495CG-40) ................................................................ 2-J Palm Buttons (ML3495D-40) ........................................................................ 2-K Electrical Enclosure (ML5000-030) .............................................................. 2-L Operator Station (ML5000-040) ................................................................... 2-M Control Panel Door Assembly (ML)(MLU4380) ........................................... 2-N Control Panel Door Assembly (MLA)(MLA5100) ......................................... SECTION III ELECTRICAL COMPONENTS 3-A Panel Assembly, Operator Station “ML” (ML5000-050)................................ 3-B Panel Assembly, Operator Station “MLA” (MLA5100) .................................. 3-C Panel Assembly, High Voltage (ML4750H) .................................................. 3-D Panel Assembly, Low Voltage (ML4750L) ................................................... 3-E Deck Box (ML5000-270) .............................................................................. 3-F LVDT Box (ML5000-260) ............................................................................. 3-G Coolant Box (ML3495D-50) ......................................................................... 3-H Coolant Box (ML3495CG-50) ....................................................................... SECTION IV OPTIONAL ITEMS 4-A Automatic Size Control (EC4500A) .............................................................. 4-B Transformer Kit (PEM1083A) ....................................................................... iii iii iii iv iv v v vi 1 2 4 6 10 18 20 24 26 30 32 38 40 41 42 43 44 46 47 48 49 50 51 52 54 56 58 60 62 64 65 66 72 74 76 78 80 81 82 84 86 90 94 96 98 100 102 104 “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 OVERALL BASIC MACHINE 3 1 4 10 5 7 14 8 12 15 13 2 6 11 9 20 24 27 16 23 22 25 26 19 18 21 17 OVERALL - BASIC MACHINE Page 2 OVERALL BASIC MACHINE PARTS LIST COVERING FIGURE “OVERALL” 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 N/S 24 N/S 25 26 N/S N/S 27 N/S ORDER BY PART NUMBER ----------------------EC4023 EC4024 EC4051A EC4052A ----ML3495 ----EC4485 EC6510A EC6519A EC6518A --PHM484A EC4291A PHM788A PHSM966 EC4292 ML3340 ML3360 QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 DESCRIPTION ......Upper Stroker (see Fig. 1-A) ......Lower Stroker (see Fig. 1-B) ......Feed Unit (see Fig. 1-C) ......Expand / Retract System (see Fig. 1-D) ......Cam Assembly (see Fig. 1-F) ......Spindle (see Fig. 1-E) ......Outside Stroker (see Fig. 1-G) ......Universal Honing Fixture (see Fig. 1-J) ......Machine Base Assembly (see Fig. 2-B) ......Tray Assembly (see Fig. 2-C) ......Deck Assembly (see Fig. 2-D) ......Right Hood Rest ......Left Hood Rest ......Right Hood Prop ......Left Hood Prop ......Front Panel (see Fig. 1-I) ......Foot Pedal Assembly (see Fig. 2-A) ......Coolant System (see Fig. 2-H) ......Electrical Enclosure (see Fig. 2-K) ......Operator Station (see Fig. 2-L) ......Gage Tray Assembly (Optional) ......Side Tray Assembly (Optional) includes ........Side Tray Mat ........Spacer (Pkg. of 2) ......Hood Assembly (see Fig. 1-H) ........Latch (Pkg. of 1) ......Spindle Splash Guard ......Knob ........Screw ........Spacer ......Left Guard Pane Assembly (CE Machines ONLY)(see Fig. 2-F) ......Right Guard Pane Assembly (CE Machines ONLY)(see Fig. 2-G) N/S indicates Not Shown Page 3 SECTION I BASIC MACHINE-TOP FIGURE 1-A – UPPER STROKER Page 4 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-A” 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 ORDER BY PART NUMBER --EC1512 PHSM498 PHWM407 PHWM501 EC1526 EC1531 PBR138 PBR139 EC1532 PBR140 PBR59 EC1534 EC1536 EC1537 PHSM582 PHKM102 EC1551 EC1552 PHSM495 EC1553 PMO710 EC1560 PHWM532 PNP299 EC1564 PHSM539 PEC127 PEM251 PES663 ML4730 ML4733 PHNM401 EC1566 PHSM538 PDB320 EC4376 ML4731 ML4732 ML4734 ML4742 ML4316 ECA7559 ECA7558 QTY. Ref. 1 15 26 18 1 1 2 1 1 1 2 1 1 1 2 1 1 1 11 1 1 1 4 1 1 1 1 1 6 1 1 2 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Upper Stroker includes ......Front Stroker Frame (see Fig. 1-B, 1 of 2, item 39) ......Screw ( M8 x 1,25 x 30mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Rear Frame Member ......Crankshaft ......Bearing ......Bearing ......Connecting Rod ......Bearing ......Bearing (Ball) ......Crank Bearing Bracket ......Right Frame Member ......Left Frame Member ......Screw (M8 x 1,25 x 50mm HHCS) ......Parallel Key(5 x 5 x 14mm) ......Stroker Pulley ......Wedge ......Screw (M8 x 1,25 x 20mm (HHCS) ......Washer ......Motor (see Fig. 2-K, item 19) ......Stroker Motor Bracket Assy. ......Flatwasher (M8) ......Electrical Decal ......Wedge ......Screw (M8 x 1,25 x 50mm HHCS) ......Conduit Connector ......Sealing 'O' Ring w/Retainer ......Modular Prox Switch ......Stroke Length #1 Prox Cable (see Fig. 3-E, item 13) ......Stroke Pulley #1 Prox Cable (see Fig. 3-E, item 23) ......Nut, Hex (M8 x 1,25) ......Stroker Motor Pulley ......Screw (M6 x 1,0 x 8 mm SHSS) ......Belt ......Proximity Sensors Support ......Stroke Length #2 Prox Cable (see Fig. 3-E, item 24) ......Stroke Length #3 Prox Cable (see Fig. 3-E, item 26) ......Stroke Pulley #2 Prox Cable (see Fig. 3-E, item 18) ......Stroke Pulley Rear Prox Cable (see Fig. 3-E, item 14) ......Proximity Switch Bracket ......Stroker Pulley Target ......Proximity Switch Bracket N/S indicates Not Shown Page 5 SECTION I BASIC MACHINE-TOP FIGURE 1-B – LOWER STROKER (1 of 2) Page 6 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-B” - (1 of 2) 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 28 29 30 31 32 33 34 35 36 37 38 39 ORDER BY PART NUMBER --PDB206 EC1636 EC1637 PHSM962 PHM212 EC4768 EC1639 PHPM535 EC1641 EC1642 PHSM964 EC1646 PBR214 EC1647 PPPM411 EC1648 EC4769 PHNM408 EC1653 PSP527 PHNM419 EC4771 PHM373 EC1661X1 PBR59 EC1664 PHPM512 PHSM496 PHNM443 EC1656 PBR216 EC1657 EC1658 PSP530 EC1659 PHSM495 PHWM407 PHWM501 EC1512 QTY. Ref. 1 1 2 4 1 1 1 1 2 1 2 1 2 1 1 1 1 4 1 1 2 1 1 1 4 1 2 1 1 2 2 1 1 2 1 2 2 2 Ref. DESCRIPTION ....Lower Stroker (1 of 2) includes ......Timing Belt ......Belt Connector ......Belt Clamp ......Screw (M3 x 0,5 x 12mm SHCS) ......Timing Pulley ......Pulley Shaft ......Idler Pulley ......Dowel Pin (M8 x 24mm) ......Pulley Bracket ......Tensioning Block ......Screw (M6 x 1,0 x 35mm SHCS) ......Cross Beam Pivot ......Roller ......Pin ......Grease Fitting (M6 x 1,0 x 5mm) ......Short Rod ......Long Rod ......Nut, Hex Jam (M10 x 1,5) ......Guide Block ......Disc Spring ......Nut, Hex (M10 x 1,5) ......Spacer ......Hand Lever ......Cross Beam ......Bearing (Ball) ......Stroker Shaft Clamp ......Dowel Pin (M10 x 24mm) ......Screw (M10 x 1,5 x 40mm HHCS) ......Locknut (M10 x 1,5) ......Yoke Link ......Bearing ......Roller Yoke ......Pin ......Disc Spring ......Yoke Guide ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Front Stroker Frame (see Fig. 1-A, item 1) N/S indicates Not Shown Page 7 SECTION I BASIC MACHINE-TOP FIGURE 1-B – LOWER STROKER (2 of 2) Page 8 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-B” - (2 of 2) ITEM NO. 1 2 3 4 5 6 6 7 8 9 10 10a 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 ORDER BY PART NUMBER --EC1594 EC1595 PHSM691 PHWM509 PHWM530 EC1670 MLA1670 PHSM495 PHWM407 PHWM501 ML1850 MLA4865 PFC118 PPP439 EC1861 PHSM625 PHWM406 EC1862 PHNM401 EC1867 PHPM548 PHSM598 PHWM531 EC4841 PBR228 EC1869 EC1871SC PHSM534 EC1872SC PHSM963 EC1876SC EC1885* EC1890* PHSM966* PHM494* EC1781* EC1512 QTY. Ref. 1 1 2 4 2 1 1 4 6 4 1 1 1 2 1 2 6 1 1 1 1 2 3 2 4 1 1 2 1 4 2 1 1 1 1 1 Ref. DESCRIPTION ....Lower Stroker (2 of 2) includes ......Seal ......Front Pillow Block Assembly (see Fig. 1-L) ......Screw (M6 x 1,0 x 25mm HHCS) ......Lockwasher (M6) ......Washer (M6) ......Rear Pillow Block Assembly (ML)(see Fig. 1-M) ......Rear Pillow Block Assembly (MLA)(see Fig. 1-M) ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Stroker Driveshaft Assembly (ML)(see Fig. 1-N) ......Stroker Driveshaft Assembly (MLA)(see Fig. 1-O) ......Air Cylinder ......Elbow ......Unlatching Cyl. Base ......Screw (M5 x 0,8 x 50mm SHCS) ......Lockwasher (M5) ......Rod End ......Nut, Hex (M8 x 1,25) ......Lifter Pivot Block ......Dowel Pin (M10 x 36mm) ......Screw (M8 x 1,25 x 35mm HHCS) ......Flatwasher (M10) ......Lifter Arm ......Bushing ......Roller Shaft ......Roller ......Screw (M6 x 1,0 x 20mm SHCS) ......Lifter Bar ......Screw (M5 x 0,8 x 20mm SHCS) ......Stop Collar Nut ......Top Clamp Block Assembly ......Bottom Clamp Assembly ......Screw (M6 x 1,0 x 25mm SHCS) ......Hand Lever ......Carriage Position Screw ......Front Stroker Frame (see Fig. 1-A, item 1) N/S indicates Not Shown *NOTE: Not used on MLA5000 Machines. Page 9 SECTION I BASIC MACHINE-TOP FIGURE 1-C – FEED UNIT (1 of 4) Page 10 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-C” (1 of 4) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ORDER BY PART NUMBER --EC2555 EC2571 PHSM548 PHSM963 EC2615 EC2618 EC2619 EC2621 PHKM103 EC2622 EC2623 PBR213 EC2624 EC2636 PBR212 EC2637 PHWM501 PHRM303 EC2638 PHSM520 PHWM528 PHWM527 QTY. Ref. 1 1 1 1 1 1 1 1 1 1 1 1 2 1 6 1 2 2 2 2 2 2 DESCRIPTION ....Feed Unit (1 of 4) includes ......Feed Unit Frame ......Retraction Stop ......Screw (M8 x 1,25 x 16mm SHCS) ......Screw (M5 x 0,8 x 20mm SHCS) ......Yoke Assembly ......Rod ......Spring ......Adjustment Disc ......Parallel Key ......Rod End ......Jam Nut ......Roller ......Pivot Pin ......Linkage Yoke ......Roller Bearing ......Spring Link Pivot Pin ......Flatwasher (M8) ......E-Ring (6mm) ......Control Link ......Screw (M4 x 0,7 x 10mm SHCS) ......Lockwasher (M4) ......Washer (M4) N/S indicates Not Shown Page 11 SECTION I BASIC MACHINE-TOP FIGURE 1-C – FEED UNIT (2 of 4) Page 12 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-C” (2 of 4) 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 ORDER BY PART NUMBER --ML2640 ML2645 EC2648 EC2649 PPPM411 EC2656 EC2657 EC2658 PHSM573 PHWM516 PHSM516 EC2659 EC2661 EC2803 PHSM535 PHSM405 PHSM541 PHWM509 PHNM407 PHR363 EC2652 PHSM431 PHWM406 EC2670 EC2675 EC2673 PHR361 PHSM495 PHWM407 PHWM501 EC2619 EC2674 EC2651 EC2691 EC2692 PHWM518 EC4407 PHSM466 PFC108 PFC104 MLA4859 CRG868 PHSM667 PHWM528 PHNM402 ML4727 PEM983 PES669 ML4741 EC2638 EC2555 QTY. Ref. 1 1 2 1 4 1 2 4 2 2 4 2 1 1 3 5 1 9 1 1 1 4 4 1 1 1 2 8 8 4 1 1 1 1 1 4 1 1 1 2 1 2 2 4 4 1 1 1 1 2 1 DESCRIPTION ....Feed Unit (2 of 4) includes ......Right Input Link ......Left Input Link ......Counterbalance Pivot Block ......Counterbalance Pivot Pin ......Grease Fitting (M6 x 1,0 x 5mm) ......Input Link Frame ......Stop Block ......Compression Pad ......Screw (M4 x 0,7 x 20mm SHCS) ......Flatwasher (M4) ......Screw (M5 x 0,8 x 25mm SHCS) ......Washer Plate ......Input Link Pivot Pin ......Input Lever Bracket ......Screw (M6 x 1,0 x 12mm SHCS) ......Screw (M6 x 1,0 x 16mm SHCS) ......Screw (M6 x 1,0 x 16mm BHCS) ......Lockwasher (M6) ......Nut, Hex (M6 x 1,0) ......E-Ring (8mm) ......Control Link Retainer ......Screw (M5 x 0,8 x 10mm BHCS) ......Lockwasher (M5) ......Right Frame Section ......Left Frame Section ......Counterbalance Pivot Pin ......E-Ring (12mm) ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Spring ......Spring Support ......Actuator Rod End ......Right Actuator Bracket ......Left Actuator Bracket ......Flatwasher (M6) ......Disassembly Warning Label ......Setscrew (M6 x 1,0 x 6mm SHSS) ......Air Cylinder ......Flow Control Valve ......Anti-Glaze Prox. Switch Bracket ......Flatwasher ......Screw (M4 x 0,7 x 6mm BHCS) ......Lockwasher (M4) ......Nut, Hex (M4 x 0,7) ......Prox Mounting Plate ......Mounting Collar ......Modular Prox Switch, Pnp, N.O. ......Cable, Anti Glaze Upper Limit Prox. (see Fig. 3-E, item 15) ......Control Link ......Feed Unit Frame N/S indicates Not Shown Page 13 SECTION I BASIC MACHINE-TOP FIGURE 1-C – FEED UNIT (3 of 4) Page 14 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-C” (3 of 4) 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 ORDER BY PART NUMBER --EC2676 EC1787 PHM479 EC2677 PHSM588 EC2678 PHSM771 EC2680 PHPM538 EC2683 PBR216 EC2684 EC2686 PHR361 EC2687 PHSM597 PHNM401 PHSM402 EC2849 PHSM401 PHWM519 PHNM434 EC2894 EC2897 PHRM305 PHSM495 PHWM407 PBR213 PHPM539 EC2696 EC2697 EC2698 PHSM598 EC2693 PHSM599 PHWM518 PHWM509 PHNM407 EC2803 EC2537 EC2555 EC2580 QTY. Ref. 2 2 2 2 4 2 4 1 1 1 1 1 2 2 1 2 5 2 1 2 2 3 1 1 2 4 7 2 1 2 1 1 3 2 1 2 1 1 1 1 1 Ref. DESCRIPTION ....Feed Unit (3 of 4) includes ......Force Adjustment Screw ......Pad ......Ball Plunger ......Stop Collar ......Screw (M5 x 0,8 x 6mm SHSS) ......Flexible Coupling ......Setscrew (M6 x 1,0 x 12mm SHSS) ......Main Lever ......Dowel Pin (M10 x 30mm) ......Indicator Point ......Bearing ......Main Pivot Pin ......Spacer ......E-Ring (12mm) ......Overtravel Stop Bar ......Screw (M8 x 1,25 x 25mm SHSS) ......Nut, Hex (M8 x 1,25) ......Screw (M5 x 0,8 x 16mm SHCS) ......Bracket ......Screw (M5 x 0,8 x 12mm SHCS) ......Flatwasher (M5) ......Nut, Insert (M5 x 1,8,) ......Link (see Fig. 1-D, item 38) ......Pin ......E-Ring (3,2mm) ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Roller ......Dowel Pin (M6 x 24mm) ......Feed Control Arm ......Control Arm Extension ......Control Arm Spacer ......Screw (M8 x 1,25 x 35mm HHCS) ......Spacer ......Screw (M6 x 1,0 x 60mm SHCS) ......Flatwasher (M6) ......Lockwasher (M6) ......Nut, Hex (M6 x 1,0) ......Input Lever Bracket ......Retraction Yoke (see Fig. 1-E, 2 of 2, item 12) ......Feed Unit Frame ......Indicator Frame Assembly (see Fig. 1-C, 4 of 4) N/S indicates Not Shown Page 15 SECTION I BASIC MACHINE-TOP FIGURE 1-C – FEED UNIT (4 of4) Page 16 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-C” (4 of 4) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 ORDER BY PART NUMBER --EC2580 EC2578 PBR517 EC2579 PSP222 PHPM534 PHNM434 EC4491 EC2582 EC4467 PHW109 PHNM435 EC2583 PSP327 EC2584 PHSM963 PHWM519 QTY. Ref. 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 3 1 DESCRIPTION ....Feed Unit (4 of 4) includes ......Indicator Frame Assy. ......Indicating Finger ......Ball ......Spacer ......Compression Spring ......Dowel Pin (M4 x 50) ......Nut, Insert (M5 x 1,8) ......Split Bushing ......LVDT (see Fig. 3-F, item 11) ......Clip ......Flatwasher (#6) ......Nut, Hex Jam (M27 x 3,0) ......Pin ......Extension Spring ......Spacer ......Screw (M5 x 0,8 x 20mm SHCS) ......Flatwasher (M5) N/S indicates Not Shown Page 17 SECTION I BASIC MACHINE-TOP FIGURE 1-D – EXPAND/RETRACT SYSTEM Page 18 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-D” 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 28 29 30 31 32 33 34 35 36 37 38 39 40 ORDER BY PART NUMBER --EC2842 MBB982 PHRM308 PSP328 MLA2549 PHSM495 PHWM407 EC2892 PHNM420 PFC109 PFC104 PPP439 PHR363 EC2890 EC2896 PHM475 EC2898 EC2956 EC2887 PHRM305 EC2957 EC2885 PHNM434 PHSM401 PHWM519 ML4727 PEM983 PES669 PES670 PHWM528 PHNM402 PHWM516 ML4735 ML4736 MLU2018 PHSM622 PHWM541 EC2894 EC2856 EC2555 QTY. Ref. 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 2 2 2 2 2 1 1 8 8 4 1 1 1 2 2 Ref. Ref. Ref. DESCRIPTION ....Expand/Retract System includes ......Link ......Flatwasher ......E-Ring (5mm) ......Extension Spring ......Retraction Cylinder Bracket ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Retraction Cyl.Pivot Pin ......Nut, Hex Jam (M16 x 2,0) ......Air Cylinder ......Flow Control Valve ......Elbow ......E-Ring (8mm) ......Rod End Assembly ......Foot Pedal Chain ......Chain Connector ......Tri-Coupling ......Spring Connector Link ......Pin ......E-Ring (3,2mm) ......Spring (connects to EC4110) (see Fig. 2-C, item 20) ......Cable Hook Assembly (see Fig. 1-P) ......Nut, Insert (M5 x 1,8,) ......Screw (M5 x 0,8 x 12mm SHCS) ......Flatwasher (M5) ......Prox Mounting Plate ......Mounting Collar ......Modular Prox Switch, PNP, N.O. ......Modular Prox Switch, PNP, N.C. ......Lockwasher (M4) ......Nut, Hex (M4 x 0,7) ......Flatwasher (M4) ......Foot Pedal, #1 Prox Cable (see Fig. 3-E, item 22) ......Foot Pedal, #2 Prox Cable (see Fig. 3-E, item 21) ......Electric Clutch (see Fig. 1-U, item 3) ......Screw (M6 x 1,0 x 12 HHCS) ......Washer ......Link (see Fig. 1-C, 3 of 4, item 23) ......Cam Housing (see Fig. 1-F, item 1) ......Feed Unit Frame (see Fig. 1-C, 1 of 4, item 1) N/S indicates Not Shown Page 19 SECTION I a BASIC MACHINE-TOP FIGURE 1-E – SPINDLE (1 of 2) Page 20 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-E” (1 of 2) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 14a 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 ORDER BY PART NUMBER EC2010A EC2016 EC2017 PHPM531 PBR201 EC2018 PBR200 PHNM413 PHM785 EC2019 PHM784 PHSM550 PHSM405 EC2041 EC2040 PHSM551A PPPM411 PHK112 EC2070 PHSM538 PMO967 ML2110 PHSM556 PHWM531 PHWM521 PHNM419 EC2114 PHSM498 PHWM407 PHWM532 EC1564 PHSM539 PDB340 PNP299 PEC127 PEM251 QTY. Ref. 1 1 1 2 1 1 1 1 1 1 3 4 1 1 8 1 1 1 2 1 1 4 4 4 4 1 4 4 4 1 1 1 1 1 1 DESCRIPTION ....Spindle (1 of 2) includes ......Spindle Housing ......Bearing Spacer ......Dowel Pin (M6 x 12mm) ......Tapered Roller Bearing ......Spindle Shaft ......Bushing ......Bearing Retaining Nut ......Seal ......Rear Seal Housing ......Seal ......Screw (M3 x 0,5 x 8mm SHCS) ......Screw (M6 x 1,0 x 16mm SHCS) ......Spindle Nose Washer ......Spindle Nose Assembly ......Set Screw(M8 x .75 x 16 Flat Point) (Pkg. of 8) ......Grease Fitting (M6 x 1,0 x 5mm) ......Parallel Key ......Spindle Pulley ......Screw (M6 x 1,0 x 8mm SHSS) ......Spindle Motor (see Fig. 2-K, item 23) ......Spindle Motor Base ......Screw ( M10 x 1,5 x 25mm FSHCS) ......Flatwasher (M10) ......Lockwasher (M10) ......Nut, Hex (M10 x 1,5) ......Motor Pulley ......Screw (M8 x 1,25 x 30mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Wedge ......Screw (M8 x 1,25 x 50mm HHCS) ......Belt ......Electrical Decal ......Conduit Connector ......Sealing 'O' Ring w/Retainer N/S indicates Not Shown Page 21 SECTION I BASIC MACHINE-TOP FIGURE 1-E – SPINDLE (2 of 2) Page 22 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-E” (2 of 2) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 ORDER BY PART NUMBER --EC2501 EC4439 EC2516 PBR211 EC2512 PHSM556 EC2515 PHSM520 EC2532 PHSM495 PHWM407 EC2537 QTY. Ref. 1 1 1 2 1 1 1 2 1 3 3 Ref. DESCRIPTION ....Spindle (2 of 2) includes ......Wedge Hook ......Feed Rod ......Cover Plate ......Bearing ......Shoulder Washer ......Screw (M10 x 1,5 x 25mm SHCS) ......Guided Feed Rod (see Fig. 1-Q) ......Screw (M4 x 0,7 x 10mmSHCS) ......Torque Bracket ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Retraction Yoke (see Fig. 1-C, 3 of 4, item 40) N/S indicates Not Shown Page 23 SECTION I BASIC MACHINE-TOP FIGURE 1-F – CAM ASSEMBLY Page 24 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-F” 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 --EC2856 PBR218 EC2858 PHRM307 EC2846 PBR220 PHR362 EC2840 EC2847 EC2871 PHSM490 EC2826 PHSM401 EC2830 EC2844 PHSM540 EC2834 PHSM573 EC2820 EC2823 EC2835 PHSM507 PHSM966 PHWM509 PHWM518 QTY. Ref. 1 2 1 1 1 2 1 1 1 1 3 2 4 1 1 3 1 1 1 1 1 1 4 4 4 DESCRIPTION ....Cam Assembly includes ......Cam Housing (see Fig. 1-F, item 39) ......Bearing ......Cam Shaft ......Retaining Ring ......Sleeve ......Bearing ......Retaining Ring, External (2in.) ......Auto Lever Assembly ......Shim Cover ......Eccentric Cam ......Screw (M4 x 0,7 x 12mm SHCS) ......Dog Block ......Screw (M5 x 0,8 x 12mm SHCS) ......Cable Lever Assembly ......End Plate ......Screw (M4 x 0,7 x 10mm SHCS) ......Dog Collar ......Screw (M4 x 0,7 x 20mm SHCS) ......Damper Lever Assembly ......Dog Block ......Spring Lever Assembly ......Screw (M5 x 0,8 x 30mm SHCS) ......Screw (M6 x 1,0 x 25mm SHCS) ......Lockwasher (M6) ......Flatwasher (M6) N/S indicates Not Shown Page 25 SECTION I BASIC MACHINE-TOP FIGURE 1-G – OUTSIDE STROKER (1 of 2) Page 26 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-G” (1 of 2) 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 ORDER BY PART NUMBER --EC1811 EC1815 PPPM411 EC1821 PHSM548 PHSM405 EC1822 PHSM402 PHSM966 PHWM509 PHWM518 MLU1825 EC1782 EC1787 PHSM422 EC1784 EC1788 PSP228 PBR199 PBR198 PBR197 PHNM437 EC1786 PHSM963 EC4291 EC4292 PHM788 QTY. Ref. 2 2 2 2 8 9 2 2 15 14 14 1 1 1 1 1 1 1 2 2 1 1 1 3 1 1 1 DESCRIPTION ....Outside Stroker (1 of 2) includes ......Ball Bushing Shaft ......Pillow Block Assembly (see Fig. 1-R) ......Grease Fitting (M6 x 1,0 x 5mm) ......Shaft Support ......Screw (M8 x 1,25 x 16mm SHCS) ......Screw (M6 x 1,0 x 16mm SHCS) ......Collar ......Screw (M5 x 0,8 x 16mm SHCS) ......Screw (M6 x 1,0 x 25mm SHCS) ......Lockwasher (M6) ......Flatwasher (M6) ......Stroker Carriage Assembly ......Carriage Position Handwheel ......Pad ......Screw (M5 x 0,8 x 12mm SHCS) ......Spacer ......Bearing/Spring Locator Plate ......Wave Spring ......Thrust Bearing Washer ......Thrust Bearing Roller & Cage ......Thrust Bearing Center Washer ......Bearing Nut ......Bearing Locator Plate ......Screw (M5 x 0,8 x 20mm SHCS) ......Spindle Splash Guard ......Spacer ......Knob Page 27 SECTION I BASIC MACHINE-TOP FIGURE 1-G – OUTSIDE STROKER (2 of 2) Page 28 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-G” (2 of 2) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER --EC3795 PEC139 PEC140 PFC103 PPP477 PPP478 PPP190 PPP439 ML5505 PHNM425 PHSM473 PHWM516 PFC115 PFC117 PPPM423 EC4110 QTY. Ref. 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 Ref. DESCRIPTION ....Outside Stroker (2 of 2) includes ......Cable, ASC Port ......Clamp ......Plug ......Filter Regulator ......Adapter ......Street Elbow ......Hose Barb ......Elbow ......Manifold Assembly (see Fig. 1-S) ......Nut, Insert (M4 x 1,8) ......Screw (M4 x 0,7 x 40mm SHCS) ......Flatwasher (M4) ......Flow Control Valve ......Regulator ......Elbow ......Machine Cover Frame (see Fig. 2-C, item 16) N/S indicates Not Shown Page 29 SECTION I BASIC MACHINE-TOP FIGURE 1-H – HOOD ASSEMBLY Page 30 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-H” ITEM NO. 1 2 3 4 5 6 7 8 9 N/S N/S 10 N/S N/S 11 12 13 14 15 16 17 18 19 20 21 22 ORDER BY PART NUMBER --EC4140 EC4146 PHSM964 PHWM509 PHWM530 PHSM402 PHWM529 PHNM434 ML4250A EC4250 PDL204A ML4255A EC4255 PDL204A PHM484 PHNM436 PHSM535 PET713 PHNM405 PHSM438 PHWM510 PNP430 --EC1090 EC1095 EC4110 QTY. Ref. 1 1 2 10 10 2 2 2 1 1 1 1 1 1 2 8 8 4 2 2 4 2 1 Ref. Ref. Ref. DESCRIPTION ....Hood Assembly includes ......Rear Panel Assembly ......Guide Plate ......Screw (M6 x 1,0 x 35mm SHCS) ......Lockwasher (M6) ......Washer (M6) ......Screw (M5 x 0,8 x 16mm SHCS) ......Washer (M5) ......Nut, Insert (M5 x 1,8) ......Right Hood includes ........Right Hood Assembly (see Fig. 2-C, item 14) ........Decal Set, Right (specify burgundy or black) ......Left Hood includes ........Left Hood Assembly (see Fig. 2-C, item 15) ........Decal Set, Left (specify burgundy or black) ......Latch ......Nut, Self Clinching (M6 x 1,0) ......Screw (M6 x 1,0 x 12mm SHCS) ......Terminal ......Nut, Hex (M5 x 0,8) ......Screw (M5 x 0,8 x 12mm PPHS) ......Lockwasher, External Tooth (M5) ......Ground Symbol Label ......Ground Wire ......Right Beam Assembly (see Fig. 2-D, item 1) ......Left Beam Assembly (see Fig. 2-D, item 2) ......Machine Cover Frame (see Fig. 2-C, item 16) N/S indicates Not Shown Page 31 SECTION I BASIC MACHINE-TOP FIGURE 1-I – FRONT PANEL (1 of 3) Page 32 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-I” (1 of 3) ITEM NO. 1 2 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 28 29 30 31 32 33 34 35 36 ORDER BY PART NUMBER --ML4765 ML2724CE ML2724EN EC2726 EC2727 EC2728 EC2731 ML2736 PHSM550 PHM121 EC2735 PHSM588 EC2739 EC2741 PHM119 PHM120 PHSM401 PHWM529 PHSM535 PHSM405 PHWM509 PHWM530 POR135 EC2913 PHSM424 PHWM518 EC2914 EC2918 PHSM609 PHRM308 EC2920 EC2931 PHSM421 EC2732 EC2737 MLU2000 PDB338 QTY. Ref. 1 1 1 2 2 2 1 1 6 2 2 4 1 2 2 2 3 3 4 2 6 6 1 1 2 2 1 1 1 1 1 1 4 1 1 1 1 DESCRIPTION ....Front Panel (1 of 3) includes ......Front Panel Assembly ......Front Panel Overlay (CE Machines ONLY) ......Front Panel Overlay (Non-CE Machines ONLY) ......Knob Casting ......Feed Force Input Shaft ......Output Gear ......Finishing Force Dial ......Feed Force Dial Face ......Screw (M3 x 0,5 x 8mm SHCS) ......Pinion ......Coupling Assembly ......Screw (M5 x 0,8 x 6mm SHSS) ......Gear Cluster Bracket ......Intermediate Gear Shaft ......Gear ......Gear ......Screw (M5 x 0,8 x 12mm SHCS) ......Washer (M5) ......Screw (M6 x 1,0 x 12mm SHCS) ......Screw (M6 x 1,0 x 16mm SHCS) ......Lockwasher (M6) ......Washer (M6) ......O-Ring (7,5 ID x 2,5 mm) ......Standoff ......Screw (M6 x 1,0 x 20mm HHCS) ......Flatwasher (M6) ......Feed Regulator Screw ......Knob ......Screw (M4 x 0,7 x 6mm SHSS) ......E-Ring (5mm) ......Damper Assembly (see Fig. 1-T) ......Feed Regulator Dial ......Screw (M4 x 0,7 x 5mm SHSS) ......Roughing Force Dial ......Roughing Dial Face ......Stone Saver Idler Assembly (see Fig. 1-V) ......Belt N/S indicates Not Shown Page 33 SECTION I BASIC MACHINE-TOP FIGURE 1-I – FRONT PANEL (2 of 3) Page 34 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-I” (2 of 3) ITEM NO. 1 2 3 4 5 6 6 7 8 9 10 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 46 47 48 49 50 51 52 53 54 55 ORDER BY PART NUMBER --EC2766 EC2761 EC2762 PHPM540 EC2763 EC2764M EC2764 EC2769 PHSM608 PHWM535 EC2781 EC2784 EC2783 PHSM573 EC2786 PBR223 EC2772 PHSM538 EC2771 EC2773 EC2799 PBR215 PHWM518 PHWM509 PHSM607 EC2768 PHM213 PDB207 EC2796 EC2797 PHSM402 EC2918 PHSM609 PHR363 PHNM408 EC2777 EC2774 EC2776 PHPM514 PFC112 PFC114 PFC113 PPPM422 PFC110 PFC116 PHSM401 EC2791 PHSM613 EC2792 EC2788 EC2787 EC2782 PHWM519 PHSM963 PHSM574 ML4765 QTY. Ref. 1 1 1 3 1 1 1 1 2 1 1 1 1 2 1 1 2 2 1 1 1 1 2 2 2 1 1 1 2 1 1 2 1 1 4 1 1 1 2 1 1 1 5 1 2 2 1 2 1 2 1 1 2 2 2 1 DESCRIPTION ....Front Panel (2 of 3) includes ......Feed Dial Shaft ......Feed Knob ......Knob Handle ......Groove Pin, Flat Head (M2 x 6mm) ......Feed Dial Disc ......Feed Dial Face (Metric) ......Feed Dial Face (Inch) ......Index Piece ......Screw (M3 x 0,5 x 20mm SHCS) ......Washer ......Compensator Gear ......Spring Per Print ......Spring Housing ......Screw ......Clutch Housing ......Bearing ......Clamp Collar ......Screw (M6 x 1,0 x 8mm SHSS) ......Feed Shaft ......Drag Wheel ......Shaft Support Bracket ......Bearing ......Flatwasher (M6) ......Lockwasher (M6) ......Screw (M6 x 1,0 x 30mm SHCS) ......Pulley Shaft ......Timing Pulley ......Timing Belt ......Drag Spring Clamp ......Drag Spring ......Screw (M5 x 0,8 x 16mm SHCS) ......Knob ......Setscrew (M4 x 0,7 x 6mm SHSS) ......E-Ring (8mm) ......Nut, Hex Jam (M10 x 1,5) ......Compensator Screw ......Clevis ......Link ......Roll Pin (M6 x 16mm) ......Push Button Valve ......Valve Adapter ......Valve ......Elbow ......Air Cylinder ......Flow Control Valve ......Screw (M5 x 0,8 x 12mm SHCS) ......Rack Rod End ......Screw ......Rack ......Standoff ......Spring Opening Plate ......Rack Support ......Flatwasher (M5) ......Screw (M5 x 0,8 x 20mm SHCS) ......Screw (M4 x 0,7 x 30mm SHCS) ......Front Panel Assembly N/S indicates Not Shown Page 35 SECTION I BASIC MACHINE-TOP FIGURE 1-I – FRONT PANEL (3 of 3) Page 36 SECTION I BASIC MACHINE-TOP PARTS LIST COVERING FIGURE “1-I” (3 of 3) ITEM NO. 1 1 2 3 4 5 6 7 8 9 10 11 12 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 ORDER BY PART NUMBER --ML2751M ML2751 ML2754 ML2756 PES378 PHSM401 PHWM529 MAN692 EC2991 EC2992 PHSM604 PHNM400 ML2996EN ML2996CE EC2994 EC2762 PHSM609 PES659 PES961 PES644 EC3782 PED32 EC3786 PEM1066 PEM971 ML7001 PNP331 ML4765 QTY. Ref. 1 1 1 1 1 4 4 4 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Front Panel (3 of 3) includes ......Panel Meter, 4.5in. (Metric) ......Panel Meter, 4.5in. (Inch) ......Gasket ......Indicator Electrical Enclosure ......Four Position Selector (see Fig. 3-F, item 12) ......Screw (M5 x 0,8 x 12mm SHCS) ......Washer (M5) ......Nut, Hex (#6-32) ......Tape Per Print ......Index Piece ......Screw (M3 x 0,5 x 12mm SHCS) ......Nut, Hex (M3 x 0,5) ......Stroker Overlay (Inch) ......Stroker Overlay (Metric) ......Stroke Length Handwheel ......Knob Handle ......Screw (M4 x 0,7 x 6mm SHSS) ......Key Switch (CE Machines ONLY) ......Mounting Collar (CE Machines ONLY) ......Contact, N.O., Screw Term. (CE Machines ONLY) ......Sparkout Led Cable ......Potentiometer Operator ......Cable, Sparkout Potentiometer (see Fig. 3-F, item 9) ......Green Pilot Light Head ......Light Block, LED Green ......Reverse Switch Label ......Safety Glass Label ......Front Panel Assembly N/S indicates Not Shown Page 37 SECTION I BASIC MACHINE-TOP 36 55 56 47 52 54 53 6 40 39 38 5 1 57 4 16 3 17 35 20 24 12 27 25 30 31 42 43 13 14 29 41 45 11 9 22 21 26 18 31 10 8 19 28 37 2 51 7 23 46 50 49 33 15 34 44 32 41 FIGURE 1-J – UNIVERSAL HONING FIXTURE PARTS LIST COVERING FIGURE “1-J” 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 38 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-TOP PARTS LIST COVERING FIGURE “1-J” 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 39 SECTION I BASIC MACHINE-TOP 6 5 7 4 2 8 3 1 FIGURE 1-K – RUNOUT INDICATOR & TORQUE BAR PARTS LIST COVERING FIGURE “1-K” ITEM NO. 1 2 3 4 5 6 7 8 ORDER BY PART NUMBER EC6550A --EC6551 CGM4007 CGM4009A EC6552 PHPM447 PHSM614 ML6190 N/S indicates Not Shown Page 40 QTY. 1 1 1 1 1 1 1 1 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.) ....Torque Arm SECTION I BASIC MACHINE-TOP FIGURE 1-L – FRONT PILLOW BLOCK ASSEMBLY PARTS LIST COVERING FIGURE “1-L” ITEM NO. 1 2 3 4 ORDER BY PART NUMBER EC1595 EC1596 PBR196 PHM783 PPPM411 QTY. Ref. 1 1 2 1 DESCRIPTION ....Front Pillow Block Assembly includes ......Pillow Block ......Ball Bushing ......Seal ......Grease Fitting (M6 x 1,0 x 5mm) N/S indicates Not Shown Page 41 SECTION I BASIC MACHINE-TOP FIGURE 1-M – REAR PILLOW BLOCK ASSEMBLY PARTS LIST COVERING FIGURE “1-M” ITEM NO. 1 1 2 3 4 5 ORDER BY PART NUMBER EC1670 MLA1670 EC1671 MLA1671 PBR196 PHM783 PHPM548 PPPM411 N/S indicates Not Shown Page 42 QTY. Ref. Ref. 1 1 1 2 2 1 DESCRIPTION ....Rear Pillow Block Assembly (ML) includes ....Rear Pillow Block Assembly (MLA) includes ......Rear Pillow Block (ML) ......Rear Pillow Block (MLA) ......Ball Bushing ......Seal ......Dowel Pin ......Grease Fitting (M6 x 1,0 x 5mm) SECTION I BASIC MACHINE-TOP FIGURE 1-N – STROKER DRIVESHAFT ASSEMBLY “ML” PARTS LIST COVERING FIGURE “1-N” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 ORDER BY PART NUMBER ML1850 EC1850 EC1853 EC1855 EC1857SC EC1880 EC4828 EC4832 PHSM437 PHSM507 PHWM406 PHWM528 PSP225 QTY. Ref. 1 2 1 1 1 1 1 2 3 3 2 1 DESCRIPTION ....Stroker Driveshaft Assembly (ML) includes ......Stroker Drive Shaft Assy. ......Latch Plate ......Latch Wedge ......Spacer ......Stroker Extension Tube ......Front Latch Finger ......Rear Latch Finger ......Screw (M4 x 0,7 x 25mm SHCS) ......Screw (M5 x 0,8 x 30mm SHCS) ......Lockwasher (M5) ......Lockwasher (M4) ......Compression Spring, N/S indicates Not Shown Page 43 SECTION I BASIC MACHINE FIGURE 1-O – STROKER DRIVESHAFT ASSEMBLY “MLA” Page 44 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “1-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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 N/S N/S ORDER BY PART NUMBER MLA4865 EC1753 EC1765 EC1767 EC1769 EC1771 EC1772 EC1853 EC1855 EC1857 EC1876 EC4827 EC4828 EC4829 EC4831 EC4832 EC4834 EC4836 EC4837 EC4850 EC4860 ML1755 ML1757 MLA1883 ML1759 MLA1752 PFC122 PFC123 PHM372 PHNM405 PHSM427 PHSM437 PHSM507 PHSM515 PHSM520 PHSM534 PHSM613 PHSM701 PHWM406 PHWM517 PHWM528 PPP439 PPP441 PPPM430 PSP225 PFC101 PFC115 QTY. Ref. 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 2 4 1 2 4 3 1 7 3 2 1 1 1 1 2 1 DESCRIPTION ....Stroker Driveshaft Assembly (MLA) includes ......Latch Plate ......Latch Cam Assembly ......Cam Lever ......Large Spacer ......Small Spacer ......Clamp Nut ......Latch Plate ......Latch Wedge ......Spacer ......Stop Collar Nut ......Spacer ......Front Latch Finger ......Union Plate ......Union ......Rear Latch Finger ......Proximity Sensor ......Proximity Sensor Support ......Air Cylinder ......Stroker Extension Tube ......Stroker Drive Shaft Assembly ......Latch Wedge Assembly ......Spring Plate ......Locking Collar ......Backup Plate ......Latch Base ......Flow Control Valve ......Quick Exhaust Valve ......Knob ......Nut, HeX (M5 x 0,8) ......Screw (M5 x 0,8 x 40mm SHCS) ......Screw (M4 x 0,7 x 25mm SHCS) ......Screw (M5 x 0,8 x 30mm SHCS) ......Screw (M8 x 1,25 x 25mm SHCS) ......Screw (M4 x 0,7 x 10mm SHCS) ......Screw (M6 x 1,0 x 20mm SHCS) ......Screw (M4 x 0,7 x 16mm SHCS) ......SetScrew (M5 x 0,8 x 6mm SCPSS) ......Lockwasher (M5) ......Lockwasher (M4) ......Lockwasher (M4) ......Elbow ......Exhaust Muffler ......Nipple ......Compression Spring ......Solenoid Valve ......Flow Control Valve N/S indicates Not Shown Page 45 SECTION I BASIC MACHINE-TOP FIGURE 1-P – CABLE HOOK ASSEMBLY PARTS LIST COVERING FIGURE “1-P” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 ORDER BY PART NUMBER EC2885 EC2848 EC2874 EC2875 EC2880 EC2906 EC2948 PHNM402 PHNM407 PHSM520 PHWM516 PHWM518 N/S indicates Not Shown Page 46 QTY. Ref. 1 1 1 1 1 1 3 2 2 2 2 DESCRIPTION ....Cable Hook Assembly includes ......Cable Bracket ......Cable Spring ......Spring Retainer Assy. ......Cable Hook Assy. ......Cable ......Proximity Switch Bracket ......Nut, Hex (M4 x 0,7) ......Nut, Hex (M6 x 1,0) ......Screw (M4 x 0,7 x 10mm SHCS) ......Flatwasher (M4) ......Flatwasher (M6) SECTION I BASIC MACHINE-TOP FIGURE 1-Q – GUIDE FEED ROD PARTS LIST COVERING FIGURE “1-Q” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ORDER BY PART NUMBER EC2515 EC2520 EC2525 EC2536 EC2537 EC2538 EC2541 EC2542 PBR215 PHM122 PHM213 PHSM966 PHWM509 PHWM518 PPPM411 QTY. Ref. 1 1 1 1 1 1 1 1 1 1 4 2 7 1 DESCRIPTION ....Guide Feed Rod includes ......Feed Rod Guide Assembly ......Guided Feed Rod Assembly ......Feed Screw ......Retractor Yoke ......Feed Screw Gear ......Bracket ......Intermediate Shaft ......Bearing ......Spur Gear ......Timing Pulley ......Screw (M6 x 1,0 x 25mm SHCS) ......Lockwasher (M6) ......Flatwasher (M6) ......Grease Fitting (M6 x 1,0 x 5mm) N/S indicates Not Shown Page 47 SECTION I BASIC MACHINE-TOP FIGURE 1-R – PILLOW BLOCK ASSEMBLY PARTS LIST COVERING FIGURE “1-R” ITEM NO. 1 2 3 4 ORDER BY PART NUMBER EC1815 EC1816 EC1817 PBR196 PHM783 N/S indicates Not Shown Page 48 QTY. Ref. 1 1 2 2 DESCRIPTION ....Pillow Block Assembly includes ......Pillow Block ......Spacer ......Ball Bushing ......Seal SECTION I BASIC MACHINE FIGURE 1-S – MANIFOLD ASSEMBLY PARTS LIST COVERING FIGURE “1-S” ITEM NO. 1 2 3 3 4 5 6 6 ORDER BY PART NUMBER ML5505 PFC153 PFC206 PPP440 PPPM427 PPP441 PPPM449 --PFC101 QTY. Ref. 6 1 1 1 2 1 2 2 DESCRIPTION ....Manifold Assembly includes ......Solenoid Valve ......Block ......Straight Fitting (ML) ......Straight Fitting (MLA) ......Exhaust Muffler ......Pipe Plug, Hex Socket ......Blanking Plates (ML) ......Blanking Plates (MLA) N/S indicates Not Shown Page 49 SECTION I BASIC MACHINE FIGURE 1-T – DAMPER ASSEMBLY PARTS LIST COVERING FIGURE “1-T” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 ORDER BY PART NUMBER EC2920 CRG939 EC2925 EC2926 EC2927 EC2930 EC2935 EC2936 EC2937 EC2939 KKN905 KKN912 PHSM421 PSP223 N/S indicates Not Shown Page 50 QTY. Ref. 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Damper Assembly includes ......O-Ring ......Cylinder Cap ......Spacer Tube ......Damper Weight ......Stop Collar ......Piston Pivot ......Piston Pivot ......Metering Screw ......Spring Cup ......Piston ......Cylinder ......Screw (M4 x 0,7 x 5mm SHSS) ......Spring SECTION I BASIC MACHINE FIGURE 1-U – CYCLE TIME CONTROL MOTOR PARTS LIST COVERING FIGURE “1-U” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 ORDER BY PART NUMBER MLU2015 MLA4854 MLU2011 MLU2018 MLU2022 MLU4856 PHS683 PHNM407 PHS508 PHS614 PHSM623 PHSM1089 PHW342 PMO166 PHSM622 PHWM541 PEM299 PEM139 QTY. Ref. 1 1 1 1 1 2 2 3 2 1 2 4 1 Ref. Ref. 2 2 DESCRIPTION ....Cycle Time Control Motor Assembly includes ......Motor Bracket ......Motor Mounting Plate ......Electric Clutch (see Fig. 1-D, item 35) ......Torque Arm ......Anti-Glaze Drive Gear ......Screw (#10-32 x 5/8 BHCS) ......Nut, Hex (M6 X 1,0) ......Screw (#6-32 x 7/8 SHCS) ......Screw (#10-32 x 1/2 BHCS) ......Screw (M4 x 0,7 x 8 BHCS) ......Screw (M6 x 1,0 x 16 HHCS) ......Flatwasher (#10) ......DC Gearmotor - Extended Shaft ......Screw (M6 x 1,0 x 12 HHCS)(see Fig. 1-D, item 36) ......Washer (see Fig. 1-D, item 37) ......Socket (18-16 Awg) ......Clamp N/S indicates Not Shown Page 51 SECTION I BASIC MACHINE FIGURE 1-V – STONE SAVER IDLER ASSEMBLY PARTS LIST COVERING FIGURE “1-V” ITEM NO. 1 2 3 4 5 6 7 8 9 10 ORDER BY PART NUMBER MLU2000 MLU2003 PBR135 MLU2006 MLU2001 MLU2002 MLU2009 PHSM490 PHWM517 PHNM402 PDB338 N/S indicates Not Shown Page 52 QTY. Ref. 1 2 1 1 1 1 2 2 2 1 DESCRIPTION ....Stone Saver 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) ......Belt NOTES Page 53 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-A – FOOT PEDAL ASSEMBLY Page 54 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-A” 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 28 29 30 31 32 33 34 35 36 37 38 ORDER BY PART NUMBER ML2900 ML2905 ML2931 ML2932 PHPM545 ML2933 EC6138 PHSM405 PHNM456 PHSM775 PHSM535 PHWM509 PHS701 ML2914 ML2913 PBR306 KN383 PHSM774 PHWM518 PHNM405 ML2923 ML2922 PHR361 ML2911 ML2912 ML2927 PHNM407 EC2973 PSP334 PHNM402 ML2926 PHNM436 EC2885 EC2966 EFCB01590 ML2928 ML2940 PEC104 PHN125 QTY. Ref. 1 1 1 1 1 1 2 1 1 4 7 1 2 2 10 2 1 5 2 3 1 10 1 2 1 4 1 1 1 1 3 1 2 1 1 1 1 1 DESCRIPTION ....Foot Pedal Assembly includes ......Pedal Base Assembly ......Pedal Overtravel Stop ......Safety Latch ......Groove Pin ......Bushing ......Washer ......Screw (M6 x 1,0 x 16mm SHCS) ......Nut, Hex Jam (M8) ......Screw (M8 x 1,25 x 55mm SHCS) ......Screw (M6 x 1,0 x 12mm SHCS) ......Lockwasher (M6) ......Screw (1/2 x 3/4in. SSS) ......Pivot Link ......Link ......Clip Bearing ......Nut, Hex (3/8-16) ......Screw (6 x 20mm SSS) ......Flatwasher (M6) ......Nut, Hex (M5) ......Spacer ......Pivot Link Pin ......E-Ring ......Pedal ......Pin ......Bottom Cover ......Nut, Hex (M6) ......Cable End ......Extension Spring ......Nut, Hex (M4) ......Top Cover ......Nut, Self Clinching (M6) ......Cable Hook Assembly ......Bumper Strip ......Conduit ......Back Cover ......Safety Cover Assembly ......Connector Conduit ......Locknut N/S indicates Not Shown Page 55 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-B – MACHINE BASE ASSEMBLY Page 56 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-B” ITEM NO. 1 2 3 4 4 5 6 7 8 9 10 11 12 12 13 13 14 15 16 17 18 19 20 N/S ORDER BY PART NUMBER --EC4810 PHSM458 PHNM420 EC3818 EC3819 PHWM518 PHWM509 PHNM407 PEC104 PHWM564 PHN125 CGM1048 EC4724 EC4790 EC4865 EC4724 PHSM510 PHW399 EC4821 EC4822 EC4823 EC2967 EFCB01590 ML3300 QTY. Ref. 1 1 1 1 1 4 4 4 2 1 1 18 1 1 1 1 18 18 2 2 2 2 1 1 DESCRIPTION ....Machine Base Assembly includes ......Machine Base ......Screw (M16 x 2,0 x 50mm HHCS) ......Nut, Hex (M16 x 2,0) ......Brake Resistor Box, D Voltage (see Fig. 2-K, item 22) ......Brake Resistor Box, G Voltage (see Fig. 2-K, item 22) ......Flatwasher (M4) ......Lockwasher (M6) ......Nut, Hex (M6 x 1,0) ......Connector Conduit ......Flatwasher (M20) ......Locknut (1/2" NPT) ......Isolator Bushing ......Cover (ML) ......Cover (MLA) ......Backside Transformer Support (Non-CE Machines ONLY) ......Backside Transformer Support (CE Machines ONLY) ......Screw (M6 x 1,0 x 12mm BHCS) ......Nylon Retaining Washer ......Hand Rest Strip ......Hand Rest Strip ......Hand Rest Strip ......Bumper Strip ......Conduit ......CE Guard Module (CE Machines ONLY)(see Fig. 2-E) N/S indicates Not Shown Page 57 SECTION I BASIC MACHINE FIGURE 2-C – TRAY ASSEMBLY Page 58 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “2-C” ITEM NO. 1 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ORDER BY PART NUMBER --EC4008 EC4009 EC4010 ML4015 EC4015 ML4020 EC4806 EC4807 PHSM966 PHWM509 EC4023 EC4024 PHNM434 PHSM401 PHWM519 EC4051 EC4052 EC4110 PHSM495 PHWM407 PHWM501 EC2957 --- QTY. Ref. 1 1 1 1 1 1 1 1 2 2 1 1 8 8 2 1 1 4 4 4 4 1 Ref. DESCRIPTION ....Tray Assembly includes ......Right Edge Piece ......Left Edge Piece ......Right Beam Cover Assy. (Non-CE Machines ONLY) ......Right Beam Cover Assy. (CE Machines ONLY) ......Left Beam Cover Assy. (Non-CE Machines ONLY) ......Left Beam Cover Assy. (CE Machines ONLY) ......Right Corner Block ......Left Corner Block ......Screw (M6 x 1,0 x 25mm SHCS) ......Lockwasher (M6) ......Right Hood Rest ......Left Hood Rest ......Nut, Insert (M5 x 1,8,) ......Screw (M5 x 0,8 x 12mm SHCS) ......Flatwasher (M5) ......Right Hood Prop (connects to EC4250)(see Fig. 1-H, item 9) ......Left Hood Prop (connects to EC4255)(see Fig. 1-H, item 10) ......Machine Cover Frame (see Fig. 1-H, item 21) ......Screw (M8 x 1,25 x 20mm HHCS) ......Lockwasher (M8) ......Flatwasher (M8) ......Spring (see Fig. 1-D, item 21) ......Deck Assembly (see Fig. 2-D) N/S indicates Not Shown Page 59 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-D – DECK ASSEMBLY Page 60 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-D” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 ORDER BY PART NUMBER --EC1090 EC1095 EC1119 PHSM532 EC1116 CGM1048 EC1171 PHWM521 PHSM496 ML1172 EC1183 EC1184 EC1189 PHM495 PPPM417 PHW374 EC4618 PHSM965 QTY. 1 1 2 8 8 8 1 12 12 1 2 1 1 2 2 1 1 2 DESCRIPTION ....Deck Assembly includes ......Right Beam Assembly (see Fig. 1-H, item 19) ......Left Beam Assembly (see Fig. 1-H, item 20) ......Grounding Strap ......Screw (M10 x 20mm w/M8 x 1,25 Thd SHCS) ......Washer ......Isolator Bushing ......Deck ......Lockwasher (M10) ......Screw (M10 x 1,5 x 40mm HHCS) ......Spindle Frame ......Seal ......Plug ......Sink ......Stopper ......Bulkhead Union ......Flatwasher (.483 ID x .900 OD x .050 Thk, Nylon) ......Rail ......Screw (M8 x 1,25 x 20mm SHCS) N/S indicates Not Shown Page 61 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-E – CE GUARD MODULE Page 62 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-E” ITEM NO. 1 2 3 ORDER BY PART NUMBER --ML3495 ML3340 ML3360 QTY. Ref. 1 1 1 DESCRIPTION ....CE Guard Module includes ......CE Light Curtains (see Fig. 2-I) ......Left Guard Pane Assembly (see Fig. 2-F) ......Right Guard Pane Assembly (see Fig. 2-G) N/S indicates Not Shown Page 63 SECTION I BASIC MACHINE FIGURE 2-F – LEFT GUARD PANE ASSEMBLY PARTS LIST COVERING FIGURE “2-F” ITEM NO. 1 2 3 4 5 6 7 8 9 10 ORDER BY PART NUMBER ML3340 ML3343 ML3344 ML3345 ML3355 ML3371 PHNM407 PHNM489 PHSM541 PHWM509 PHWM518 N/S indicates Not Shown Page 64 QTY. Ref. 1 8 1 1 1 2 10 2 12 20 DESCRIPTION ....Left Guard Pane Assembly includes ......Guard Pane ......Clip ......Left Guard Assembly ......Guard Bracket Assembly ......Trim ......Nut, Hex (M6 x 1,0) ......Nut, Acorn (M6 x 1,0) ......Screw (M6 x 1,0 x 16mm BHCS) ......Lockwasher (M6) ......Flatwasher (M6) SECTION I BASIC MACHINE FIGURE 2-G – RIGHT GUARD PANE ASSEMBLY PARTS LIST COVERING FIGURE “2-G” ITEM NO. 1 2 3 4 5 6 7 8 9 10 ORDER BY PART NUMBER ML3360 ML3343 ML3344 ML3365 ML3355 ML3371 PHNM407 PHNM489 PHSM541 PHWM509 PHWM518 QTY. Ref. 1 8 1 1 1 2 16 2 12 18 DESCRIPTION ....Right Guard Pane Assembly includes ......Guard Pane ......Clip ......Right Guard Assembly ......Guard Bracket Assembly ......Trim ......Nut, Hex (M6 x 1,0) ......Nut, Acorn (M6 x 1,0) ......Screw (M6 x 1,0 x 16mm BHCS) ......Lockwasher (M6) ......Flatwasher (M6) N/S indicates Not Shown Page 65 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-H – COOLANT SYSTEM (1 0F 3) Page 66 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-H” (1 of 3) 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 ORDER BY PART NUMBER ML3495D ML3495CG EC4750 EC3480 PEM987 PHWM501 PHSM495 PHM449 PHSM441 EC3481 PHSM432 PHSM673 EC3813 PHNM407 PHNM401 CK578 PHSM674 PHNM441 PF224 CH376 KN568 KN172 EC3496 EC3498 PHSM515 PEM252 PEC220 PHN125 PNP299 PNP345 PPPM446 PPP130 PNP101 KN231 PHW328 KN370 PPPM425 PNP476 PNP477 PPPM434 PPPM544 PPPM514 EC3321 --- QTY. 1 1 1 2 3 32 8 4 12 2 8 4 2 8 8 2 2 2 4 4 8 8 1 1 4 1 1 1 1 1 4 1 1 4 1 1 1 1 1 1 1 1 1 Ref. DESCRIPTION ....Coolant System (Non-CE Machines ONLY) includes ....Coolant System (CE Machines ONLY) includes ......Reservoir Assembly ......Pressure Relief Valve ......Rubber Cushioned Clamp ......Flatwasher (M8) ......Screw (M8 x 1,25 x 20mm HHCS) ......Swivel Caster ......Screw (M8 x 1,25 x 12mm BHCS) ......Valve Body ......Screw (M5 x 0,8 x 12mm BHCS) ......Screw (M8 x 1,25 x 40mm SHCS) ......Bumper Bracket ......Nut, Hex (M6) ......Nut, Hex (M8) ......Bumper Rubber ......Screw (M5 x 0,8 x 20mm SHCS) ......Locknut (M5) ......Flex Bolt Mounting ......Spacer ......Flatwasher ......Nut, Hex (5/16-18) ......Pump Base ......Motorized Pump ......Screw (M8 x 1,25 x 25mm SHCS) ......Sealing 'O' Ring w/Retainer ......Strain Relief Connector ......Locknut (1/2 NPT) ......Electrical Decal ......Arrow Label-Straight ......Elbow ......Pipe Plug ......Electrical Spec Plate ......Drivescrew ......Flatwasher ......Flatwasher ......Bulkhead Union ......Sunburst Logo ......Sunnen Name Logo ......Hose Assembly ......Hose Assembly ......Flexible Tubing ......Cable, Cart Motor (see Fig. 3-G/3-H, item 18) ......Coolant Box (see Fig. 3-G/3-H) N/S indicates Not Shown Page 67 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-H – COOLANT SYSTEM (2 0F 3) Page 68 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-H” (2 of 3) 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 ORDER BY PART NUMBER ML3495D ML3495CG PPPM416 EC3476 PHWM501 PHWM407 PHSM495 EC3480 EC3486SC PHS1061 PFC165 PPPM404 PPP161 MB2368 PHM558 PPP533 PF162 PHSM534 PHWM518 PHWM509 PHNM407 PHM494 PHNM453 PFC205 PHN265 PHW407 EC3440 PPPM414 PF246 PPPM446 PF247 PF244 PF243 EC3625 EC3630 EC3620 PHSM598 PPP461 PF317 PPPM435 78156 PPPM419 79717 QTY. 1 1 4 2 2 3 2 1 1 2 1 1 2 2 1 1 1 2 3 2 2 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Coolant System (Non-CE Machines ONLY) includes ....Coolant System (CE Machines ONLY) includes ......Nipple ......Tray Retainer ......Flatwasher (M8) ......Lockwasher (M8) ......Screw (M8 x 1,25 x 20mm HHCS) ......Pressure Relief Valve ......Output Connection Block ......Screw (1/4-20 x 1/2 HHMS w/Sil O-Ring) ......Pneumatic Valve ......Male Connector ......Reducer Bushing (3/8-1/2 NPT) ......Hose Barb ......3/4" Hose Kwik-Clamp ......Relief Valve ......Mntg Bracket-Front Half ......Screw (M6 x 1,0 x 20mm SHCS) ......Flatwasher (M6) ......Lockwasher (M6) ......Nut, Hex (M6) ......Hand Lever ......Nut ......Liquid Level Guage ......Nut, Hex Jam (1/2-20) ......Flatwasher (1/2in) ......Filter Canister ......Bushing ......Air Vent ......Elbow ......Spring Hold Down ......Gasket ......Cover ......Clamp Yoke Assembly, Half ......Tee Handle Assembly ......Clamp Assembly - Half ......Screw (M8 x 1,25 x 35mm HHCS) ......Hose Clamp ......Intake Strainer ......Hose Assembly ......Tubing, Natural Nylon ......Intake Hose Assembly ......Tubing, Plastic N/S indicates Not Shown Page 69 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-H – COOLANT SYSTEM (3 0F 3) Page 70 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-H” (3 of 3) ITEM NO. 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 ORDER BY PART NUMBER ML3495D ML3495CG ML3225 EC3741 PHSM495 EC3844 ML3230 ML3233 ML3234 EC4745 ML3385 PHSM505 PHSM588 PHWM518 EC3842 EC3843 PHM558 EC3817 PHSM607 PHM788 PHM789 PHM530 PHM403 PHM483 PHM435 EC3470 EC3471 EC3680 EC3812 EC3811 PHSM613 PHWM516 79714 79717 QTY. 1 1 1 2 4 2 2 2 1 1 1 2 2 2 1 1 1 4 4 4 4 4 34 2 2 1 1 1 1 1 2 2 1 1 DESCRIPTION ....Coolant System (Non-CE Machines ONLY) includes ....Coolant System (CE Machines ONLY) includes ......Manifold Assembly ......Nut Plate ......Screw (M8 x 1,25 x 20mm HHCS) ......Corner Plug ......Hinge ......Guard Mount ......Guard ......Drip Tray Assembly (Non-CE Machines ONLY) ......Drip Tray Assembly (CE Machines ONLY) ......Screw (M4 x 0,7 x 12mm BHCS) ......Setscrew (M5 x 0,8 x 6mm SHSS) ......Flatwasher (M6) ......Spring Per Print ......Spring Per Print ......3/4" Hose Kwik-Clamp ......Coolant Nozzle Base ......Screw (M6 x 1,0 x 30mm SHCS) ......Knob ......Adapter ......Check Valve ......Snap Link Feeder ......Nozzle ......Nozzle ......Sediment Tray Assembly ......Sediment Tray ......Reservoir Cover Assembly ......Reservoir Liner ......Drip Tray Liner ......Screw ......Flatwasher (M4) ......Tubing, Plastic ......Tubing, Plastic N/S indicates Not Shown Page 71 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-I – CE LIGHT CURTAIN (CE Machines ONLY) Page 72 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-I” 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 26 26 27 28 29 30 31 ORDER BY PART NUMBER ML3495CG EC4350 EC4365 PHWM518 PHWM509 PHNM407 ML3385 EC4482 EC4484 EC4481 ML3318 ML3320 ML3323 ML3328 ML3329 ML3330 ML3333 ML3348 PED3122 PED3123 PEM1096 PHNM405 PHW719 PHSM434 PHSM510 PHSM1096 PHWM516 PHWM558 PHWM519 PHWM406 PHW311 PHNM200 QTY. 1 1 1 17 17 31 1 1 1 2 2 1 4 1 1 1 2 2 1 1 4 8 2 4 4 4 4 12 4 4 12 12 DESCRIPTION ....CE Light Curtain (CE Machines ONLY) includes ......Oil Cart, Left (see Fig. 3-G/3-H, item 20) ......Hand Rest Assy, Right (see Fig. 3-G/3-H, item 19) ......Flatwasher (M6) ......Lockwasher (M6) ......Nut, Hex (M6) ......Drip Tray Assembly (CE Machines ONLY) ......Cable Tray ......Cable Tray Side ......Hand Rest Cover Left ......Spacer ......Left Light Curtain Angle Assembly ......Restraining Plate ......Right Drip Angle ......Left Drip Angle ......Right Light Curtain Angle Assembly ......Clamp Strap ......Extension Panel ......Light Curtain Transmitter (see Fig. 3-G/3-H, item 21) ......Light Curtain Receiver (see Fig. 3-G/3-H, item 22) ......Light Curtain Bracket Set ......Nut, Hex (M5) ......Grommet ......Screw (M5 x 0,8 x 16mm BHCS) ......Screw (M6 x 1,0 x 12mm BHCS) ......Self Clinching Stud ......Flatwasher (M4) ......Nylon Spacer ......Flatwasher (M5) ......Lockwasher (M5) ......Star Washer ......Nut (M6) N/S indicates Not Shown Page 73 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-J – PALM BUTTONS (Non-CE Machines ONLY) Page 74 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-J” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 ORDER BY PART NUMBER ML3495D EC4350 EC4365 PHWM518 PHWM509 PHNM407 EC4745 EC4482 EC4484 EC4481 KKN167 PHSM510 PHW719 QTY. 1 1 1 17 17 13 1 1 1 2 2 4 2 DESCRIPTION ....Palm Buttons (Non-CE Machines ONLY) includes ......Oil Cart, Left (see Fig. 3-G/3-H, item 20) ......Hand Rest Assy, Right (see Fig. 3-G/3-H, item 19) ......Flatwasher (M6) ......Lockwasher (M6) ......Nut, Hex (M6) ......Drip Tray Assembly (Non-CE Machines ONLY) ......Cable Tray ......Cable Tray Side ......Hand Rest Cover Left ......Plug Button ......Screw (M6 x 1,0 x 12mm BHCS) ......Grommet N/S indicates Not Shown Page 75 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-K – ELECTRICAL ENCLLOSURE Page 76 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-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 22 23 24 25 N/S ORDER BY PART NUMBER --EC4340 PEM655 PHSM438 PEM824 PEM251 PEC128 PEM301 PEM252 PEC179 PHN125 CK5706 PEM319 KN153 KN383 PEM982 PEM462 EC4408 ML3870 EFCC01800 EFCB01525 ML3778 EC3818 EC3819 EFCC01800 PEC104 ML4260 EC4810 QTY. 1 2 8 1 3 3 3 1 2 1 1 1 16 16 1 1 1 2 1 1 1 1 1 1 1 1 1 DESCRIPTION ....Electrical Enclosure includes ......Electrical Enclosure Assembly ......Outlet Filter ......Screw (M5 X 0.8 X 12mm PPHS) ......Oiltight Hole Seal ......Sealing 'O' Ring w/Retainer ......Conduit Connector ......Locknut ......Sealing 'O' Ring w/Retainer ......Strain Relief Connector ......Locknut (1/2" NPT) ......Extension Shaft (279mm) ......Disconnect Handle ......Flatwasher ......Nut, Hex (3/8-16) ......Top Entry Hood ......Female Insert 6 Position ......Electrical Enclosure Mat ......Conduit, CTC Motor Cable ......Conduit, Stroker Motor (see Fig. 1-A, item 21) ......Conduit, Coolant System (see Fig. 2-H/2-I) ......Conduit, Deck Box (see Fig. 3-E) ......Conduit, D Voltage (see Fig. 2-B, item 14) ......Conduit, G Voltage (see Fig. 2-B, item 14) ......Conduit, Spindle Motor (see Fig. 1-E, 1 of 2, item 19) ......Conduit Connector ......Panel Assembly (see Fig. 3-B & 3-C) ......Machine Base N/S indicates Not Shown Page 77 SECTION II BASIC MACHINE-BOTTOM FIGURE 2-L – OPERATOR STATION Page 78 SECTION II BASIC MACHINE-BOTTOM PARTS LIST COVERING FIGURE “2-L” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 12 ORDER BY PART NUMBER --EC4339 ML4470 PHSM738 PHWM501 PHWM407 PHNM401 PHNM456 EC4773 MLU4385 PHSM535 PHWM509 ML4380 MLA5100 QTY. 1 1 4 3 7 3 4 1 1 4 4 Ref. Ref. DESCRIPTION ....Operator Station includes ......Control Panel & Accessory Mount ......Control Panel Support Assembly ......Screw (M8 x 1,25 x 30mm SHCS) ......Flatwasher (M8) ......Lockwasher (M8) ......Nut, Hex (M8 x 1,25) ......Nut, Jam (M8 x 1,25) ......Bushing ......Enclosure ......Screw (M6 X 1,0 X 12mm SHCS) ......Lockwasher (M6) ......Control Panel Door Assembly (ML)(see Fig. 2-M) ......Control Panel Door Assembly (MLA)(see Fig. 2-N) N/S indicates Not Shown Page 79 SECTION I BASIC MACHINE FIGURE 2-M – CONTROL PANEL DOOR ASSEMBLY (ML) PARTS LIST COVERING FIGURE “2-M” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER MLU4380 MLU4385 89019 PHWM516 PHSM505 PHWM528 PHNM402 EC4420 PHM536 PHWM519 PHWM510 PHNM405 PEM1018 PHWM518 PHWM509 PHNM407 --- N/S indicates Not Shown Page 80 QTY. Ref. 1 1 13 13 1 7 1 2 1 1 1 1 1 1 1 1 DESCRIPTION ....Control Panel Door Assembly (ML) includes ......Enclosure ......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. 3-A) SECTION I BASIC MACHINE FIGURE 2-N – CONTROL PANEL DOOR ASSEMBLY (MLA) PARTS LIST COVERING FIGURE “2-N” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ORDER BY PART NUMBER MLA5100 MLU4385 89019 PHWM516 PHSM505 PHWM528 PHNM402 EC4420 PHM536 PHWM519 PHWM510 PHNM405 PEM1018 PHWM518 PHWM509 PHNM407 --- QTY. Ref. 1 1 13 13 1 7 1 2 1 1 1 1 1 1 1 1 DESCRIPTION ....Control Panel Door Assembly (MLA) includes ......Enclosure ......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. 3-B) N/S indicates Not Shown Page 81 SECTION II ELECTRICAL COMPONENTS FIGURE 3-A – PANEL ASSEMBLY, OPERATOR STATION “ML” Page 82 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-A” ITEM NO. 1 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 28 ORDER BY PART NUMBER QTY. --MLU1484EN MLU1484CE PED2151 PES652A PES653A PES651A PES655 PES654 PEM966 PEM968 PEM967 PES656A PEM961A PEM962A PED2203A PHWM533 PHSM550 PHWM510 PET714 PHNM405 PED2222 PES646 PES647A PEM972A PHSM745 PEM702A PEM895A PNP430 MLU4390 Ref. 1 1 1 2 3 21 1 4 1 2 1 1 15 15 1 4 4 1 1 1 1 15 3 1 30 8 1 1 Ref. DESCRIPTION ....Panel Assembly, Operator Station (ML) includes ......Control Panel Overlay (English, Non-CE Machines ONLY) ......Control Panel Overlay (ICON, CE Machines ONLY) ......Text Display ......Selector Switch, 3 Position (Pkg. of 1) ......Selector Switch, 3 Position (Pkg. of 1) ......Selector Switch, 2 Position (Pkg. of 1) ......Pushbutton, Red Mushroom ......Pushbutton Head w/o Cap ......Push Button Cap, Flush Green ......Push Button Cap, Extended Red ......Push Button Cap, Flush Blue ......Pushbutton, Illuminated, White ......Mounting Collar (Pkg. of 1) ......Adapting Pillar (Pkg. of 1) ......Printed Circuit Board, Operator Station Display ......Lockwasher (M3) ......Screw (M3 x 0,5 x 8mm SHCS) ......Lockwasher, External Tooth (M5) ......Terminal ......Nut, Hex (M5 x 0,8) ......CPU Board ......Contact, NO ......Contact Block, NC ......Light Block, LED, White ......Screw (M3 x 1,0 x 21mm Plasti-Grip) ......6 Pole Plug (Pkg. of 1) ......9 Pole Plug ......Ground Symbol Label ......Control Panel Door Assembly (see Fig. 2-M) N/S indicates Not Shown Page 83 SECTION II ELECTRICAL COMPONENTS FIGURE 3-B – PANEL ASSEMBLY, OPERATOR STATION “MLA” Page 84 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-B” ITEM NO. 1 2 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 28 29 30 31 32 33 N/S ORDER BY PART NUMBER QTY. --MLA5100 MLA4433EN MLA4433CE PED2151 PES652A PES653A PES651A PES655 PES654 PEM966 PEM968 PEM967 PES656A PEM961A PEM962A PED2203A PHWM533 PHSM550 PHWM510 PET714 PHNM405 PED2212 PES644 PED2222 PES646 PES647A PEM972A PHSM745 PEM702A PEM895A PEM783 PEM782 PED2213 PEM784 PNP430 Ref. 1 1 1 1 3 3 4 1 4 1 2 1 1 15 15 1 4 4 1 1 1 1 4 1 18 3 1 30 15 3 6 6 1 6 1 DESCRIPTION ....Panel Assembly, Operator Station (MLA) includes ......Control Panel Door Assembly (see Fig. 2-N) ......Control Panel Overlay (English, Non-CE Machines ONLY) ......Control Panel Overlay (ICON, CE Machines ONLY) ......Text Display ......Selector Switch, 3 Position (Pkg. of 1) ......Selector Switch, 3 Position (Pkg. of 1) ......Selector Switch, 2 Position (Pkg. of 1) ......Pushbutton, Red Mushroom ......Pushbutton Head w/o Cap ......Push Button Cap, Flush Green ......Push Button Cap, Extended Red ......Push Button Cap, Flush Blue ......Pushbutton, Illuminated, White ......Mounting Collar (Pkg. of 1) ......Adapting Pillar (Pkg. of 1) ......Printed Circuit Board, Operator Station Display ......Lockwasher (M3) ......Screw (M3 x 0,5 x 8mm SHCS) ......Lockwasher, External Tooth (M5) ......Terminal ......Nut, Hex (M5 x 0,8) ......CPU Board (MLA5000) ......Contact, NO ......CPU Board ......Contact, NO ......Contact Block, NC ......Light Block, LED, White ......Screw (M3 x 1,0 x 21mm Plasti-Grip) ......6 Pole Plug (Pkg. of 1) ......9 Pole Plug ......Standoff ......Screw (#6-32 x 1/4 SBHM) ......PCB, Automation I/O ......Tapped Spacer ......Ground Symbol Label N/S indicates Not Shown Page 85 Page 86 58 59-60 61 62 63 64 65-66 67 68 1 2 56-57 3 4 55 5-6-7 8 54 69 9 11 52-53 70-71 10 FIGURE 3-C – PANEL ASSEMBLY, HIGH VOLTAGE 51 49-50 14 13 12 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 “3-C” ITEM NO. 1 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 PED2165 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 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) ......Power Supply, 24V (400V Supply; CGMIAGX Panel ONLY) ......Din Rail ......AC/DC Relay, 222 PLC (Not Required on CGMIAGX Panel) ......PLC I/O Module, 24VDC (Not Required on CGMIAGX 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 Machines 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 87 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “3-C” (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 88 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 Machines Panel ONLY) ......Diode Assembly (CE Machines 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 Machines Panel ONLY) ......Control Relay, 24V (CE Machines Panel ONLY) ......Diode Assembly (CE Machines Panel ONLY) ......Wiring Duct Cover (2in.) ......Wiring Duct (2in.) ......End Stop ......Fuse ......Fuseholder, Ultrasafe Class CC * Quantity varies, depending on features. NOTES Page 89 Page 90 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 3-D – 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 “3-D” 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, 222 PLC (Not Required on CGWIAGX Panel) ......PLC I/O Module, 24VDC (Not Required on CGWIAGX Panel) ......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 91 SECTION I BASIC MACHINE PARTS LIST COVERING FIGURE “3-D” (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 PED3008 ML4905 WDA0340 WCA0340 PHSM440 PED3012 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 92 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. NOTES Page 93 SECTION II ELECTRICAL COMPONENTS FIGURE 3-E – DECK BOX Page 94 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-E” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 19 20 21 22 23 24 25 26 27 N/S ORDER BY PART NUMBER --EC3788 PEC127 PEM251 PEM301 PEC179 PEM252 PHN125 PEM823 PEM653 ML4725 PHSM438 PHSM535 ML4730 EC4742 ML4741 EC3785 ML3782 ML4734 CBL457 EC3796 EC3779 ML4736 ML4735 ML4733 ML4731 ML3778 ML4732 ML3781 PEM154 DESCRIPTION QTY. Ref. 1 1 1 1 8* 8* 8* 6* 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ....Deck Box includes ....Junction Box ....Conduit Connector ....Sealing 'O' Ring w/Retainer ....Locknut ....Strain Relief Connector ....Sealing 'O' Ring w/Retainer ....Locknut (1/2" NPT) ....Knockout Plug (22,5mm) ....Panel ....Terminal Block Assembly ....Screw (M5 x 0,8 x 12mm PPHS) ....Screw (M6 x 1,0 x 12mm SHCS) ....Cable, Modular Prox. Switch (see Fig. 1-A, item 30) ....Cable, Stroke Pulley Rear Prox. (see Fig. 1-A, item 40) ....Cable, Anti Glaze Upper Limit Prox. (see Fig. 1-C, 2 of 4, item 49) ....Cable, LVDT Box (see Fig. 3-F, item 10) ....Cable, Green Spindle Reverse Light ....Cable, Stroke Pulley #2 Prox. (see Fig. 1-A, item 39) ....Cable, Spindle Rev. Enable Switch (Non-CE Machines ONLY) ....Cable, Stoker Key Switch (CE Machines ONLY) ....Cable, ASC (see Fig. 4-A, item 58) ....Cable, Modular Prox. Switch (see Fig. 1-D, item 34) ....Cable, Modular Prox. Switch (see Fig. 1-D, item 33) ....Cable, Modular Prox. Switch (see Fig. 1-A, item 31) ....Cable, Stroke Length #2 Prox. (see Fig. 1-A, item 37) ....Cable, Electrical Enclosure (see Fig. 2-K, item 21) ....Cable, Stroke Length #3 Prox. (see Fig. 1-A, item 38) ....Cable, Solenoid Stack ....Label N/S indicates Not Shown *NOTE: Quantities shown are for CE Machines. All other are 7. Page 95 SECTION II ELECTRICAL COMPONENTS FIGURE 3-F – LVDT BOX Page 96 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-F” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 13 N/S ORDER BY PART NUMBER --PES379 PED1057 PEM701 PHSM1081 PHWM533 PEC179 PEM252 PHN125 EC3786 EC3785 EC2582 PES378 EC2751 EC2751-M PNP299 QTY. Ref. 2 1 2 4 4 2 2 2 1 1 1 1 1 1 1 DESCRIPTION ....LVDT Box includes ....Contact Block ....LVDT Conditioner ....Plug, 12 Pole ....Screw (M3 x 0,5 x 6mm SHCS) ....Lockwasher (M3) ....Strain Relief Connector ....Sealing 'O' Ring w/Retainer ....Locknut (1/2" NPT) ....Cable, Sparkout Potentiometer (see Fig.1-I, 3 of 3, item 21) ....Cable, Deck Box (see Fig. 3-E, item 16) ....Cable, LVDT (see Fig. 1-C, item 9) ....Four Position Selector (SW1)(see Fig. 1-I, 3 of 3, item 4) ....Meter (Domestic) ....Meter (Metric) ....Label N/S indicates Not Shown Page 97 SECTION II ELECTRICAL COMPONENTS FIGURE 3-G – COOLANT BOX, CD/CE Page 98 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-G” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ORDER BY PART NUMBER ML3495D EC3041 PEM653 ML4726 PHSM438 PEM252 PEC180 PHN125 PEC179 PEM681 PEM823 PEM154 PEM4601 PEM460 PHW156 PHSM505 PHNM402 PEM461 EC3321 ML4729 ML4728 QTY. Ref. 1 1 1 6 3 1 3 2 1 4 2 1 1 4 4 4 1 1 1 1 DESCRIPTION ....Coolant Box (Non-CE Machines ONLY) includes ......Junction Box ......Panel ......Tb-44 Terminal Block ......Screw (M5 x 0,8 x 12mm PPHS) ......Sealing 'O' Ring w/Retainer ......Strain Relief Connector ......Locknut (1/2 NPT) ......Strain Relief Connector ......Knock-Out Plug (27,.8mm) ......Knockout Plug (22,5mm) ......Wire & Cable Marking Label ......Gasket ......Panel Mount Base ......Washer ......Screw (M4 x 0,7 x 12mm BHCS) ......Nut ......10 Position Male Insert ......Cable, Cart Motor (see Fig. 2-H, 1 of 3, item 41) ......Cable, Right Start Button (see Fig. 2-J, item 2 ) ......Cable, Left Start Button (see Fig. 2-J, item 1) N/S indicates Not Shown Page 99 SECTION II ELECTRICAL COMPONENTS FIGURE 3-H – COOLANT BOX, CG Page 100 SECTION II ELECTRICAL COMPONENTS PARTS LIST COVERING FIGURE “3-H” ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ORDER BY PART NUMBER ML3495CG EC3041 PEM653 ML4726 PHSM438 PEM252 PEC180 PHN125 PEC179 PEM681 PEM823 PEM154 PEM4601 PEM460 PHW156 PHSM505 PHNM402 PEM461 EC3321 ML4729 ML4728 ML3377 ML3378 QTY. Ref. 1 1 1 6 5 1 5 4 1 2 2 1 1 4 4 4 1 1 1 1 1 1 DESCRIPTION ....Coolant Box (CE Machines ONLY) includes ......Junction Box ......Panel ......Tb-44 Terminal Block ......Screw (M5 x 0,8 x 12mm PPHS) ......Sealing 'O' Ring w/Retainer ......Strain Relief Connector ......Locknut (1/2 NPT) ......Strain Relief Connector ......Knock-Out Plug (27,.8mm) ......Knockout Plug (22,5mm) ......Wire & Cable Marking Label ......Gasket ......Panel Mount Base ......Washer ......Screw (M4 x 0,7 x 12mm BHCS) ......Nut ......Male Insert, 10 Position ......Cable, Cart Motor (see Fig. 2-H, 1 of 3, item 41) ......Cable, Right Start Button (see Fig. 2-I, item 2) ......Cable, Left Start Button (see Fig. 2-I, item 1) ......Cable, Light Curtain Transmitter (see Fig. 2-I, item 18) ......Cable, Light Curtain Receiver (see Fig. 2-I, item 19) N/S indicates Not Shown Page 101 SECTION IV OPTIONAL ITEMS FIGURE 4-A – AUTOMATIC SIZE CONTROL PARTS LIST COVERING FIGURE “4-A” 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 102 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 x 30 Soc. Hd. Cap) ......Washer (M6) ......Pivot Block ......Clamp Pin ......Screw (M8 x 1.25 x 20 Soc. Hd. Cap) ......Screw (M6 x 1 x 16 Soc. Hd. Cap) ......Pivot Bushing ......Guide Rod ......Set Screw (M5 x .8 x 6 Cup Point) ......Arm ......Bumper ......Screw (M5 x .8 x 16 Button Hd. Cap) ......Washer (M5) ......Shaft (Parts continued on next page) SECTION III OPTIONAL ITEMS PARTS LIST COVERING FIGURE “4-A” 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 PEC111A 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 x 25 Soc. Hd. Cap) ......Washer (M6) ......End Plate ......Screw (M8 x 1.25 x 20 Flat Hd. Cap) ......Adjustment Rod ......Stop Collar ......Set Screw (M4 x .7 x 6 Cup Point) ......Lock Knob ......Fine Position Knob ......Set Screw (M4 x .7 x 6 Cup Point) ......Clamp Rod ......Retaining Ring ......Clamp Knob ......Set Screw (M4 x .7 x 6 Cup Point) ......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 x 10 Soc. Hd. Cap) ........Set Screw (M4 x .7 x 8 Flat Point) ........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 103 SECTION III OPTIONAL ITEMS 3 2 4 1 7 6 5 7 6 FIGURE 4-B – TRANSFORMER KIT PARTS LIST COVERING FIGURE “4-B” 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 104 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 20mm SHCS) ......Flatwasher (M8) ......Lockwasher (M8) ......Screw (M8 x 1,25 x 20mm SHCS) 5 NOTE 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. Page 105 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) x x BY 0.03937 3.281 = = TO GET INCHES (in) FEET (ft) “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. 0711 SUNNEN PRODUCTS LIMITED No. 1 Centro, Maxted Road Hemel Hempstead, Herts HP2 7EF ENGLAND Phone: ++ 44 1442 39 39 39 Fax: ++ 44 1442 39 12 12 www.sunnen.co.uk e-mail: [email protected] SUNNEN AG 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 – Automotive: 1-800-772-2878 • Industrial: 1-800-325-3670 International Division Fax: 314-781-6128 Fabrikstrasse 1 8586 Ennetaach-Erlen, Switzerland Phone: ++ 41 71 649 33 33 Fax: ++ 41 71 649 34 34 www.sunnen.ch e-mail: [email protected] SHANGHAI SUNNEN MECHANICAL CO., LTD. 889 Kang Qiao East Road, PuDong Shanghai 201319, P.R. China Phone: 86 21 5 813 3322 Fax: 86 21 5 813 2299 www.sunnensh.com e-mail: [email protected] SUNNEN ITALIA S.R.L. http://www.sunnen.com e-mail: [email protected] Viale Stelvio 12/15 20021 Ospiate di Bollate (MI) Italy Phone: 39 02 383 417 1 Fax: 39 02 383 417 50 www.sunnenitalia.com e-mail: [email protected] ©COPYRIGHT SUNNEN® PRODUCTS COMPANY 2007, ALL RIGHTS RESERVED