REPAIR PARTS CATALOG FOR SUNNEN KROSSGRINDING SYSTEM

Transcription

1 REPAIR S CATALOG FOR SUNNEN KROSSGRINDING SYSTEM MODEL: KGM -5000NT & KGM -1000NT THIS CATALOG COVERS THE ABOVE MODEL BEGINNING WITH SERIAL KGM, KROSSGRINDING, SUNNEN, AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST. LOUIS, MO 63143, U.S.A. PHONE: X-KGM-1007D

2 Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment. ii

3 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 S 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 AND 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. Step Step 2. Step 3. Step 4. 1 MVH-4499A 1...Spindle Cap includes 2 PHSM Screw (M6 x 1 x 16 SHCS) 3 PHW Washer (M6) 4 MVH Inner Spindle Nose 14 PEM-870A 1...Cable Carrier includes 15 PEM Cable Carrier Bracket 16 PEM Cable Carrier Bracket 17 PHSM Screw (M3 x 0,5 x 5mm FHCS) iii

4 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. Emergency breakdown support is available on a 24 hour / 7 day basis. 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: Sunnen Industrial Customer Service toll free at: Customers outside the USA, contact your local authorized Sunnen Distributor. Additional information available at: or sunnen@sunnen.com 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

5 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 ICULAR 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 S 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

6 SAFETY INSTRUCTIONS READ FIRST This machine, like any equipment, may be dangerous if used improperly. Please read all warnings and instructions before attempting to use this machine. Always disconnect power at main enclosure before servicing machine. 1 Always wear eye protection when operating this machine. NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing this equipment. 1 DO NOT attempt any repair or maintenance procedure beyond those described in this book. Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions. Due to the wide variety of machine configurations, all possibilities cannot be described in these instructions. Instructions for safe use and maintenance of optional equipment ordered through Sunnen, will be provided through separate documentation and/or training provided by your Sunnen Field Service Engineer or Technical Services Representative. DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment. 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

7 TABLE OF CONTENTS PAGE Introduction... iii How To Order... iii How To Use This Parts List... iii General Information... iv ESD Prevention Review... iv Limited Product Warranty... v Sunnen Software License Agreement... v General Safety Instructions... vi Contents... 1 BASIC MACHINE 1-A Coolant Base Assembly (KGM-5000NT-10) B Base Assembly (KGM-5000NT-20) C Spindle Assembly, KGM5000NT (KGM-5000NT-50) D Spindle Assembly, KGM1000NT (KGM-1000NT) E Stroke Mechanism, Upper (KGM-5000NT-30) F Stroke Mechanism, Lower (KGM-5000NT-40) G Stroker Assembly (KGM-5000NT-60) H Coolant Reservoir (KGM-5000NT-180) I Panel Assembly, Coolant Access Door, Lower (KGM-5000NT-80) J Panel Assembly, Electrical (KGM-5000NT-70) K Panel Assembly, Rear (KGM-5000NT-90) L Panel Assembly, Left Side (KGM-5000NT-100) M Panel Assmelby, Right Side (KGM-5000NT-110) N Panel Assembly, Guards (KGM-5000NT-150) O Panel Assembly,Front (KGM-5000NT-120) P Panel Assembly, Door, Upper (KGM-5000NT-140) BASIC MACHINE COMPONENTS 2-A Electrical Enclosure Assembly (KGM-8215) B Pneumatic Control Panel Assembly (KGM-7000) C Hood Cover Assembly (KGM-8065) D Hood Cover Assembly, CE (KGM-8230) E High Pressure Coolant Junction (KGM-7380) F Low Pressure Coolant Junction (KGM-7385) G Filter Canister Assembly (KGM-7390) H Magnetic Separator Assembly (KGM-7090) I Stroker Positioning Unit (KGM-7325) J Spindle Motor Assembly, KGM5000NT (KGM-7310) K Spindle Motor Assembly, KGM1000NT (KGM-7340) L Idler Assembly (KGM-2715) M Coolant Tray Assembly (KGM-7405) N Spindle Assembly, KGM5000NT (KGM-2040) O Spindle Assembly, KGM1000NT (KGM-2035) P Spindle Pulley Assembly (KGM-2065) Q Bearing Assembly (KGM-2355) R Feed Assembly (KGM-7320) S Feed Rod Assembly (KGM-2360) T Pillow Block Assembly (KGM-2405) U Carriage Stop Clamp Assmebly (KGM-7010) V Stroker Carriage Assembly (KGM-7235) W Flexible Coolant Line, 90 Deg. (KGM-7395) X Flexible Coolant Line (KGM-7400) Y Crank Assembly (KGM-2690) Z Pillow Block Assembly (KGM-2660) AA Stroke Position Lock Mechanism (CGM-2740) AB Pivot & Pillow Block Assembly (KGM-2670) AC Stroker Length Lock (KGM-2665) AD Coolant Lines (KGM-5000NT-190) AE Air Filtering System (KGM-7001) AF Manifold (KGM-1672) ELECTRICAL 3-A Electrical Enclosure (KGM-8220) B Electrical Panel (KGM-8700) C Start Button Assembly (KGM-8000) D Operator Panel (KGM-5000NT-170) KGM, KROSSGRINDING, 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

8 SECTION 1 - BASIC MACHINE KGM-5000NT-10 FIGURE 1-A COOLANT BASE ASSEMBLY Page 2

9 S LIST COVERING FIGURE 1-A SECTION 1 BASIC MACHINE Ref....Coolant Base Assembly includes 1 KGM Machine Base Weldment 2 CK Bumper Rubber 3 PHSM Screw (M5 x 0,8 x 16mm SHCS) 4 KGM Tank Guide 5 PHSM Screw (M6 x 1,0 x 20mm SHCS) 6 PHWM Lockwasher (M6) 7 PHNM Nut (M6 X 1,0mm Hex) 8 PHSM Screw (M12 x 1,75 x 35mm HHCS) 9 KGM Filter Canister Assembly (See Fig. 2-G) 10 PHWM Flatwasher (M6) 11 PF Mounting Bracket, Front Half 12 KGM Retainer 13 KGM Cup Seal 14 PHSM Screw (M8 x 1,25 x 40mm HHCS) 15 PHW Washer, Sealing (3/8in.) 16 KGM Drip Ledge 17 KGM Separator Overflow Tray 18 KGM Riser 19 KGM Magnetic Separator Assembly (See Fig. 2-H) 20 PNP Decal, Electrical 21 PHNM Nut (M8 x 1,25mm Hex) 22 PHWM Lockwasher (M8) 23 PHWM Flatwasher (M8) 24 PEM Rubber Cushioned Clamp (3/4in.) 25 PHSM Screw (M8 x 1,25 x 16mm SHCS) 26 PHN Locknut 27 KN Flatwasher (.328 ID X.750 OD X.060in. Thick) 28 KGM Shim 29 KGM High Pressure Coolant Junction (See Fig. 2-E) 30 PHS U-Bolt (5/16-18 x 2-3/16 in.) 31 PHS U-Bolt (5/16-18 x 2-11/16 in.) 32 KGM Low Pressure Coolant Junction (See Fig. 2-F) 33 KGM Shim 34 PHW Lockwasher (5/16in.) 35 CH Spacer 36 PF Flex Bolt Mounting 37 KN Nut (5/16-18in. Hex) 38 PHSM Screw (M8 x 1,25 x 25mm SHCS) 39 KGM Pump Base 40 PEC Strain Relief Connector 41 PEM Sealing 'O' Ring With Retainer 42 PEM Locknut 43 PPPM Elbow 44 EC Motorized Pump Page 3

10 SECTION 1 BASIC MACHINE KGM-5000NT-20 FIGURE 1-B BASE ASSEMBLY Page 4

11 S LIST COVERING FIGURE 1-B SECTION 1 BASIC MACHINE Ref....Base Assembly includes 1 KGM Coolant Tray Assembly (See Fig. 2-M) 2 PHWM Flatwasher (M8) 3 PHSM Screw (M8 x 1,25 x 20mm HHCS) 4 PHWM Lockwasher (M8) 5 PHNM Nut (M8 x 1,25mm Hex) 6 CGM Isolator Bushing 7 KGM Machine Rail 8 EC Washer 9 PHSM Screw (M10 x 20mm SHSS) 10 KGM Deck 11 PHWM Lockwasher (M10) 12 PHSM Screw (M10 x 1,5 x 40mm HHCS) 13 KGM Spindle Motor Assembly (See Fig. 2-J) 14 PHWM Flatwasher (M10) 15 PHSM Screw (M10 x 1,5 x 30mm HHCS) 16 KGM Adjustment Block 17 PHSM Screw (M6 x 1,0 x 20mm SHCS) 18 PHWM Flatwasher (M6) 19 PHSM Screw (M6 x 1,0 x 50mm HHCS) 20 PHNM Nut (M6 x 1,0 Hex) 21 KGM Oil Gage Assembly 22 PHSM Screw (M5 x 0,8 x 30mm SHCS) 23 KGM Stroker Positioning Unit (See Fig. 2-I) 24 KGM Key 25 PHSM Screw (M8 x 1,25 x 12mm FHCS) 26 KGM Spindle Housing 27 PHSM Screw (M8 x 1,25 x 30mm HHCS) 28 PHSM Screw (M8 x 1,25 x 30mm SHCS) 29 KGM Manifold 30 PPPM Male Connector (M6 to 4mm) 31 PPPM Grease Fitting, 45 Deg. 32 PHSM Screw (M4 x 0,7 x 30mm SHCS) 33 PEM Cable Clamp Tubing, Black Nylon (5/32OD x 8in.) 35 KGM Pipe Hanger 36 PHWM Flatwasher (M4) Page 5

12 SECTION 1 BASIC MACHINE KGM-5000NT-50 FIGURE 1-C SPINDLE ASSEMBLY, KGM5000NT Page 6

13 S LIST COVERING FIGURE 1-C SECTION 1 BASIC MACHINE Ref....Spindle Assembly includes 1 KGM Spindle Assembly (See Fig. 2-N) 2 PHSM Screw (M5 x 0,8 x 16mm SHCS) 3 CGM Spindle Adapter Cap 4 PHSM Screw (M6 x 1,0 x 16mm SHCS) 5 CGM Hose Barb 6 PHW Flatwasher 7 PPP Hose Barb 8 PDB Belt, Poly-Rib 9 KGM Support Block 10 PHWM Flatwasher (M8) 11 PHWM Lockwasher (M8) 12 PHSM Screw (M8 x 1,25 x 30mm HHCS) 13 KGM Slide Plate 14 KGM Slide Block 15 KKN Flatwasher 16 PHSM Screw (M8 x 1,25 x 60mm SHCS) 17 KGM Feed Assembly (See Fig. 2-R) 18 KGM Cover 19 PHSM Screw (M4 x 0,7 x 6mm BHCS) 20 PHNM Nut (M8 x 1,25mm Hex) 21 PHM Grease Seal 22 PHN Bearing Locknut 23 PHSM Screw (M4 x 0,7 x 16mm SHCS) 24 KGM Bearing Assembly (See Fig. 2-S) 25 KGM Bearing Washer NOT USED 27 KGM Cap 28 KGM Adapter 29 KGM Gearhead 30 PHWM Lockwasher (M6) 31 PHSM Screw (M6 x 1,0 x 50mm SHCS) 32 PMO Feed Motor 33 PHSM Screw (M6 x 1,0 x 20mm SHCS) 34 PHM Seal Page 7

14 SECTION 1 BASIC MACHINE KGM-1000NT FIGURE 1-D SPINDLE ASSEMBLY, KGM1000NT Page 8

15 S LIST COVERING FIGURE 1-D SECTION 1 BASIC MACHINE Ref....Spindle Assembly includes 1 KGM Spindle Motor Assembly (See Fig. 2-K) 2 PHWM Flatwasher (M10) 3 PHWM Lockwasher (M10) 4 PHSM Screw (M10 x 1,5 x 40mm HHCS) 5 KGM Spindle Assembly (See Fig. 2-O) 6 PDB Belt 7 KGM Adjustment Block 8 PHSM Screw (M6 x 1,0 x 20mm SHCS) 9 PHNM Nut (M6, Hex) 10 PHWM Flatwasher (M6) 11 PHSM Screw (M6 x 1,0 x 50mm HHCS) Page 9

16 SECTION 1 BASIC MACHINE KGM-5000NT-30 FIGURE 1-E STROKE MECHANISM, UPPER Page 10

17 S LIST COVERING FIGURE 1-E SECTION 1 BASIC MACHINE Ref....Stroke Mechanism, Upper includes 1 KGM Frame Member, Left 2 PHWM Flatwasher (M8) 3 PHWM Lockwasher (M8) 4 PHSM Screw (M8 x 1,25 x 30mm HHCS) 5 KGM Tensioning Block 6 PHSM Screw (M5 x 0,8 x 16mm SHCS) 7 PHSM Setscrew (M8 x 1,25 x 40mm FPSS) 8 KGM Crank Bearing Support, Front 9 PHSM Screw (M8 x 1,25 x 60mm HHCS) 10 KGM Crank Assembly (See Fig. 2-Y) 11 PHNM Nut (M8 X 1,25mm Hex) 12 KGM Frame Member, Front 13 KGM Frame Member, Rear 14 KGM Sensor Bracket 15 PES Modular Prox Switch (24V 12mm) 16 PHWM Flatwasher (M10) 17 PHWM Lockwasher (M10) 18 PHSM Screw (M10 x 1,5 x 20mm HHCS) 19 KGM Stroker Pulley 20 CGM Bushing 21 PHWM Flatwasher (M6) 22 PHSM Screw (M6 x 1,0 x 30mm HHCS) 23 PHK Key, Square (3/16 X 1/2in. Long) 24 KGM Mounting Plate 25 PHSM Screw (M10 x 1,5 x 30mm HHCS) 26 PMO Brake Motor 27 PHKM Parallel Key (8 x 7 x 36mm) 28 KGM Stroke Motor Pulley 29 PHSM Setscrew (M5 x 0,8 x 8mm CPSS) 30 PDB Belt, Poly-Rib 31 PNP Electrical Decal 32 PNP Label, Straight Arrow 33 PHSM Screw (M10 x 1,5 x 10mm HHCS) 34 CBL Cable, DC Proximity (2m, 90 Deg.) 35 PEM Sealing O-Ring w/retainer 36 PEC Strain Relief Connector 37 PEM Locknut Page 11

18 SECTION 1 BASIC MACHINE KGM-5000NT-40 FIGURE 1-F STROKER MECHANISM, LOWER Page 12

19 S LIST COVERING FIGURE 1-F SECTION 2 BASIC MACHINE COMPONENTS Ref....Stroker Mechanism, Lower includes 1 KGM Right Frame Member 2 PHWM Flatwasher (M8) 3 PHWM Lockwasher (M8) 4 PHSM Screw (M8 x 1,25 x 30mm HHCS) 5 KGM Pillow Block Assembly (See Fig. 2-Z) 6 PHWM Washer (Limit) 7 PHSM Screw (M8 x 1,25 x 20mm HHCS) 8 CGM Stroke Position Lock Mechanism (See Fig. 2-AA) 9 KGM Pivot And Pillow Block Assembly (See Fig. 2-AB) 10 MVH Clamp Nut 11 KGM Shaft 12 KGM Stroker Length Lock (See Fig. 2-AC) 13 PBR Thrust Bearing 14 MVH Clamp Screw 15 PHWM Lockwasher (M5) 16 PHSM Screw (M5 x 0,8 x 12mm SHCS) 17 PFC Regulator 18 PPPM Elbow, Female 19 KGM Motor Plate 20 PHSM Screw (M6 x 1,0 x 16mm FHCS) 21 PMO Stroke Length Motor 22 PHWM Flatwasher (M5) 23 PHSM Screw (M5 x 0,8 x 20mm SHCS) 24 KGM Stroke Length Screw Assembly 25 KGM Socket 26 PHSM Screw (M5 x 0,8 x 6mm CPSS) 27 KGM Crank Assembly (See Fig. 2-Y) Page 13

20 SECTION 1 BASIC MACHINE KGM-5000NT-60 FIGURE 1-G STROKER ASSEMBLY Page 14

21 S LIST COVERING FIGURE 1-G SECTION 1 BASIC MACHINE Ref....Stroker Assembly includes 1 KGM Plate 2 PHSM Screw (M8 x 1,25 x 20mm FHCS) 3 EC Shaft Support, Right 4 PHSM Setscrew (M8 x 1,25 x 12mm FPSS) 5 PHWM Lockwasher (M6) 6 PHSM Screw (M6 x 1,0 x 16mm SHCS) 7 KGM Shaft Support, Left 8 PHSM Screw (M4 x 0,7 x 20mm SHCS) 9 KGM Encoder Bracket, Left 10 PHSM Screw (M5 x 0,8 x 30mm SHCS) 11 CGM Ball Bushing Shaft 12 KGM Pillow Block Assembly (See Fig. 2-T) 13 PHSM Setscrew (M5 x 0,8 x 6mm CPSS) 14 KGM Carriage Stop Clamp Assembly (See Fig. 2-U) 15 KGM Encoder Bracket, Right 16 PHM Seal 17 KGM Seal Retainer 18 PHSM Screw (M4 x 0,7 x 12mm BHCS) 19 KGM Stroker Carriage Assembly (See Fig. 2-V) 20 PHWM Flatwasher (M6) 21 PHSM Screw (M6 X 1.0 X 30mm HHCS) 22 KGM Flange 23 PHWM Flatwasher (M5) 24 PHWM Lockwasher (M5) 25 PHSM Screw (M5 x 0,8 z 25mm SHCS) 26 KGM Flexible Coolant Line, 90 Deg. (See Fig. 2-XW 27 KGM Flexible Coolant Line (See Fig. 2-X) 28 KGM Encoder Adjustment Block, Horizontal 29 PHWM Flatwasher (M5) 30 PHSM Screw (M5 x 0,8 x 16mm SHCS) 31 KGM Encoder Adjustment Block, Vertical 32 PHSM Screw (M5 x 0,8 x 20mm SHCS) 33 PHWM Flatwasher (M4) 34 PHWM Lockwasher (M4) 35 PHSM Screw (M4 x 0,7 x 45mm SHCS) 36 KGM Cable Chain Bracket 37 PHWM Flatwasher (M6) 38 PHNM Nut (M6 x 1,0mm Hex) 39 PEM Cable Carrier Bracket 40 PHSM Screw (M6 x 1,0 x 16mm BHCS) 41 PEM Cable Carrier (18 Links) 42 PEM Cable Carrier Bracket 43 PHSM Screw (M6 x 1,0 x 8mm BHCS) 44 KGM Heidenhain Linear Encoder 45 PHNM Nut (M4 x 0,7mm Hex) 46 PG Flatwasher 47 PHSM Screw (M4 x 0,7 x 30mm SHCS) 48 PHSM Screw (M4 x 0,7 x 16mm SHCS) 49 PPPM Straight Male Connector 50 KGM Stroker Drive Shaft 51 PHW Lockwasher (1/4) Page 15

22 SECTION 1 BASIC MACHINE FIGURE 1-H COOLANT RESERVOIR KGM-5000NT-180 S LIST COVERING FIGURE 1-H Ref....Coolant Reservoir includes 1 KGM Reservoir Assembly 2 PF Relief Valve, MC (1/2 in) 3 PPP Relief Valve, NSW (1/2 in) 4 KGM Valve Bracket 5 PPP Hose Barb 6 CK Hose Clamp 7 KGM Swarf Bucket Page 16

23 SECTION 1 BASIC MACHINE FIGURE 1-I PANEL ASSEMBLY, COOLANT ACCESS DOORS, LOWER KGM-5000NT-80 S LIST COVERING FIGURE 1-I Ref....Panel Assembly, Coolant Access Doors, Lower includes Edge Trim 2 KGM Access Door Weldment 3 KGM Door Weldment 4 KGM Panel Brace 5 KGM Mounting Bracket 6 KGM Mounting Bracket 7 PHM Latch Housing 8 PHM Latch Drive Stud 9 PHM Latch Pawl 10 PHM Latch Pawl 11 PHM Pull Tab 12 PHSM Screw 13 PHWM Flatwasher (M6) Page 17

24 SECTION 1 BASIC MACHINE FIGURE 1-J PANEL ASSEMBLY, ELECTRICAL KGM-5000NT-70 Page 18

25 SECTION 1 BASIC MACHINE Ref....Panel Assembly, Electrical includes 1 KGM Electrical Enclosure Assembly (See Fig. 2-A) 2 PHM Leveling Pad 3 PHSM Screw (M12 x 1,75 x 80mm HHCS) 4 PHWM Flatwasher (M12) 5 KGM Spacer 6 PHWM Lockwasher (M12) 7 PHNM Nut, Jam 8 KGM Back Support 9 PHWM Flatwasher (M8) 10 PHWM Lockwasher (M8) 11 PHSM Screw (M8 x 1,25 x 35mm HHCS) 12 PHWM Flatwasher (M8) 13 PHNM Nut (M8 x 1,25mm Hex) 14 KGM Pneumatic Control Panel Assembly (See Fig. 2-B) 15 PHWM Flatwasher (M6) 16 PHWM Lockwasher (M6) 17 PHSM Screw (M6 x 1,0 x 12mm BHCS) 18 KGM Left Hinge 19 PHWM Washer (M6) 20 PHSM Screw (M6 x 1,0 x 20mm SHCS) 21 KGM Top Rear Panel 22 PHNM Nut (M6 X 1,0mm Hex) 23 MBB Flatwasher 24 PHSM Screw (M6 x 1,0 x 25mm SHCS) 25 PNP Warning Decal - Do Not Drill 26 PNP Electrical Decal 27 PPPM Hex Socket Pipe Plug 28 PNP CE Label 29 LTA Patent Label 30 PEM Spiral Wrap (2 Ft) S LIST COVERING FIGURE 1-J Page 19

26 SECTION 1 BASIC MACHINE FIGURE 1-K PANEL ASSEMBLY, REAR KGM-5000NT-90 S LIST COVERING FIGURE 1-K Ref....Panel Assembly, Rear includes 1 KGM Panel Weldment, Rear 2 KGM Panel Bracket 3 PHWM Flatwasher (M6) 4 PHWM Lockwasher (M6) 5 PHNM Nut (M6 x 1,0mm Hex) 6 KGM Bracket 7 PHW Washer (1/4 x 1) Page 20

27 SECTION 1 BASIC MACHINE FIGURE 1-L PANEL ASSEMBLY, LEFT SIDE KGM-5000NT-100 S LIST COVERING FIGURE 1-L Ref....Panel Assembly, Left Side includes 1 KGM Panel Weldment, Front 2 KGM Panel Bracket 3 PHWM Flatwasher (M6) 4 PHWM Lockwasher (M6) 5 PHNM Nut (M6 x 1,0mm Hex) 6 KGM Splash Shield 7 KGM Cover Seal 8 PHSM Screw, (M6 x 1,0 x 20mm SHCS) 9 PHSM Screw (M6 x 1,0 x 16mm SHCS) N/S PDL Decal Set (KGM5000NT) N/S PDL Decal Set (KGM1000NT) Page 21

28 SECTION 1 BASIC MACHINE FIGURE 1-M PANEL ASSEMBLY, RIGHT SIDE KGM-5000NT-110 Page 22 S LIST COVERING FIGURE 1-M Ref....Panel Assembly, Right Side includes 1 KGM Panel Weldment, Right Side 2 KGM Panel Bracket 3 PHWM Flatwasher (M6) 4 PHWM Lockwasher (M6) 5 PHNM Nut (M6 x 1,0mm Hex) 6 KGM Splash Shield Weldment 7 KGM Cover Seal 8 PHSM Screw, (M6 x 1,0 x 20mm SHCS) 9 KGM Bracket 10 PHSM Screw (M6 x 1,0 x 16mm SHCS) 11 PHW Washer (1/4 x 1)

29 SECTION 1 BASIC MACHINE KGM-5000NT-150 FIGURE 1-N PANEL ASSEMBLY, GUARDS S LIST COVERING FIGURE 1-N Ref....Panel Assembly, Guards includes 1 KGM Front Panel Support 2 PHWM Flatwasher (M6) 3 PHWM Lockwasher (M6) 4 PHNM Nut (M6 x 1,0mm Hex) 5 KGM Front Panel Assembly 6 PHSM Screw (M6 x 1,0 x 16mm SHCS) 7 PHWM Washer, Trim 8 PHSM Screw (M6 x 1,0 x 16mm SHCS) 9 KGM Support Bracket Assembly 10 PHWM Flatwasher (M6) 11 KGM Start Button Assembly (See Fig. 3-D) 12 PHSM Screw (M6 x 1,0 x 12mm BHCS) 13 PHM Cap 14 KGM Trim Cap, Right Side 15 PHSM Setscrew (M6 x 1,0 x 8mm FPSS) 16 KGM Trim Cap, Left Side 17 KGM Hood Cover Assembly (See Fig. 2-C) 17 KGM Hood Cover Assembly, CE (See Fig. 2-D) 18 KGM Front Cover 19 KGM Right Side Cover 20 KGM Left Side Cover 21 KGM Plate *...Trim, Edge (*26in.) Page 23

30 SECTION 1 BASIC MACHINE KGM-5000NT-120 FIGURE 1-O PANEL ASSEMBLY, FRONT Page 24

31 S LIST COVERING FIGURE 1-O SECTION 1 BASIC MACHINE Ref....Panel Assembly, Front includes 1 KGM Spindle Housing Interface 2 PHSM Screw (M4 x 0,7 x 10mm SHCS) 3 KGM Cover 4 PHWM Flatwasher (M4) 5 PHSM Screw (M4 x 0,7 x12mm SHCS) 6 KGM Spacer 7 PHWM Lockwasher (M5) 8 PHSM Screw (M5 x 0,8 x 12mm SHCS) 9 KGM Front Panel 10 KGM Cover Assembly 11 PHWM Flatwasher (M6) 12 PHWM Lockwasher (M6) 13 PHNM Nut (M6 x 1,0mm Hex) 14 PED LED Indicator, Green 15 PEC Receptacle 16 CGM Gasket 17 PEC Receptacle Cover 18 KGM Cover 19 PHWM Lockwasher (M4) 20 PHNM Nut (M4 x 0,7mm Hex) 21 PEM Locknut 22 KGM LID 23 PHSM Screw (M5 x 0,8 x 12mm PHTS) 24 PEM Seal 25 PEC Cable Strain Relief 26 KGM Cover Assembly 27 PHWM Flatwasher (M8) 28 PHWM Lockwasher (M8) 29 PHNM Nut (M8 x 1,25mm Hex) 30 KGM Back Right Member 31 PHSM Screw (M6 x 1,0 x 16mm SHCS) 32 PHWM Flatwasher (M6) 33 PHSM Screw (M6 x 1,0 x 16mm BHCS) 34 PNP Label, Sunburst Logo 35 PNP Label, Sunnen Name Logo 36 EC EC Link Control 37 PHNM Locknut (M6 x 1,0mm Hex) 38 KGM Terminal Block Assembly 39 KGM Top Cover N/S PDL Decal Set (KGM1000NT) N/S Weather Stripping (32in.) NOTE: Items included in PDL202 replaces items 34 & 35 on KGM1000NT. Page 25

32 SECTION 1 BASIC MACHINE FIGURE 1-P PANEL ASSEMBLY, DOORS, UPPER KGM-5000NT-140 Page 26

33 SECTION 1 BASIC MACHINE S LIST COVERING FIGURE 1-P Ref....Panel Assembly, Doors, Upper includes 1 KGM Door Weldment, Front, Upper 2 KGM Door Weldment, Right Side, Upper 3 PHM Door Latch 4 KGM Hinge Bracket 5 KGM Hinge 6 PHSM Screw (M5 x 0,8 x 10mm BHCS) 7 PHWM Lockwasher (M5) 8 PHNM Nut (M5 x 0,8mm Hex) 9 PHWM Flatwasher (M6) 10 PHWM Lockwasher (M6) 11 PHNM Nut (M6 x 1,0mm Hex) 12 KGM Block Spacer 13 PHWM Flatwasher (M5) 14 PHNM Nut (M4 x 0,7mm Hex) 15 PEM Safety Key 16 PHWM Flatwasher (M4) 17 PHWM Lockwasher (M4) 18 PHSM Screw (M4 x 0,7 x 10mm SHCS) 19 KGM Door Latch 20 PHSM Screw (M5 x 0,8 x 16mm BHCS) 21 PES Safety Interlock 22 PHSM Screw (M4 x 0,7 x 10mm SHCS) 23 KGM8151 *...Spacer (As Required) 24 KKN Bumper Strip 25 PNP Sunburst Logo (KGM5000NT) 26 PNP Sunnen Name Logo (KGM5000NT) 27 PNP KGM Logo (KGM5000NT) 28 PNP Trademark Label (KGM5000NT) 29 KGM8152 *...Spacer (As Required) 30 PEC Strain Relief Connector 31 PEC Multi-Hole Cord Grip N/S PDL Decal Set (KGM1000NT) NOTE: Items included in PDL202 replaces items 25, 26, 27, & 28 on KGM1000NT. Page 27

34 SECTION 2 - BASIC MACHINE COMPONENTS FIGURE 2-A ELECTRICAL ENCLOSURE ASSEMBLY KGM-8215 Page 28

35 SECTION 2 BASIC MACHINE COMPONENTS S LIST COVERING FIGURE 2-A - - KGM8215 Ref....Electrical Enclosure Assembly includes 1 CK Holder, Print 2 KGM Electrical Panel 3 KGM Electrical Enclosure 4 KGM Door Weldment, Right 5 KGM Door Weldment, Left 6 KGM L-Handle 7 KGM Rod Control w/clip 8 KGM Cam 9 KGM Rod w/rollers 10 KGM Rod Guide 11 KGM Rod Adapter 12 KGM Adapter 13 KGM Screw (M6 x 23mm HHCS) 14 KGM Screw (4,2 x 13mm) 15 KGM Hinge Enclosure 16 KGM Hinge Pin 17 KGM C-Clip 18 KN Drivescrew 19 PEC Cable Connector Frame 20 PEM Outlet Filter 21 PEM Filter Fan 22 PEM Handle 23 PEM Seal, Oil Tight Hose 24 PHNM Nut (M5 x 0,8mm Hex) 25 PHNM Nut (M12 x 1,75mm Hex) 26 PHNM Nut, Jam (M12 x 1,75mm Hex) 27 PHS Screw (3/4-10 x 1in. HHCS) 28 PHSM Screw (M5 x 0,8 x 16mm SHCS) 29 PHSM Screw (M12 x 1,75 x 30mm HHCS) 30 PHSM Screw (M5 x 0,8 x 12mm PHTS) 31 PHSM Stud (M12 x 1,75 x 70mm Long) 32 PHWM Lockwasher (M5) 33 PHWM Lockwasher (M12) 34 PHWM Flatwasher (M12) 35 PHWM Flatwasher (M5) 36 PNP Electrical Spec Plate 37 KGM Braking Resistor Assembly 38 PHWM Flatwasher (M6) 39 PHWM Lockwasher (M6) 40 PHNM Nut (M6 x 1,0mm Hex) N/S *...Weather Stripping (As Required) N/S *...Gasket (As Required) N/S *...Edge Trim (As Required) N/S MSP42351 *...Double Sided Tape (As Required) *NOTE: Order length as required. Page 29

36 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-B PNEUMATIC CONTROL PANEL ASSEMBLY KGM-7000 S LIST COVERING FIGURE 2-B - - KGM7000 Ref....Pneumatic Control Panel Assembly includes 1 KGM Identification Tag 2 KGM Air Filtering System (See Fig. 2-AE) 3 PHWM Flatwasher (M5) 4 PHWM Lockwasher (M5) 5 PHSM Screw (M5 x 0,8 x 12mm SHCS) 6 KGM Identification Tag 7 KGM Manifold (See Fig. 2-AF) 8 PHWM Flatwasher (M4) 9 PHWM Lockwasher 10 PHSM Screw (M4 x 0,7 x 30mm SHCS) Weather Stripping 12 KGM Cover 13 PEM Locknut 14 PEM Seal 15 PEC Elbow Connector 16 PEM Connection Module 17 PHSM Screw (M5 x 0,8 x 12mm PHTS) 18 DRB Din Rail (175mm) 19 KGM Pneumatic Control Panel Assembly 20 KGM Pneumatic Unit Shim 21 PHSM Screw (M5 x 0,8 x 20mm HHCS) Page 30

37 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-C HOOD COVER ASSEMBLY S LIST COVERING FIGURE 2-C KGM KGM8065 Ref....Hood Cover Assembly includes 1 KGM Tool Cover Assy 2 KGM Front Plate 3 PHSM Screw (M6 x 1,0 x 12mm BHCS) 4 PHWM Flatwasher (M6) 5 PHWM Lockwasher (M6) 6 PHNM Nut (M6 x 1,0mm Hex) 7 KGM Pane 8 KGM Cover Support 9 PHWM Flatwasher (M5) 10 PHWM Lockwasher (M5) 11 PHNM Nut (M5 x 0,8mm Hex) 12 KGM Cover Support 13 KGM Cover Support 14 PHWM Flatwasher (M6) 15 ECA Handle 16 PHSM Screw (M6 x 1,0 x 16mm SHCS) 17 PHNM Nut (M6 x 1,0mm) 18 KGM Slide 19 PHSM Screw (M6 x 1,0 x 25mm SHCS) 20 PHWM Flatwasher (M6) 21 PHSM Screw (M5 x 0,8 x16mm FHCS) 22 PHW Washer, Nylon Page 31

38 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-D HOOD COVER ASSEMBLY, CE (1 of 4) KGM S LIST COVERING FIGURE 2-D - - KGM8230 Ref....Hood Cover Assembly, CE (1 of 4) includes 1 EC ISO-Damp Bushing 2 KGM Front Panel Weldment 3 PHM Grommet 4 PHNM Nut 5 PHSM Screw (M6 x 1,0 x 16mm SHCS) 6 PHSM Screw (M6 x 1,0 x 25mm SHCS) 7 PHWM Flatwasher (M6) 8 PHWM Washer Page 32

39 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-D HOOD COVER ASSEMBLY, CE (2 of 4) KGM S LIST COVERING FIGURE 2-D - - KGM8230 Ref....Hood Cover Assembly, CE (2 of 4) includes 1 KGM Access Door Weldment 2 KGM Hinge Bracket 3 KGM Plate - Door Latch 4 KGM Splash Guard Weldment 5 KGM Pull Handle 6 KGM Splash Guard 7 MB Flatwasher.(195 ID x.443 OD x.065 Thk) 8 PEC Strain Relief Connector 9 PEM Safety Interlock Key 10 PES Safety Interlock Switch 11 PHNM Nut, Hex (M4 x 0,7) 12 PHNM Nut, Hex (M5 x 0,8) 13 PHNM Nut, Hex (M6 x 1,0) 14 PHS Screw (#8-32 x 3/4 SHCS) 15 PHSM Screw (M4 x 0,7 x 8mm BHCS) 16 PHSM Screw (M5 x 0,8 x 10mm SHCS) 17 PHSM Screw (M5 x 6 x 20mm HHCS) 18 PHSM Screw (M5 x 0,8 x 10mm SHCS) 19 PHWM Lockwasher (M5) 20 PHWM Lockwasher (M6) 21 PHWM Flatwasher (M4) 22 PHWM Lock Washer (M4) 23 PHWM Flatwasher (M5) 24 PHWM Flatwasher (M6) Page 33

40 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-D HOOD COVER ASSEMBLY, CE (3 of 4) KGM S LIST COVERING FIGURE 2-D - - KGM8230 Ref....Hood Cover Assembly, CE (3 of 4) includes 1 KGM Access Door Weldment 2 KGM Access Door Bezel 3 KGM Side Window Panel 4 PHNM Nut, Hex (M6 x 1,0) 5 PHWM Flatwasher (M6) Page 34

41 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-D HOOD COVER ASSEMBLY, CE (4 of 4) KGM S LIST COVERING FIGURE 2-D 14 PHWM Flatwasher (M5) - - KGM8230 Ref....Hood Cover Assembly, CE (5 of 5) includes 1 KGM Front Cover 2 KGM Door Extension 3 PED Light Curtain Transmitter 4 PED Light Curtain Receiver 5 PEM Light Curtain Bracket Set 6 PHM Grommet 7 PHNM Nut, Hex (M5 X 0.8) 8 PHNM Nut, Hex (M6 X 1.0) 9 PHSM Screw (M5 x 0,8 x 12mm BSHCS) 10 PHSM Screw (M6 x 1,0 x 12mm BSHCS) 11 PHWM Lockwasher (M5) 12 PHWM Lockwasher (M6) 13 PHWM Flatwasher (M6) Page 35

42 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-E HIGH PRESSURE COOLANT JUNCTION KGM-7380 S LIST COVERING FIGURE 2-E - - KGM7380 Ref....High Pressure Coolant Junction includes 1 CK Hose Clamp 2 PPP Hose Barb 3 PPPM Street Elbow, 90 Deg. 4 PPPM Elbow 5 PPPM Tee (1/2 BSPT Female) 6 PPPM Nipple Page 36

43 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-F LOW PRESSURE COOLANT JUNCTION KGM-7385 S LIST COVERING FIGURE 2-F - - KGM7385 Ref....Low Pressure Coolant Junction includes 1 PES Flow Switch 2 PPPM Nipple, Reducing (1 x 1/2 BSPT Hex) 3 PPPM Tee (1/2 BSPT Female) 4 PPPM Elbow 5 PPPM Street Elbow, 90 Deg. 6 PPP Hose Barb 7 CK Hose Clamp 8 PFC Pneumatic Valve 9 PPP Elbow Page 37

44 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-G FILTER CANISTER ASSEMBLY KGM-7390 S LIST COVERING FIGURE 2-G - - KGM7390 Ref....Filter Canister Assembly includes 1 EC Filter Canister 2 PF Spring Hold Down 3 PF Gasket 4 PF Cover 5 EC Clamp Assembly, Half 6 EC Clamp Yoke Assembly, Half 7 EC Tee Handle Assembly 8 PHWM Lockwasher (M8) 9 PHSM Screw (M8 x 1,25 x 35mm HHCS) 10 PF Air Vent 11 PPPM Elbow 12 PPPM Adapter (1/2 NPT Female To 1/2 BSPT Male) 13 PPP Nipple, Closed (1/2 NPT x 1-1/8in.) 14 PPP Mini Ball Valve 15 PPP Hose Barb 16 CK Hose Clamp Page 38

45 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-H MAGNETIC SEPARATOR ASSEMBLY KGM-7090 S LIST COVERING FIGURE 2-H - - KGM7090 Ref....Magnetic Separator Assembly includes 1 KGM Overflow Tray 2 PPP Street Elbow (2 NPT) 3 CGM Gap Plate 4 PG Screw (8-32 x.375in. FHCS) 5 CL Nut (8-32in. Hex) 6 MSA Screw (1/4-20 x.50in. HHCS) 7 CGM Bracket 8 KGM Motor 9 KGM Gearbox Page 39

46 SECTION 2 BASIC MACHINE COMPONENTS KGM-7325 FIGURE 2-I STROKER POSITIONING UNIT Page 40

47 SECTION 2 BASIC MACHINE COMPONENTS - - KGM7325 Ref....Stroker Positioing Unit includes 1 PPP Breather 2 PPP Male Swivel Run Tee 3 PPP Reducer Bushing (1/4 Male To 1/8 Female NPT) 4 PHSM Screw (M6 x 1,0 x 45mm SHCS) 5 CGM Air Cylinder 6 KGM Rod Extension 7 KGM Flange 8 PHM Seal 9 PPPM Grease Fitting (M6 x 1,0 x 5mm) 10 PBR Ball Bushing 11 PHM Seal 12 PHK Key, Square (3/32 x 5/8in.) 13 PHS Setscrew (#10-24 x 1/4in. FPSS) 14 PDB Drive Belt 15 CGM Pulley 16 KGM Floating Seal 17 KGM Shaft 18 KGM Positioning Unit Housing 19 KGM Idler Assembly (See Fig. 2-L) 20 KGM Drive Roller 21 KGM Driver Yoke 22 PBR Bearing 23 PHSM Screw (M4 x 0,7 x 10mm FHCS) 24 PHWM Lockwasher (M5) 25 PHSM Screw (M5 x 0,8 x 16mm SHCS) 26 KGM Motor Mounting Block 27 PHWM Flatwasher (M6) 28 PHWM Lockwasher (M6) 29 PHSM Screw (M6 x 1 x 16mm HHCS) 30 PHWM Flatwasher (M5) 31 PMO Stroke Position Motor 32 PHS Setscrew (#10-32 x 1/8in. FPSS) 33 KGM Motor Pulley 34 KN Setscrew (#10-32 x 1/4in. FPSS) 35 KGM Motor Bracket 36 KGM Cover Plate 37 KGM Plug 38 PHSM Screw (M5 x 0,8 x 12mm FHCS) 39 KGM Washer S LIST COVERING FIGURE 2-I Page 41

48 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-J SPINDLE MOTOR ASSEMBLY, KGM5000NT KGM-7310 Page 42 S LIST COVERING FIGURE 2-J - - KGM7310 Ref....Spindle Motor Assembly includes 1 PMO977SF 1...Motor 2 PHSM Setscrew (M6 x 1,0 x 12mm SHSS) 3 KGM Motor Pulley 4 KGM Motor Plate 5 PHSM Screw (M10 x 1,5 x 20mm HHCS) 6 PHWM Lockwasher (M10) 7 PHWM Flatwasher (M10) 8 PHNM Nut (M4 x 0,7mm Hex) 9 PHWM Lockwasher (M4) 10 PHWM Flatwasher (M4) 11 PEM Fan (240 CFM) 12 PEM Finger Guard 13 PHSM Screw (M4 x 0,7 x 16mm SHCS) 14 PHWM Flatwasher (M4) 15 MVH Terminal Cover 16 PHS Screw (#6-32 x 3/4in. PHMS) 17 PEC Cable Strain Relief 18 PEM Sealing O-Ring w/retainer 19 PNP Electrical Decal 20 PNP Arrow Label

49 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-K SPINDLE MOTOR ASSEMBLY, KGM1000NT KGM-7340 S LIST COVERING FIGURE 2-K - - KGM7340 Ref....Spindle Motor Assembly includes 1 KGM Gearbox Plate 2 KGM Gearbox 3 PHWM Flatwasher (M12) 4 PHSM Screw (M12 x 1,75 x 35mm HHCS) 5 PHM Taper Lock Bushing 6 PHM Timing Pulley 7 PMO Motor 8 PHS Screw (1/2-13 x 1.25 HHCS) 9 PEC Cable Strain Relief 10 PEM Sealing O-Ring w/retainer 11 PEM Locknut, NPT 12 PNP Electrical Decal 13 PNP Arrow Label Page 43

50 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-L ILDER ASSEMBLY KGM-2715 S LIST COVERING FIGURE 2-L - - KGM2715 Ref....Idler Assembly includes 1 KGM Idler Frame 2 CGM Idler Shaft 3 PBR Bearing 4 PHM Rubber Bumper 5 KGM Idler Roller Page 44

51 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-M COOLANT TRAY ASSEMBLY KGM-7405 S LIST COVERING FIGURE 2-M - - KGM7405 Ref....Coolant Tray Assembly includes 1 KGM Drip Tray Assembly 2 KGM Return Pipe 3 PPP Elbow, 90 Deg. 4 CK Hose Clamp, Kwik Snap 5 PPP Hose Nipple, Plastic 6 PPPM Coupling, Anchor (1/2 NPT) 7 PHW Washer 8 PHWM Washer (M4) 9 PHSM Screw (M4 x 16mm SHCS) 10 PHM Tee (1/4) 11 PHM Valve (1/4 Loc-Line) 12 PHM Elbow (1/4 Loc-Line) 13 PHNM Nut (M4 x 0,7mm Hex) 14 KGM Screen 15 PHM Hose Clamp (3/4in.) 16 PHW Flatwasher (1-1/4in.) 17 KGM Reticulated Pad N/S *...Tube (3/4 OD X 1/2in. ID)(As Required) Page 45

52 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-N SPINDLE ASSEMBLY, KGM5000NT KGM-2040 S LIST COVERING FIGURE 2-N - - KGM Spindle Assembly includes 1 KGM Feed Rod Assembly (See Fig. 2-S) 2 KGM Spherical Washer 3 KGM Spindle Nose 4 PHSM Setscrew (M8 x 0,75 x 16mm FPSS) 5 CGM Coolant Shield 6 PHM Seal 7 KGM Spindle Shaft 8 POR O Ring 9 PBR Angular Contact Bearing Set 10 PPPM Pneumatic Fitting (Male Elbow) 11 KGM Spindle Bearing Housing Assembly 12 KGM Bearing Spacer Set 13 PHN Bearing Locknut 14 KGM Cover 15 PHSM Screw (M3 X 0.5 X 25mm SHCS) 16 PHM Seal 17 PHK Key, Rectangular 18 KGM Spindle Pulley Assembly (See Fig. 2-P) Page 46

53 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-O SPINDLE ASSEMBLY, KGM1000NT KGM-2035 S LIST COVERING FIGURE 2-O - - KGM Spindle Assembly includes 1 KGM Feed Rod Assembly (See Fig. 2-S) 2 KGM Spherical Washer 3 KGM Spindle Nose 4 PHSM Setscrew (M8 x 0,75 x 16mm FPSS) 5 CGM Coolant Shield 6 PHM Seal 7 KGM Spindle Shaft 8 POR O Ring 9 PBR Angular Contact Bearing Set 10 PPPM Pneumatic Fitting (Male Elbow) 11 KGM Spindle Bearing Housing Assembly 12 KGM Bearing Spacer Set 13 PHN Bearing Locknut 14 KGM Cover 15 PHSM Screw (M3 X 0.5 X 25mm SHCS) 16 PHM Seal 17 PHK Key, Rectangular 18 PHM Timing Pulley 19 PHM Taper Lock Bushing Page 47

54 SECTION 2 BASIC MACHINE COMPONENTS KGM-2065 FIGURE 2-P SPINDLE PULLEY ASSEMBLY S LIST COVERING FIGURE 2-P - - KGM2065 Ref....Spindle Pulley Assembly includes 1 KGM Spindle Pulley Blank 2 KGM Bushing 3 PHSM Screw (M6 x 1,0 x 25mm HHCS) 4 PHWM Lockwasher (M6) Page 48

55 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-Q BEARING ASSEMBLY KGM-2355 S LIST COVERING FIGURE 2-Q - - KGM2355 Ref....Bearing Assembly includes 1 KGM Bearing Sleeve 2 PBR Bearing, Single Row Angular Contact Page 49

56 SECTION 2 BASIC MACHINE COMPONENTS KGM-7320 FIGURE 2-R FEED ASSEMBLY Page 50 S LIST COVERING FIGURE 2-R - - KGM7320 Ref....Feed Assembly includes 1 PPPM Grease Fitting 2 CGM Ball Nut 3 KGM Feed Motor Adapter 4 PHN Bearing Locknut 5 PBR Bearing 6 KGM Ball Screw Assembly 7 PHSM Setscrew (M5 x 0,8 x 10mm FPSS) 8 KGM Bearing Retainer 9 PHSM Screw (M4 x 0,7 x 16mm SHCS) 10 KGM Bearing Retainer 11 KGM Flange 12 PHSM Screw (M6 x 25mm SHCS) 13 PNP Label, Warning N/S CK Flatwasher N/S CK Flatwasher

57 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-S FEED ROD ASSEMBLY KGM-2360 S LIST COVERING FIGURE 2-S - - KGM2360 Ref....Feed Rod Assembly includes 1 PHM Seal 2 PHR Retaining Ring, Internal 3 KGM Spindle Adapter 4 KGM Feed Rod 5 PHP Needle Roller Pin 6 KGM Universal Pin 7 KGM Keyed Feed Rod 8 PHS Screw ( #4-40 x 3/16in. SHCS) 9 CGM Key 10 PPPM Grease Fitting (M6 x 1.0 x 5mm) Page 51

58 SECTION 2 BASIC MACHINE COMPONENTS FIGURE 2-T PILLOW BLOCK ASSEMBLY KGM-2405 S LIST COVERING FIGURE 2-T - - KGM2405 Ref....Pillow Block Assembly includes 1 KGM Pillow Block 2 KGM Spacer 3 PHM Seal 4 PBR Ball Bushing 5 PPPM Grease Fitting, 45 Deg. Page 52