REPAIR PARTS CATALOG FOR SUNNEN POWER STROKED HONING MACHINE

REPAIR S CATALOG FOR SUNNEN POWER STROKED HONING MACHINE MODEL: ML5000 SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST. LOUIS, MO 63143, U.S.A. PHONE: 3147812100 X-ML-5001D

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

INTRODUCTION Illustrations show all major components in exploded detail. Item numbers on each illustration are keyed to the corresponding parts list, providing a descriptive identification of each part. The parts lists include assemblies as well as detail parts. An item listed without a part number can be obtained as a component of the complete assembly of which it is a part. Standard hardware items are listed with complete descriptions, such as Item 29 below. These may be purchased at your local hardware store, but it is important to replace an item with one having the same dimensions as the original. In some places brand names and part numbers are shown. These may change depending upon availability. Sunnen Products Company reserves the right to make changes, without notice, to materials, specifications, colors, designs and accessories included with units. HOW TO ORDER When ordering replacement parts be sure to include the following information to ensure prompt shipment of correct parts: 1. The part number and description of each part desired, obtained from this parts catalog. 2. The quantity of each part desired. 3. The voltage, frequency and phase, when ordering electrical parts. 4. The model and serial number of the machine, obtained from the name plate, where there is any question concerning a part. HOW TO USE THIS 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 NonCE Machines) to denote domestic machines from exported machines. The CE version is constructed to meet the requirements of the European market, and is available to any customer. Step 1. 4 1 2 3 15 17 14 Step 2. Step 3. Step 4. 1 MVH4499A 1...Spindle Cap includes 2 PHSM405 3...Screw (M6 x 1 x 16 SHCS) 3 PHW354 3...Washer (M6) 4 MVH4422 1...Inner Spindle Nose 14 PEM870A 1...Cable Carrier includes 15 PEM871 1...Cable Carrier Bracket 16 PEM872 1...Cable Carrier Bracket 17 PHSM600 1...Screw (M3 x 0,5 x 5mm FHCS) iii

GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care and maintenance this equipment will give years of service. READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT. IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with the planning and installation of your SUNNEN equipment. Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time. Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance of your equipment. Troubleshooting information can also be found within the Instructions. If you cannot find what you need, call for technical support. Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in the literature packaged with your equipment. Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the following information available: Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it. Have Model Number and Serial Number printed on your equipment Specification Nameplate. Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data. For Troubleshooting, additional information may be required: Power distribution information (type delta, wye, power factor correction; other major switching devices used, voltage fluctuations) Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding). Use of any optional devices/equipment between the Drive & motor (output chokes, etc.). For fast service on your orders call: Sunnen Automotive Customer Service toll free at: 18007722878 Sunnen Industrial Customer Service toll free at: 18003253670 Customers outside the USA, contact your local authorized Sunnen Distributor. Additional information available at: http://www.sunnen.com or email: 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. Antistatic bubble wrap has been included for use at the machine when an ESD safe workstation is not available. You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you: GROUND ISOLATE NEUTRALIZE iv

SUNNEN LIMITED PRODUCT WARRANTY SUNNEN Products Company and its subsidiaries (SPC) warrant that all new SPC honing machines, gaging equipment, tooling, and related equipment will be free of defects in material and/or workmanship for a period of one year from the date of original shipment from SPC. Upon prompt notification of a defect during the oneyear period, SPC will repair, replace, or refund the purchase price, with respect to parts that prove to be defective (as defined above). Any equipment or tooling which is found to be defective from improper use will be returned at the customer's cost or repaired (if possible) at customer's request. Customer shall be charged current rates for all such repair. Prior to returning any SPC product, an authorization (RMA#) and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer. Warranty Limitations and Exclusions This Warranty does not apply to the following: Normal maintenance items subject to wear and tear: (belts, fuses, filters, etc). Damages resulting from but not limited to: Shipment to the customer (for items delivered to customer or customer's agent F.O.B., Shipping Point) Incorrect installation including improper lifting, dropping and/or placement Incorrect electric power (beyond +/ 10% of rated voltage) including intermittent or random voltage spikes or drops Incorrect air supply volume and/or pressure and/or contaminated air supply Electromagnetic or radio frequency interference from surrounding equipment (EMI, RFI) Storm, lightning, flood or fire damage Failure to perform regular maintenance as outlined in SPC manuals Improper machine setup or operation causing a crash to occur Misapplication of the equipment Use of nonspc machines, tooling, abrasive, fixturing, coolant, repair parts, or filtration Incorrect software installation and/or misuse Nonauthorized customer installed electronics and/or software Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES. SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND, EXPRESS OR IMPLIED, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A 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 nonexclusive right, without right to sublicense, to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software. SPC reserves all rights including rights not otherwise expressly granted, and retain title and ownership to the Software including all subsequent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied on removable media (floppy disk), you, as Licensee, may copy the Software only for back up purposes; or you may request that SPC copy the Software for you for the same purposes. All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement. The Software and accompanying written materials (including the user's manual, if any) are provided in an "as is" condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct, indirect, consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use. It is recognized that some states do not allow the exclusion or limitation of liability for consequential or accidental damages and to the extent this is true, the above limitations may not apply. Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement. SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement. v

SAFETY INSTRUCTIONS READ FIRST The ML2000, like any machine tool, may be dangerous if used improperly. As a result of our commitment to continual safety improvement, many new safety features have been incorporated into this machine. However, these features cannot protect the operator from all hazards of misuse or abuse of the product. Please read all warnings and instructions before attempting to use this machine. DO NOT turn power on until all guards and covers are securely in place. DO NOT remove or defeat any safety device. Depressing foot pedal with power ON can start spindle and stroker motion. Use foot pedal ONLY to start a honing cycle after workpiece is securely fixtured and located on honing tool. Begin each new setup by depressing Emergency Stop button to clear all previous spindle and stroker speed settings. NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing ML2000. 1 Always wear eye protection when operating ML2000. DO NOT attempt any repair or maintenance procedure beyond those described in this book. Contact your Sunnen Service Representative for repairs not covered in this book. Manual stroked honing and truing should only be performed by operators trained to use safe manual honing practices. The key for switch to disable stroker and allow manual honing should be kept by a supervisor or skilled honing operator to prevent unauthorized manual honing. Much of the safety of the honing operation is dependent on how workpiece is fixtured. Several standard fixturing components are available but each is limited to certain types of applications. Homemade fixtures are also not uncommon and can be quite effective if designed and used properly. Sometimes it is necessary to clamp workpieces lightly when honing with special fixtures to minimize bore distortion. Likewise, tooling for small diameter honing is inherently fragile. Therefore, Always start a new setup with speeds and feed forces that are much lower than recommended to test stability of tooling and fixturing. After that, speeds and feed forces may be increased slowly to recommended values. If specially built automation components are added to this system, be sure that safety is not compromised. If necessary, obtain special enlarged work area safety system from Sunnen Products Co. Indicates CE version ONLY. 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous. vi

CONTENTS PAGE Introduction... 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 SECTION I A Side View... 2 B Upper Stroker... 4 C Lower Stroker... 6 D Feed Unit... 8 E Front View... 11 F Expand/Retract System... 12 G Motor Assembly (MLU-2015)... 14 H Save Saver Idler Assembly (MLU2000... 15 I Spindle... 16 J Cam Assembly... 19 K Outside Stroker... 20 L Front Panel (Inside)... 22 M Front Panel (Outside)... 25 N Universal Honing Fixture... 26 O Foot Pedal... 28 P Runout Indicator & Torque Bar... 29 Q Coolant System (without Cycle Start)... 30 R Coolant System (with Cycle Start)... 33 S Operator Station Enclosure (MLU-4380)... 37 SECTION II ELECTRICAL COMPONENTS T Operator Control Panel... 39 U Control Panel... 40 V Control Panel... 44 SECTION III OPTIONAL S W Automatic Size Control... 48 X Transformer Kit... 50 SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. Copyright 2007 by Sunnen Products Company Printed in U.S.A. Page 1

SECTION I 1 3 4 5 10 16 7 8 9 23 24 25 21 22 12 18 20 19 13 6 14 2 17 25 11 28 29 26 30 31 27 FIGURE A SIDE VIEW S LIST COVERING FIGURE A 1 - - - 1...Upper Stroker (See Fig. B) 2 - - - 1...Lower Stroker (See Fig. C) 3 - - - 1...Feed Unit (See Fig. D) 4 - - - 1...Expand / Retract System (See Fig. F) 5 - - - 1...Cam Assembly (See Fig. J) 6 - - - 1...Spindle (See Fig. I) 7 - - - 1...Outside Stroker (See Fig. K) 8 - - - 1...Front Panel, Inside (See Fig. L) 9 - - - 1...Universal Honing Fixture (See Fig. N) 10 EC4010 1...Right Beam Cover Assembly 10 EC4317 1...Right Beam Cover Assembly (CE Machines ONLY) 11 EC4015 1...Left Beam Cover Assembly 11 EC4476 1...Left Beam Cover Assembly (CE Machines ONLY) 12 EC4023 1...Right Hood Rest 13 EC4024 1...Left Hood Rest (Parts continued on next page) Page 2

S LIST COVERING FIGURE A SECTION I N/S PHNM434 4...Insert Nut (M5) 14 PHSM401 6...Screw (M5 x 0,8 x 12 SHCS) 15 EC4022 1...Left Corner Block N/S EC4021 1...Right Corner Block N/S PHSM966 2...Screw (M6 x 1,0 x 25 SHCS) N/S PHWM509 2...Lockwasher (M6) 16 EC4051A 1...Right Hood Prop 17 EC4052A 1...Left Hood Prop 18 EC4110 1...Machine Cover Frame N/S PHSM495 4...Screw (M8 x 1,25 x 20 HHCS) N/S PHWM407 4...Lockwasher (M8) N/S PHWM501 4...Washer (M8) 19 EC4140 1...Rear Panel Assembly 20 EC4146 1...Guide Plate N/S PHSM964 2...Screw (M6 x 1,0 x 35 SHCS) N/S PHWM509 2...Lockwasher (M6) N/S PHWM530 2...Washer (M6) N/S PHSM402 2...Screw (M5 x 0,8 x 18 SHCS) N/S PHWM519 2...Washer (M5) N/S PHNM407 2...Nut (M5) 21 PFC103A 1...Filter Regulator 22 PPP439A 1...Elbow 23 PPP477 1...Adapter 24 PPP478 1...Street Elbow 25 PPP190 1...Hose Barb 26 EC5505 1...Solenoid Valve Manifold 27 PHSM574 2...Screw (M4 x 0,7 x 30 SHCS) 28 PPP 440A 1...Straight Fitting 29 PFC 102A 2...Blanking Plate Assembly N/S PHNM425 2...Nut (M4) 30 PFC101A 6...Solenoid Valve 31 PPP441 2...Exhaust Muffler N/S 78156A *...Tubing (4 mm O.D. White) N/S 78157A *...Tubing (4 mm O.D. Black) N/S 78158A *...Tubing (4 mm O.D. Red) N/S 78159A *...Tubing (4 mm O.D. Blue) N/S 78160A *...Tubing (4 mm O.D. Yellow) N/S 78161A *...Tubing (4 mm O.D. Orange) N/S 78162A *...Tubing (4 mm O.D. Green) * Sold by the foot only. Page 3

SECTION I 50 49 51 47 48 42 45 44 46 41 38 43 32 37 36 39 26 33 34 35 31 20 30 4 2 3 40 8 9 21 23 22 10 9 8 23 22 24 25 11 29 28 27 5 1 6 7 FIGURE B UPPER STROKER S LIST COVERING FIGURE B 1 EC1526 1...Rear Frame Member 2 PHSM498 4...Screw (M8 x 1,25 x 30 HHCS) 3 PHWM407 4...Lockwasher (M8) 4 PHWM501 4...Washer (M8) 5 EC1560 1...Stroker Motor Bracket Assembly 6 EC1564 1...Wedge 7 PHSM539 1...Screw (M8 x 1,25 x 50 HHCS) 8 PHSM495 8...Screw (M8 x 1,25 x 20 HHCS) 9 PHWM407 8...Lockwasher (M8) 10 PHWM501 4...Washer (M8) 11 PMO710A 1...Stroker Motor 20 EC1530A 1...Crank Assembly 21 PHSM498 3...Screw (M8 x 1,25 x 30 HHCS) (Parts continued on next page) Page 4

S LIST COVERING FIGURE B SECTION I 22 PHWM407 5...Lockwasher (M8) 23 PHWM501 5...Washer (M8) 24 PHSM582 2...Screw (M8 x 1,25 x 50 HHCS) 25 EC1537 1...Left Frame Member 26 EC1536 1...Right Frame Member 27 PHSM498 4...Screw (M8 x 1,25 x 20 HHCS) 28 PHWM407 4...Lockwasher (M8) 29 PHWM501 4...Washer (M8) 30 PHSM595 1...Screw (M10 x 1,5 x 45 HHCS) 31 PHNM443A 1...Nut 32 PES663A 6...Proximity Switch, NC (Pkg. of 1) 33 ML4730A 1...Proximity Switch Cable Adaptor, Stroke Length #1 34 ML4731A 1...Proximity Switch Cable Adaptor, Stroke Length #2 35 ML4732A 1...Proximity Switch Cable Adaptor, Stroke Length #3 36 ML4733A 1...Proximity Switch Cable Adaptor, Stroke Pulley #1 37 ML4734A 1...Proximity Switch Cable Adaptor, Stroke Pulley #2 38 ECA7558 1...Proximity Switch Bracket 39 EC4376 1...Proximity Sensors Support 40 EC1566A 1...Stroker Motor Pulley with 41 PHSM538 1...Setscrew (M6 x 1,0 x 8 FPSS) 42 EC1551A 1...Stroker Pulley 43 PHKM102A 1...Key 44 PHSM495 2...Screw (M8 x 1,25 x 20 HHCS) 45 PHNM401 2...Nut (M8) 46 ECA7559 1...Stroker Pulley Target 47 PDB320A 1...Belt 48 EC1552 1...Wedge 49 PHSM495 1...Screw (M8 x 1,25 x 20 HHCS) 50 PHWM407 1...Lockwasher (M8) 51 EC1553 1...Washer (Special) N/S ML4316 1...P.S.C. Sensor Bracket N/S ML4742 1...PSC Sensor Cable Page 5

SECTION I FIGURE C LOWER STROKER S LIST COVERING FIGURE C 1 EC1512 1...Front Stroker Frame 2 PHSM498 4...Screw (M8 x 1,25 x 30 HHCS) 3 PHWM407 4...Lockwasher (M8) 4 PHWM501 4...Washer (M8) 5 EC1595 1...Front Pillow Block 6 PBR196A 1...Ball Bushing 7 PHM783A 2...Seal (Pkg. of 1) 8 PPPM411 1...Grease Fitting 9 PHSM966 2...Screw (M6 x 1,0 x 25 SHCS) 10 PHWM509 2...Lockwasher (M6) 11 PHWM530 2...Washer (M6) 12 EC1850 1...Stroker Drive Shaft Assembly 13 EC1670 1...Rear Pillow Block (Parts continued on next page) Page 6

SECTION I S LIST COVERING FIGURE C 14 PHSM495 2...Screw (M8 x 1,25 x 20 HHCS) 15 PHWM407 2...Lockwasher (M8) 16 PHWM501 2...Washer (M8) 17 PBR196A 1...Ball Bushing 18 PHM783A 2...Seal (Pkg. of 1) 19 PPPM411 1...Grease Fitting 20 EC1660A 1...Cross Beam Assembly 21 EC1656 2...Yoke Link 22 PBR216A 2...Bearing (Pkg. of 1) 23 PBR214A 1...Roller 24 EC1658 1...Pin 25 EC1657 1...Roller Yoke 26 PSP530A 2...Disc Spring (Pkg. of 2) 27 EC1659 1...Yoke Guide 28 PHNM419 1...Nut (M10) 29 PHNM408 1...Nut, Jam (M10) 30 PHSM495 2...Screw (M8 x 1,25 x 20 HHCS) 31 PHWM407 2...Lockwasher (M8) 32 PHWM501 2...Washer (M8) 33 EC1646 1...Cross Beam Pivot Assembly with 34 PBR214A 1...Roller 35 EC1647 1...Pin 36 PPPM411 1...Grease Fitting 37 EC1648 1...Short Rod 38 EC4769 1...Long Rod 39 PHNM408 2...Nut 40 EC4768 1...Pulley Shaft 41 PHM212A 1...Timing Pulley 42 EC1641 2...Pulley Bracket 43 EC1639A 1...Idler Pulley 44 PHPM535 1...Dowel Pin (8 Dia. x 20 M6) 45 EC1642 1...Tensioning Block 46 PHSM964 1...Screw (M6 x 1,0 x 35 SHCS) 47 PDB206A 1...Timing Belt 48 EC1636 1...Belt Connector 49 EC1637 2...Belt Clamp 50 PHSM962 4...Screw (M3 x 0,5 x 12 SHCS) 51 EC1653 1...Guide Block 52 EC4771 1...Spacer 53 PHM373A 1...Hand Lever 54 PSP527A 1...Disc Spring 55 PHNM419 1...Nut (M10) 56 PHNM408 1...Nut, Jam (M10) Page 7

SECTION I 39 38 41 45 40 44 64 41 65 63 42 65 62 61 66 69 74 75 95 96 97 98 99 100 94 72 31 23 37 34 32 29 25 36 33 16 18 17 26 19 28 30 27 35 10 24 34 2 3 15 11 14 12 13 50 22 21 20 19 6 4 17 18 5 46 47 7 9 8 48 49 55 52 53 93 92 59 60 54 55 68 67 71 70 78 83 84 58 91 56 50 85 86 73 81 77 57 82 76 87 90 88 80 81 89 79 1 51 FIGURE D FEED UNIT S LIST COVERING FIGURE D 1 EC2555 1...Feed Unit Frame 2 PHSM495 4...Screw (M8 x 1,25 x 20 HHCS) 3 PHWM407 4...Lockwasher (M8) 4 EC2571 1...Retraction Stop 5 PHSM548 1...Setscrew (M8 x 1,25 x 16 FPSS) 6 PHSM963 1...Screw (M5 x 0,8 x 20 SHCS) 7 EC2849 1...Damper Spring Bracket 8 PHSM401 2...Screw (M5 x 0,8 x 12 SHCS) 9 PHWM519 2...Washer (M5) 10 PHNM434 2...Insert Nut 11 EC2687 1...Overtravel Stop Bar 12 PHSM402 2...Screw (M5 x 0,8 x 16 SHCS) 13 PHSM597 1...Setscrew (M8 x 1,25 x 25 FPSS) 14 PHNM401 1...Nut (M8) 15 EC2692A 1...Left Acuator Bracket 16 EC2691A 1...Right Actuator Bracket (Parts continued on next page) Page 8

SECTION I S LIST COVERING FIGURE D 17 PHSM405 4...Screw (M6 x 1,0 x 16 SHCS) 18 PHWM509 4...Lockwasher (M6) 19 PHWM518 4...Washer (M6) 20 PHSM495 4...Screw (M8 x 1,25 x 20 HHCS) 21 PHWM407 4...Lockwasher (M8) 22 PHWM501 4...Washer (M8) - EC2500 1...Indicator Assembly includes 23 EC2580 1...Indicator Frame Assembly 24 EC2583 1...Pin 25 EC2578 1...Indicator Finger 26 PBR517 1...Ball 27 PHPM534 1...Dowel Pin 28 PSP222 1...Spring 29 EC2579 1...Spacer 30 PSP327 2...Spring (Pkg. of 2) 31 EC4491 1...Split Bushing 32 PHNM435 2...Nut, Jam (M27 x 3,0) 33 EC2582 1...LVDT N/S EC4467 1...Clip N/S PHNM434 2...Nut, Insert (M5 x 1,8) 34 PHSM963 3...Screw (M5 x 0,8 x 20 SHCS) 35 EC2584 2...Spacer 36 PHNM434 2...Insert Nut 37 PHWM519 1...Washer (M5) 38 PFC 108A 1...Air Cylinder 39 PFC 104A 2...Flow Control Valve (Pkg. of 1) 40 EC2651 1...Actuator Rod End 41 EC2649 2...Counterbalance Pivot Pin 42 EC2648 2...Counterbalance Pivot Block 43 EC2674 1...Spring Support 44 EC2619A 1...Feed Spring 45 EC2673 1...Counterbalance Pivot Pin 46 PHR361 2...Retaining Ring 47 PPPM411 4...Grease Fitting 48 EC2670 1...Right Frame Section 49 EC2684A 1...Main Pivot Pin 50 PHR361 2...Retaining Ring 51 EC2680 1...Main Lever 52 EC2683A 1...Indicator Point 53 PHPM538 1...Dowel Pin (10 Dia. x 30) 54 PBR 216A 1...Roller Bearing 55 EC2686 2...Spacer 56 EC2675 1...Left Frame Section 57 EC4407 1...Disassembly Warning Label 58 EC2610A 1...Spring Link 59 EC2638 2...Control Link 60 PBR212A 4...Roller Bearing (Pkg. of 2) 61 EC2640 1...Right Input Link 62 EC2803 1...Input Link Bracket 63 PHSM405 3...Screw (M6 x 1,0 x 16 SHCS) (Parts continued on next page) Page 9

SECTION I S LIST COVERING FIGURE D 64 PHSM405 2...Screw (M6 x 1,0 x 16 SHCS) 65 PHWM509 2...Lockwasher (M6) 66 PHNM407 1...Nut (M6) 67 EC 2661A 1...Input Link Pivot Pin 68 PHR363 1...Retaining Ring 69 EC2656 1...Input Link Frame 70 EC2659 2...Washer Plate 71 PHSM516 4...Screw (M5 x 0,8 x 25 SHCS) 72 EC2657A 2...Stop Block (Pkg. of 1) with 73 EC2658A 2...Compression Pad (Pkg. of 2) 74 PHSM573 2...Screw (M4 x 0,7 x 20 SHCS) 75 PHWM516 2...Washer (M4) 76 EC2636 1...Linkage Yoke 77 PHM479A 2...Ball Plunger (Pkg. of 1) 78 EC1787A 2...Pad (Pkg. of 1) 79 EC2645 1...Left Input Link 80 EC2678 2...Flexible Coupling 81 PHSM463 4...Setscrew (M6 x 1,0 x 10 CPSS) 82 EC2676 2...Force Adjustment Screw 83 EC2677 2...Stop Collar 84 PHSM588 4...Setscrew (M5 x 0,8 x 6 CPSS) 85 PBR 212A 2...Roller Bearing (Pkg. of 2) 86 EC2637 1...Spring Link Pivot Pin 87 PHWM501 2...Washer (M8) 88 PHRM303 2...Retaining Ring 89 PHSM495 4...Screw (M8 x 1,25 x 20 HHCS) 90 PHWM407 4...Lockwasher (M8) 91 PNP327 1...Warning Label (Used on CE Machines only) 92 EC2652A 2...Control Link Retainer (Pkg. of 1) 93 PHWM406 4...Lockwasher 94 PHSM431 4...Screw (M5 x 0,8 x 10 BHCS) - - - - Ref....Anti-Glaze Unit includes 95a PHSM667 2...Screw 95b CRG868 2...Washer 96 ML4727 1...Prox. Mounting Plate 97a PES669 1...Module Prox. Switch 97b CBL332 1...DC Prox. Cable N/S ML4741 1...CTC Upper Limit 98 PEM983 1...Mounting Collar 99 MLA4859 1...Anti-Glaze Prox. Switch Bracket 100a PHWM528 4...Washer 100b PHNM402 4...Nut Page 10

SECTION I 13 14 5 17 1 12 8 7 6 11 9 15 16 4 3 10 2 FIGURE E FRONT VIEW S LIST COVERING FIGURE E 1 - - - 1...Front Panel (See Fig. L & M) 2 - - - 1...Foot Pedal (See Fig. O) 3 - - - 1...Coolant System (See Fig. Q & R) 4 - - - 1...Control Panel (See Fig. U) 5 - - - 1...Operator Station Enclosure (See Fig. S) 6 EC4408 1...Side Shelf Mat 7 EC4420 1...Oil Tray 8 PHM536 2...Ball Knob 9 ML4470 1...Operator Station Support 10 EC4485 1...Gage Tray Assembly (Optional) 11 EC6510A 1...Side Tray Assembly (Optional) includes 12 EC6519A 1...Side Tray Mat N/S EC6518A 1...Spacer (Pkg. of 2) 13 EC4255A 1...Left Hood Assembly 14 EC4250A 1...Right Hood Assembly N/S PHM484A 2...Latch (Pkg. of 1) 15 EC4291A 1...Spindle Splash Guard 16 PHM788A 1...Knob N/S PHSM966 1...Screw N/S EC4292 1...Spacer 17 EC4325 1...Left Guard Assembly (CE Machines ONLY) N/S EC4335 1...Right Guard Assembly (CE Machines ONLY) Page 11

SECTION I 56 39 38 40 41 37 35 43 42 27 28 12 36 13 34 21 22 18 19 20 17 16 14 15 53 52 55 20 19 24 23 25 26 31 29 30 31 32 33 1 2 3 4 46 45 44 51 50 47 49 54 48 9 11 10 8 5 6 7 FIGURE F EXPAND/RETRACT SYSTEM S LIST COVERING FIGURE F 1 EC2810 1...Cam Assembly (See Fig. J) 2 PHSM966 4...Screw (M6 x 1,0 x 25 SHCS) 3 PHWM518 4...Lockwasher (M6) 4 PHWM509 4...Washer (M6) 5 EC2842A 1...Damper Spring Link 6 PHWM518 1...Washer 7 PHRM308 1...Retaining Ring 8 PSP328A 1...Spring - EC2885 1...Cable Hook Assembly includes 9 EC2948 1...Proximity Switch Bracket 10 PHSM520 2...Screw (M4 x 0,7 x 10 SHCS) 11 PHWM516 2...Washer (M4) 12 PHNM402 2...Nut (M4) (Parts continued on next page) Page 12

SECTION I S LIST COVERING FIGURE F 13 EC2880 1...Cable Hook Assembly 14 EC2906A 1...Cable Assembly 15 PHNM402 1...Nut (M4) 16 EC2874A 1...Cable Spring 17 EC2875 1...Spring Retainer Assembly 18 EC2848 1...Cable Bracket 19 PHWM518 2...Washer (M6) 20 PHNM407 2...Nut (M6) 21 PHSM401 2...Screw (M5 x 0,8 x 12 SHCS) 22 PHWM519 2...Washer (M5) 23 PHNM434 2...Insert Nut 24 EC2957A 1...Counter Balance Spring 25 EC2956A 1...Spring Connector Link 26 EC2894A 1...Link 27 EC2897A 1...Pin with 28 PHRM305 2...Retaining Ring 29 EC2898A 1...TRiCoupling 30 EC2887A 1...Pin with 31 PHRM305 2...Retaining Ring 32 EC2896A 1...Chain 33 PHM475A 2...Chain Connector (Pkg. of 2) 34 EC2890 1...Rod End Assembly 35 PFC109A 1...Air Cylinder 36 PPP439A 1...Elbow 37 PFC104A 1...Flow Control Valve 38 EC2549 1...Retraction Cylinder Bracket 39 EC2892A 1...Retraction Cylinder Pivot Pin 40 PHNM420 1...Nut (M16) 41 PHR363 1...Retaining Ring 42 PHSM495 2...Screw (M8 x 1,25 x 20 HHcs) 43 PHWM407 2...Lockwasher (M8) 44 PEM983 2...Mounting Collar 45 PHWM528 4...Washer (M4) 46 PHNM402 4...Nut (M4) 47 ML4727 2...Proximity Mounting Plate 48 PHSM520 4...Screw (M4 x 0,7 x 10 SHCS) 49 PHWM516 4...Washer (M4) 50 PHWM528 4...Washer (M4) 51 PHNM402 4...Nut (M4) 52 PES669 1...Modular Proximity Switch, NO 53 ML4735 1...Foot Pedal #1 Proximity Cable 54 PES670 1...Modular Proximity Switch, NC 55 ML4736 1...Foot Pedal #2 Proximity Cable 56 MLU2015 1...Cycle Time Control Motor Assembly (See Fig. G) Page 13

SECTION I FIGURE G CYCLE TIME CONTROL MOTOR ASSEMBLY S LIST COVERING FIGURE G MLU2015 Ref....Cycle Time Contrl Motor Assembly includes 1 PMO166 1...DC Gearmotor - Extended Shaft 2 MLA4854 1...Motor Bracket 3 PHW342 4...Flatwasher (#10) 4 PHS614 2...Screw (#10-32 x 1/2 BHCS) 6 PHS683 2...Screw (#10-32 x 5/8 BHCS) 5 MLU2022 1...Torque Arm 7 MLU2011 1...Motor Mounting Plate 8 PHSM1089 2...Screw (M6 x 1,0 x 16 HHCS) 10 PHNM407 2...Nut, Hex (M6 X 1,0) 11 PHSM622 2...Screw (M6 x 1,0 x 12 HHCS) 12 MLU2018 1...Electric Clutch 13 PHSM623 1...Screw (M4 x 0,7 x 8 BHCS) 14 MLU4856 1...Anti-Glaze Drive Gear 15 PHS508 3...Screw (#6-32 x 7/8 SHCS) Page 14

SECTION I FIGURE H CYCLE TIME CONTROL IDLER ASSEMBLY S LIST COVERING FIGURE H - MLU2000 Ref....Cycle Time Control Idler Assembly includes 1 MLU2003 1...Pinion Bracket 2 PBR135 2...Bearing 3 MLU2006 1...Anti-Glaze Pinion Gear 4 MLU2001 1...Anti-Glaze Driven Shaft 5 MLU2002 1...Anti-Glaze Driven Sprocket 6 MLU2009 1...Pinion Support Bracket 7 PHSM490 2...Screw (M4 x 0,7 x 12 SHCS) 8 PHWM517 2...Lockwasher (M4) 9 PHNM402 2...Nut, Hex (M4 x 0,7) Page 15

SECTION I 76 80 78 77 56 84 85 83 49 57 50 44 58 43 52 51 79 65 67 61 42 81 46 48 47 45 55 58 59 60 40 82 76 68 66 64 62 53 54 38 70 69 74 75 72 41 37 11 12 73 63 71 36 34 33 39 35 1 32 31 9 30 15 19 17 18 16 20 21 24 25 22 23 27 26 28 29 13 14 10 86 FIGURE I SPINDLE S LIST COVERING FIGURE I 1 PMO967A 1...Spindle Motor 2 PHSM556 4...Screw 9 PEC127 1...Cord Grip N/S PEM251 1...Rubber Spacer 10 ML2510A 1...Spindle Motor Base 11 PHSM498 4...Screw (M8 x 1,25 x 30 HHCS) 12 PHWM407 4...Lockwasher (M8) 13 PHWM532 4...Washer (M8) 14 EC1564 1...Wedge 15 PHSM539 1...Screw (M8 x 1,25 x 50 HHCS) 16 EC2114A 1...Motor Pulley with 17 PHSM538 1...Setscrew (M6 x 1,0 x 8 FPSS) 18 EC2010A 1...Spindle Assembly 19 PHK112A 1...Key 20 PHSM405 4...Screw (M6 x 1,0 x 16 SHCS) 21 EC2041 1...Spindle Nose Washer 22 EC2040 1...Spindle Nose 23 PHSM551A 8...Setscrew (M8 x 0,75 x 16 FPSS) (Pkg. of 8) 24 PHR116 1...Retaining Ring (Parts continued on next page) Page 16

SECTION I S LIST COVERING FIGURE I 25 EC2046A 1...Drive Plate 26 EC2044 1...Inner Spindle Nose 27 PHSM549 1...Setscrew (M12 x 1,75 x 16 FPSS) 28 PHPM501 1...Dowel Pin (4 Dia. x 12) 29 EC2501A 1...Wedge Hook 30 EC2070A 1...Spindle Pulley with 31 PHSM538 1...Setscrew (M6 x 1,0 x 8 FPSS) 32 PDB340A 1...Belt 33 EC2511A 1...Feed Rod 34 EC2516 1...Cover Plate 35 PHSM520 2...Screw (M4 x 0,7 x 10 SHCS) 36 PBR211A 2...Bearing (Pkg. of 2) 37 EC2512 1...Shoulder Washer 38 PHSM556 1...Screw (M10 x 1,5 x 25 FHCS) 39 EC2532 1...Torque Bracket EC2515 1...Guide Feed Rod Unit includes 40 EC2520 1...Feed Rod Guide Assembly 41 EC2525A 1...Guide Feed Rod Assmebly 42 EC2541 1...Bracket 43 PHSM966 2...Screw (M6 x 1,0 x 25 SHCS) 44 PHWM509 2...Lockwasher (M6) 45 PHWM518 2...Washer (M6) 46 EC2536A 1...Feed Screw 47 EC2538A 1...Feed Screw Gear 48 EC2537 1...Retractor Yoke 49 EC2542 1...Intermediate Shaft 50 PHM122A 1...Gear 51 PBR215 2...Bearing 52 PHM213A 1...Timing Pulley 53 PHSM495 3...Screw (M8 x 1,25 x 20 HHCS) 54 PHWM407 3...Lockwasher (M8) 55 PBR213A 1...Roller 56 EC2693 2...Spacer 57 PHSM599 1...Screw (M6 x 1,0 x 60 SHCS) 58 PHWM518 2...Washer (M6) 59 PHWM509 1...Lockwasher (M6) 60 PHNM407 1...Nut (M6) 61 PDB207A 1...Timing Belt 62 PHM213A 1...Timing Pulley 63 PBR215 1...Bearing 64 EC2799 1...Shaft Support Bracket 65 PHSM607 2...Screw (M6 x 1,0 x 30 SHCS) 66 PHWM509 2...Lockwasher (M6) 67 PHWM518 2...Washer (M6) 68 EC2796 2...Drag Spring Clamp 69 EC2797 1...Drag Spring 70 PHSM402 1...Screw (M5 x 0,8 x 16 SHCS) 71 EC2768 1...Pulley Shaft 72 EC2773A 1...Drag Wheel (Parts continued on next page) Page 17

SECTION I S LIST COVERING FIGURE I 73 EC2772 1...Clamp Collar 74 PHSM538 1...Setscrew (M6 x 1 x 8 FPSS) 75 EC2771 1...Feed Shaft 76 EC2696 2...Feed Control Arm 77 PBR213A 1...Roller 78 PHPM539 1...Dowel Pin (6 Dia. x 24) 79 EC2698 1...Control Arm Spacer 80 PHSM598 3...Screw (M8 x 1,25 x 35 HHCS) 81 PHWM407 3...Lockwasher (M8) 82 PHWM401 3...Nut (M8) 83 EC2697 1...Control Arm Extension 84 PHSM597 1...Setscrew (M8 x 1,25 x 25 FPSS) 85 PHNM401 1...Nut (M8) 86 PHSM556 4...Screw Page 18

SECTION I FIGURE J CAM ASSEMBLY S LIST COVERING FIGURE J EC2810A 1...Cam Assembly includes 1 EC2856 1...Cam Housing 2 PBR218A 2...Bearing (Pkg. of 2) 3 EC2835A 1...Sping Lever Assembly 4 PHSM507 1...Screw (M5 x 0,8 x 30 SHCS) 5 EC2820 1...Damper Lever Assembly 6 EC2823 1...Dog Block 7 PHSM401 2...Screw (M5 x 0,8 x 12 SHCS) 8 EC2834 1...Dog Collar 9 PHSM573 1...Screw (M4 x 0,7 x 20 SHCS) 10 EC2844 1...End Plate 11 PHSM540 3...Screw (M4 x 0,7 x 10 FHCS) 12 EC2858A 1...Camshaft 13 PHRM307 1...Retaining Ring 14 EC2830A 1...Cable Lever Assembly 15 EC2826 1...Dog Block 16 PHSM401 1...Screw (M5 x 0,8 x 12 SHCS) 17 EC2846 1...Housing 18 PBR220A 2...Bearing (Pkg. of 2) 19 PHR362 1...Retaining Ring 20 EC2840A 1...Auto Lever Assembly 21 EC2847 1...Shim Cover 22 EC2871 1...Eccentric Cam 23 EC2826 1...Dog Block 24 PHSM401 1...Screw (M5 x 0,8 x 12 SHCS) 25 PHSM490 3...Screw (M4 x 0,7 x 12 SHCS) Page 19

SECTION I FIGURE K OUTSIDE STROKER S LIST COVERING FIGURE K 1 EC1172 1...Spindle Frame 2 EC1594A 1...Seal 3 EC1822 2...Collar 4 PHSM402 1...Screw (M5 x 0,8 x 16 SHCS) 5 PHSM966 6...Screw (M6 x 1,0 x 25 SHCS) 6 PHWM518 6...Washer (M6) 7 PPPM417A 2...Bulkhead Union (Pkg. of 1) 8 PFC115A 2...Flow Control Valve (Pkg. of 1) 9 PEM695A 1...Female Receptacle 10 PEC139A 1...Clamp 11 PEC140A 1...Plug 12 EC1853 2...Latch Plate 13 EC1858A 1...Front Latch Finger 14 EC1855A 1...Latch Wedge Assembly 15 PSP225A 1...Spring 16 EC1859A 1...Rear Latch Finger 17 PHSM437 2...Screw (M4 x 0,7 x 25 SHCS) 18 PHWM528 2...Lockwasher (M4) 19 EC1817 1...Spacer 20 PHSM507 3...Screw (M5 x 0,8 x 30 SHCS) 21 PHWM406 3...Lockwasher (M5) 22 EC1671 1...Rear Pillow Block 23 EC1850A 1...Stroker Drive Shaft Assembly 24 EC1866 2...Lifter Arm (Parts continued on next page) Page 20

SECTION I S LIST COVERING FIGURE I 25 PBR228A 2...Bushing (Pkg. of 2) 26 PHWM531 3...Washer 27 EC1867 1...Lifter Pivot Block with 28 PHPM548 1...Dowel Pin (36 x 10) 29 PHSM598 2...Screw (M8 x 1,25 x 35 HHCS) 30 PHWM407 2...Lockwasher (M8) 31 PHWM501 2...Washer (M8) 32 EC1871A 1...Roller 33 EC1869 1...Roller Shaft 34 PBR228A 2...Bushing (Pkg. of 2) ` 35 PHSM534 2...Screw (M6 x 1,0 x 20 SHCS) 36 PHWM530 2...Lockwasher (M6) 37 EC1872 1...Lifter Bar 38 PHSM963 4...Screw (M5 x 0,8 x 20 SHCS) 39 PHWM406 4...Lockwasher (M5) 40 EC1861 1...Unlatch Cylinder Base 41 PHSM965 2...Screw (M8 x 1.25 x 20 HHCS) 42 PHWM407 2...Lockwasher (M8) 43 PHSM625 2...Screw (M5 x 0,8 x 50 SHCS) 44 PFC118A 1...Air Cylinder 45 PPP439A 2...Elbow (Pkg. of 1) 46 EC1862 1...Rod End 47 PHNM401 1...Nut, Hex (M8 x 1,25) 48 EC1876A 2...Stop Collar Nut (Pkg. of 1) 49 EC1880A 1...Stroker Extension Tube 50 EC1781 1...Carriage Position Screw 51 EC1890A 1...Bottom Clamp Block Assembly 52 EC1885A 1...Top Clamp Block Assembly 53 PHM494A 1...Hand Lever 54 PHSM966 1...Screw (M6 x 1,0 x 25 SHCS) 55 EC1782 1...Carriage Position Handwheel 56 EC1787A 1...Pad 57 PHSM422 1...Setscrew (M5 x 0,8 x 12 CPSS) 58 PSP228A 1...Wave Spring 59 EC1784 1...Collar 60 EC1788A 1...Bearing/Spring Locator Plate 61 PBR199A 2...Thrust Bearing Washer (Pkg. of 2) 62 PBR197A 1...Center Thrust Bearing Washer 63 PBR198A 2...Thrust Bearing Roller Assembly (Pkg. of 2) 64 PHSM963 3...Screw (M5 x 0,8 x 20 SHCS) 65 EC1786 1...Bearing Locator Plate 66 PHNM437A 1...Bearing Nut 67 MLU1825 1...Stroker Carriage 68 EC1815A 2...Pillow Block Assembly (Pkg. of 1) 69 PHSM966 8...Screw (M6 x 1,0 x 25 SHCS) 70 PHWM509 8...Lockwasher (M6) 71 PHWM518 8...Washer (M6) 72 EC1811 2...Ball Bushing Shaft 73 PFC117A 1...Regulator 74 PPPM423A 1...Elbow Page 21

SECTION I 21 24 79 78 76 77 77 76 73 69 73 72 71 23 71 72 22 74 75 70 67 68 68 66 69 70 64 63 64 65 3 81 81 83 82 82 82 2 31 28 26 25 1 80 84 27 32 29 7 8 9 85 5 6 4 10 20 19 17 18 16 15 14 13 60 61 62 55 52 56 59 53 57 54 58 49 51 50 33 47 48 30 11 41 42 44 45 39 37 43 46 38 40 35 36 34 12 FIGURE L FRONT PANEL (INSIDE) Page 22

SECTION I S LIST COVERING FIGURE L 1 EC4765 1...Front Panel Assembly 1 EC4765CE 1...Front Panel Assembly (CE Machines ONLY) 2 PHSM535 4...Screw (M6 x 1,0 x 12 SHCS) 3 PHWM530 4...Washer (M6 Fender) 4 ML2756 1...Indicator Electrical Enclosure 5 PHSM401 6...Screw (M5 x 0,8 x 12 SHCS) 6 PHWM529 4...Washer (M5) 7 PED1057A 1...LVDT Circuit Board 8 PEM701 2...12 Pole Plug 9 PES379A 2...Contact Block (Pkg. of 1) 10 PEC179 3...Strain Relief Connector with N/S PEM252 1...Sealing "O" Ring w/ Retainer N/S PEM302 1...Lock Nut 11 EC2920A 1...Damper Assembly includes 12 EC2925 1...Cylinder Cap 13 CRG939A 1..."O" Ring 14 EC2927 1...Damper Weight 15 EC2926 1...Spacer Tube 16 KKN912 1...Cylinder 17 KKN905 1...Piston 18 EC2935A 1...Piston Pivot 19 EC2936 1...Piston Nut 20 EC2937A 1...Metering Screw 21 EC2939 1...Spring Cup 22 PSP223 1...Spring 23 EC2930 1...Stop Collar 24 PHSM421 1...Setscrew (M4 x 0,7 x 5 FPSS) 25 PHSM421 2...Setscrew (M4 x 0,7 x 5 FPSS) 26 EC2931 1...Feed Regulator Dial 27 PHSM421 2...Setscrew (M4 x 0,7 x 5 FPSS) 28 EC2991A 1...Coiled Tape 29 EC2914 1...Feed Regulator Screw 30 EC2913 1...Standoff 31 PHSM424 2...Screw (M6 x 1,0 x 20 HHCS) 32 PHWM518 2...Washer (M6) 33 PHRM308 1...Retaining Ring 34 EC2782 1...Rack Support 35 PHSM963 2...Screw (M5 x 0,8 x 20 SHCS) 36 PHWM519 2...Washer (M5) 37 PFC113A 1...Valve 38 PFC114A 1...Valve Adapter 39 PPPM422 5...Elbow 40 PPP479A 1...Union "Y" Fitting 41 EC2776 1...Link 42 EC2774 1...Clevis 43 PHPM514 2...Spring Pin 44 EC2777 1...Compensator Screw 45 PHNM408 4...Nut, Jam (M10) (Parts continued on next page) Page 23

SECTION I S LIST COVERING FIGURE L 46 PHR363 1...Retaining Ring 47 EC2766 1...Feed Dial Shaft 48 EC2792 1...Compensator Rack 49 EC2787 1...Spring Opening Plate 50 EC2788 2...Standoff 51 PHSM574 2...Screw (M4 x 0,7 x 30 SHCS) 52 EC2781 1...Compensator Gear 53 EC2783 1...Spring Housing 54 PHSM573 2...Screw (M4 x 0,7 x 20 SHCS) 55 EC2784A 1...Torsion Spring 56 EC2786 1...Clutch Housing 57 PBR223A 1...Roller Clutch 58 EC2772 1...Clamp Collar 59 PHSM538 1...Setscrew (M6 x 1,0 x 8 FPSS) 60 EC2771 1...Feed Shaft 61 EC2791 1...Rack Rod End 62 PHSM613 2...Screw (M4 x 0,7 x 16 SHCS) 63 PFC110A 1...Air Cylinder 64 PEC116A 2...Flow Control Valve (Pkg. of 1) 65 PHSM401 2...Screw (M5 x 0,8 x 12 SHCS) 66 EC2731 1...Finishing Force Dial N/S EC2736 1...Finishing Dial Face 67 EC2732 1...Roughing Force Dial N/S EC2737 1...Roughing Dial Face 68 EC2727 2...Feed Force Input Shaft 69 EC2728 2...Output Gear (Pkg. of 1) 70 PHSM550 6...Screw (M3 x 0,5 x 8 SHCS) 71 PHM121 2...Pinion (Pkg. of 1) 72 EC2735A 2...Coupling Assembly (Pkg. of 1) 73 PHSM588 2...Setscrew (M5 x 0,8 x 6 CPSS) 74 EC2739 1...Gear Cluster Bracket 75 PHM120 2...Gear (Pkg. of 1) 76 PHM119 2...Gear (Pkg. of 1) 77 EC2741 2...Intermediate Gear Shaft 78 PHSM401 1...Screw (M5 x 0,8 x 12 SHCS) 79 PHWM529 1...Washer (M5) 80 PES659 2...Key Switch, 2 Position (CE Machines w/spindle Reverse) 81 PES644 2...Contact, N.O., Screw Term. (CE Machines w/spindle Reverse) 82 PEM961 3...Mounting Collar (CE Machines w/spindle Reverse) 83 PEM671 1...Green LED Light Block (CE Machines w/spindle Reverse) 84 PEM1066 1...Green Pilot Light Head (CE Machines w/spindle Reverse) 85 MLU2000 1...Cycle Time Control Idler Assembly (See Fig. H) Page 24

PATENTED R L = 0.95 X A L = 0.95 X B ML-2996CE / IL-1148 SECTION I ML-5000 PRECISION HONING MACHINE 14 17 16 5 7 6 4 3 1 8 13 X 9 AK AN-600 AL BAL JAK JK BL BLR L D2 K KR LR P20 P28 R28 Y YY A B A B A 2 X 10 11 3 FIGURE M FRONT PANEL (OUTSIDE) S LIST COVERING FIGURE M 12 X0 mm 170 160 140 120 100 90 80 70 60 50 45 40 35 30 25 20 15 10 6 L IN 6.6 6.0 5.0 4.0 3.0 2.5 2.0 1.5 1.0.5.4.3.25 19 18 20 ( A > B ) ( B > A ) L L A A B B 21 22 15 1 MLU2724EN 1...Front Panel Overlay (English Version) 1 MLU2724CE 1...Front Panel Overlay (CE Icon Version) 2 PFC112A 1...Push Button 3 EC2918 2...Knob N/S PHSM609 2...Setscrew (M4 x 0,7 x 6 CPSS) 4 EC2763 1...Feed Dial Disc 5 EC2764 1...Feed Dial Face (Inch) 5 EC2764M 1...Feed Dial Face (Metric) 6 EC2761 1...Feed Knob 7 EC2762 1...Knob Handle 8 EC2769A 1...Index Piece 9 PHSM608 2...Screw (M3 x 0,5 x 12 FHCS) 10 ML2751A 1...Honing Indicator (Inch) 10 ML2751MA 1...Honing Indicator (Metric) N/S ML2754A 1...Gasket (For Indicator) 11 PES378A 1...4Position Selector Switch 12 EC2726 2...Force Knob 13 EC3782 1...Sparkout LED Cable 14 PED32 1...Potentiometer Operator N/S PES3786 1...Sparkout Potentiometer Cable includes N/S PES456A 1...Potentiometer 15 MLU2996EN 1...Stroker Overlay (English Version) 15 MLU2996CE 1...Stroker Overlay (CE Icon Version) 16 EC2994 1...Stroke Length Handwheel N/S PHSM609 1...Setscrew (M4 x 0,7 x 6 CPSS) 17 EC2762 1...Knob Handle 18 EC2992A 1...Index Piece 19 PHSM604 2...Screw (M3 x 0,5 x 12 FHCS) N/S PHNM400 2...Nut (M3) 20 PHM373 1...Hand Lever 21 PNP331 1...Label, Safety Glasses 22 - - - 2...Key Switch, 2 Position (CE Machines w/spindle Reverse) Page 25

SECTION I 55 56 36 54 47 52 53 38 39 35 37 41 40 1 57 46 45 6 5 50 49 4 3 2 11 10 17 7 9 8 16 23 20 22 19 21 18 26 28 27 31 24 30 25 29 31 42 33 43 34 44 32 41 51 12 13 14 15 FIGURE N UNIVERSAL HONING FIXTURE S LIST COVERING FIGURE N - EC6100A 1...Universal Honing Fixture includes 1 EC6117A 1...Gate 2 EC6126A 1...Right Finger 3 EC6127A 1...Left Finger 4 EC6132A 4...Spacer (Pkg. of 2) 5 KKN613C 2...Carbide Tip (Pkg. of 2) with 6 PHSM616 1...Screw (M4 x 0,7 x 8 FHCS) 7 EC6133A 2...Roller Spacer (Pkg. of 1) 8 PBR224A 2...Bearing (Pkg. of 1) 9 PHSM964 2...Screw (M6 x 1,0 x 35 SHCS) 10 PHWM509 2...Lockwasher (M6) 11 PSP330A 1...Spring 12 EC6131A 1...Finger Frame 13 PHSM534 4...Screw (M6 x 1,0 x 20 SHCS) 14 EC6134A 2...Knurled Nut (Pkg. of 2) 15 PHSM615A 2...Screw (M6 x 1,0 x 40 SHCS) (Pkg. of 2) 16 EC6141A 1...Block 17 EC6142A 1...Pin 18 PHSM534 1...Screw (M6 x 1,0 x 20 SHCS) 19 PHWM509 1...Lockwasher (M6) (Parts continued on next page) Page 26

S LIST COVERING FIGURE N SECTION I 20 PHWM534A 1...Washer (Special) 21 EC6143A 1...Arm 22 EC1767A 1...Cam Lever 23 PHM372A 1...Knob 24 PBR224A 1...Bearing 25 PHSM405 1...Screw (M6 x 1,0 x 16 SHCS) 26 PHWM518 1...Washer (M6) 27 PHRM308 1...Retaining Ring 28 EC6139A 1...Spacer 29 EC6136A 1...Lever 30 EC6137A 1...Bushing 31 EC6138A 2...Washer (Special) (Pkg. of 1) 32 PHSM425 1...Screw (M6 x 1,0 x 40 SHCS) 33 PHWM509 1...Lockwasher (M6) 34 PHWM518 1...Washer (M6) 35 EC6105A 2...Fixture Support Bar (Pkg. of 1) 36 PHSM661 6...Screw 37 EC6108A 1...Torque Finger Base 38 EC6109A 1...Torque Finger 39 PHSM607 1...Screw (M6 x 1,0 x 30 SHCS) 40 PHSM405 2...Screw (M6 x 1,0 x 16 SHCS) 41 EC6122A 2...Stop Collar (Pkg. of 1) 42 PHSM607 2...Screw (M6 x 1,0 x 30 SHCS) 43 EC6118A 1...Latch Block 44 PHSM512 2...Screw (M6 x 1,0 x 20 SHCS) 45 EC6119A 1...Gate Latch 46 PHPM546A 1...Groove Pin 47 EC6116A 1...Gate Hinge 48 PBR225A 2...Bushing (Pkg. of 2) 49 PHSM534 2...Screw (M6 x 1 x 20 SHCS) 50 PHWM518 2...Washer (M6) 51 EC6111A 2...Stop Collar (Pkg. of 1) 52 PHSM607 2...Screw (M6 x 1,0 x 30 SHCS) 53 EC6121A 1...Stop Pin 54 EC6123A 4...Finger (Pkg. of 1) 55 KKN613A 4...Carbide Tip (Pkg. of 1) 56 PHSM616 4...Screw (M4 x 0,7 x 8 FHCS) 57 PHSM966 4...Screw Page 27

SECTION I 25 28 27 24 20 19 22 34 26 32 10 13 33 3 23 18 9 8 4 20 14 21 16 12 11 6 9 7 16 15 1 17 2 2 5 31 29 30 FIGURE O FOOT PEDAL S LIST COVERING FIGURE O 1 EC2980 1...Foot Pedal Base Assembly 2 EC2984 2...Pedal Pivot Block 3 PHSM535 4...Screw (M6 x 1,0 x 12 SHCS) 4 PHWM518 4...Washer (M6) 5 EC2985A 1...Pedal Assembly 6 EC2973 1...Cable End 7 PHNM402 1...Nut (M4) 8 EC2885 1...Cable Assembly 9 PHNM407 2...Nut (M6) 10 EC2979 1...Conduit Bracket 11 PHSM535 2...Screw (M6 x 1,0 x 12 SHCS) 12 PHWM518 2...Washer (M6) 13 PHNM436 2...Insert Nut (M6) 14 EC2974 1...Pedal Stop 15 PHSM405 2...Screw (M6 x 1,0 x 16 SHCS) 16 PHWM518 4...Washer (M6) 17 PHNM407 2...Nut (M6) 18 EC2970 1...Latch Block Assembly 19 PHSM964 2...Screw (M6 x 1,0 x 35 SHCS) 20 PHWM518 4...Washer (M6) 21 PHNM407 2...Nut (M6) 22 EC4422 1...Safety Latch with 23 PHWM518 1...Washer (M6) 24 PHRM308 1...Retaining Ring 25 EC2978 1...Foot Pedal Cover 26 PHSM510 4...Screw (M6 x 1,0 x 12 BHCS) 27 PHWM518 4...Washer (M6) N/S PHNM436 2...Insert Nut (M6) 28 EC4406 1...Caution Label 29 EC4490 1...Safety Cover Assembly 30 EC 2966A 2...Bumper Strip (Pkg. of 2) 31 PNP326A 1...Foot Pedal Label (Used on CE Machines only) 32 EC121A 1...Conduit with 33 PEC104A 2...Conduit Fitting (Pkg. of 2) 34 PHM538 1...Hand Retractable Spring Plunger Page 28

SECTION I 4 6 10 3 5 7 9 11 2 8 1 12 FIGURE P RUNOUT INDICATOR & TORQUE BAR S LIST COVERING FIGURE P - EC6550A 1...Runout Indicator Assembly includes 1 - - - 1...Runout Indicator (Not Sold Separately) 2 EC6551 1...Indicator Clamp 3 CGM4007 1...Pivot Rod 4 CGM4009A 1...Cone 5 EC6552 1...Cam 6 PHPM447 1...Spring Pin 7 PHSM614 1...Shoulder Screw (8 Dia. x 25 w/ M6 Thd.) 8 EC6031A 1...Manual Torque Bar 9 CGM4241A 1...Torque Bar Base 10 PHSM619 2...Screw 11 PHWM518 2...Washer (M6) 12 ML6190 1...Torque Arm Page 29

SECTION I 39 43 38 40 50 49 26 54 51 53 52 52 55 56 57 58 53 22 59 44 42 47 48 88 38 22 46 45 41 67 58 60 69 68 37 66 70 71 72 87 73 75 79 78 74 61 65 77 63 64 62 81 76 84 97 82 23 24 31 35 22 26 36 34 32 28 33 22 89 14 15 90 27 26 25 86 1 2 85 80 83 96 95 91 22 92 94 93 21 30 91 12 11 16 19 18 20 17 29 8 10 8 9 4 6 5 13 7 3 FIGURE Q COOLANT SYSTEM S LIST COVERING FIGURE Q Page 30 - ML3495DS 1...Coolant System (230 Volt, 60 Hz) includes 1 EC4750 1...Reservoir assembly 2 EC3844 2...Corner Plug 3 EC3981 2...Caster Cover with N/S PHSM432 8...Screw N/S EC3980 2...Caster Extension N/S PHSM495 8...Screw (M8 x 1,25 x 20 HHCS) N/S PHWM501 8...Washer (M8) 4 PHM449 4...Swivel Caster 5 PHSM441 12...Screw (M8 x 1,25 x 12 BHCS) 6 PHWM501 8...Washer (M8) 7 PHSM673 4...Screw (M8 x 1,25 x 40 BHCS) 8 PHWM501 16...Washer (M8) 9 PHWM407 8...Washer 10 PHNM407 8...Nut 11 EC3813 2...Bumper Bracket 12 CK578 2...Rubber Bumper N/S PHSM674 2...Screw (M5 x 0,8 x 20 LHCS) (Parts continued on next page)

S LIST COVERING FIGURE Q N/S PHNM441 2...Nut (M5) 13 PPP130 1...Pipe Plug 14 PNP101 1...Electrical Specification Plate 15 KN231 4...Drive Screw 16 EC3496 1...Pump Base 17 PF224 4...Vibration Isolator 18 CH376 4...Spacer 19 KN172 8...Nut (5/16 x 18) 20 KN568 8...Washer (5/16) 21 EC3498 1...Motorized Moyno Pump includes N/S EC34971 1...Stator N/S EC34972 1...Joint N/S EC34973 1...Seal N/S EC34974 1...Abrasion Resistant Seal N/S PHSM515 4...Screw (M8 x 1,25 x 25 SHCS) N/S PHWM501 4...Washer (M8) N/S PHWM407 4...Washer (M8) N/S PHNM401 4...Nut (M8) 22 PPPM446 6...Elbow 23 PPPM544 1...Hose Assembly 24 PPPM434 1...Hose Assembly 25 EC3480 1...Pressure Relief Valve 26 PPPM416 4...Nipple 27 PPPM435 2...Hose Assembly 28 PPPM419 1...Intake Hose Assembly 29 PF317 1...Intake Strainer 30 PPP461 1...Hose Clamp 31 EC3476 2...Tray Retainer 32 PHSM495 2...Screw (M8 x 1,25 x 20 HHCS) 33 PHWM407 2...Washer (M8) 34 PHWM501 2...Lock washer (M8) 35 PPPM425 1...Bulkhead Union N/S PHW328 1...Washer N/S KN370 1...Washer 36 PPPM514 1...Flexible Tubing 37 EC3440 1...Filter Canister N/S PPPM414 1...Bushing 38 PF246 2...Drain Valve 39 PF243 1...Cover 40 PF244 1...Gasket N/S PF247 1...Spring Hold Down 41 PF1054 1...Filter Element (5 Micron) (Pkg of 4) 41 PF1104 1...Filter Element (10 Micron) (Pkg of 4) 42 EC3620 1...Clamp Assembly 43 EC3625 1...Clamp Yoke Assembly 44 EC3630 1...Tee Handle Assembly 45 PHSM598 1...Screw (M8 x 1,25 x 35 HHCS) 46 PHWM407 1...Lock Washer (M8) 47 PF162 1...Mounting Bracket, Front Half 48 PHM494 1...Hand Lever N/S PHWM518 3...Washer (M6) N/S PHNM453 1...Nut (M6) N/S PHSM534 2...Screw (M6 x 1,0 x 20 SHCS) N/S PHWM509 3...Lock Washer (M6) N/S PHNM407 2...Nut (M6) 49 EC3486 1...Output Connection Block 50 PHS1061 2...Screw (1/4 x 20UNC x ½ HHCS) 51 PPP533 1...Relief Valve 52 PPP161 2...Reducer Bushing SECTION I (Parts continued on next page) Page 31

SECTION I S LIST COVERING FIGURE Q 53 MB2368 2...Hose Barb 54 79710 *...Tubing (1/2 I.D. x 11/16 O.D. Tygon) 55 PFC165 1...Pneumatic Valve 56 PPPM404 1...Male Connector 57 78156 *...Tubing (5.32 O.D. Nylon, Natural Color) 58 PHM558 2...Hose Clamp 59 79717 *...Tubing (1/2 I.D. x 11/16 O.D. Tygon) 60 PHM790 2...LocLine Elbow 61 PHM791 5...LocLine Shut Off Valve 62 PHM792 3...LocLine Tee 63 PHSM613 2...Screw (M4 x 0,7 x 12 SHCS) 64 PHWM516 2...Washer (M4) 65 79714 *...Tubing (3/8 I.D. x ½ O.D. Tygon) 66 EC3817 4...Coolant Nozzel Base 67 PHSM964 4...Screw 68 PHM788 4...Knob 69 PHM789 4...Adapter 70 PHM530 4...Check Valve 71 PHM403 *...LocLine Hose 72 PHM435 2...Nozzle, 1/8 Black N/S PHM483 2...Nozzle, ¼ Orange 73 EC3838 2...Splash Gate Bumper 74 EC3833 2...Retaining Nut 75 EC3831 2...Spring Retaining Nut N/S PHSM506 4...Screw (M5 x 0,8 x 8 SHCS) 76 EC3835 1...Splash Gate Assembly 77 EC3834 1...Splash Gate Pivot 78 EC3842 1...Right Torsion Spring N/S EC3843 1...Left Torsion Spring 79 PHRM303 2...Retaining Ring N/S AG275 4...Washer 80 EC4745 1...Drip Tray Assembly 81 EC4370 1...Left Hand Rest (w/o Light Curtain) N/S PHWM518 8...Washer N/S PHWM509 8...Washer N/S PHNM407 8...Nut 82 EC4424 4...Hand Rest Strip 83 EC4343 2...Hand Rest Gasket 84 EC3811 1...Drip Tray Liner 85 EC3741 2...Nut Plate 86 PHSM495 4...Screw (M8 x 1,25 x 20 HHCS) 87 EC3680 1...Reservoir Cover Assembly 88 EC3812 1...Reservoir Liner 89 EC3477 1...Hose Clip 90 EC3470 1...Sediment Tray Assembly 91 PEC220 2...Strain Relief Connector N/S PEM252 2...Sealing O-Ring w/retainer N/S PHN125 2...Locknut 92 EC3321 1...Cart Motor Cable 93 PEM981 1...Housing N/S PEM461 1...10 Position Male Insert 94 PPP130 1...Plug 95 PHSM438 4...Screw (M5 x 0,8 x 12 STS) 96 EC4305 1...Right Hand Rest (w/o Light Curtain) 97 EC4307 2...Pushbutton Cover N/S EC4710 2...Pushbutton Cap N/S PES654 2...Pushbutton N/S PNP476 1...Sunburst Logo N/S PNP477 1...Sunnen Name Logo Page 32 * Sold by the foot only.