OPERATION & MAINTENANCE

MANUAL

for

55 TON VAN DORN PICKER MANUAL NUMBER 10-477

This manual has been supplied with the following Comptrol Sprue Picker:
Model Number: 90-129 and 90-132

9505 Midwest Avenue • Cleveland, OH 44125

Phone: 216-587-5200 Fax: 216-587-5210
Web Site: www.comptrolinc.com
MODEL NUMBER: 90-129 and 90-132
2
 Comptrol is a leading designer and manufacturer of standard products and
custom designed industrial automation systems.

Since our inception, the key to our success and growth has been our
commitment to provide our customers with a reliable source for the technology,
technical support, and design and build services they need to meet their project
objectives and application requirements. Over time, Comptrol has done more than just
expand our product lines. We also expanded our engineering, manufacturing and
integration services to keep pace with the technology and the growing demand for
packaged automation turnkey systems and standard equipment for a number of
industries including induction heating.

Whether you need a rugged and reliable standard piece of equipment such as
our Sprue Robot, a complete assembly or a total system package, you can rely on
Comptrol to deliver…

• Quality, reliable solutions

• Experienced application assistance
• Complete engineering and technical support
• Manufacturing and integration services
• Industry leading post sale service and support

Our in-house capability to assist customers with both the mechanical and
electrical aspects of a project, is what sets us apart from other suppliers.

3
 TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................................... 6
1.1 MACHINE OVERVIEW .............................................................................................................................. 7
2. SAFETY ................................................................................................................................................... 8
2.1 SAFETY DEPENDS ON YOU! ................................................................................................................... 8
2.2 MACHINE USAGE ................................................................................................................................. 8
2.3 PRECAUTIONS ..................................................................................................................................... 8
2.4 SAFETY SYMBOLS ................................................................................................................................. 9
3. SPECIFICATIONS ................................................................................................................................. 10

4. INSTALLATION ................................................................................................................................... 11
4.1 GENERAL REQUIREMENTS................................................................................................................... 11
4.2 PICKER MOUNTING ............................................................................................................................. 11
4.3 MAIN POWER AND CONTROL CONNECTIONS ........................................................................................ 12
4.4 CHECK ALL W IRE CONNECTIONS ......................................................................................................... 12
4.5 CONNECTION OF PLANT AIR ................................................................................................................ 13
4.6 START UP CHECK LIST........................................................................................................................ 14
5. MAINTENANCE ..................................................................................................................................... 15
5.1 LOCK-OUT TAG .................................................................................................................................. 15
5.2 MECHANICAL MAINTENANCE................................................................................................................ 15
5.3 PERIODIC MAINTENANCE REQUIREMENTS ............................................................................................ 16
5.4 LUBRICATION ...................................................................................................................................... 16
6. RECOMMENDED SPARE / WEAR PARTS ........................................................................................... 17
6.1 MECHANICAL RECOMMENDED SPARE / W EAR PARTS ........................................................................... 17
“X” Axis Rack Assembly ..................................................................................................................... 17
“Y” Axis Vertical Drive Belt Assembly ................................................................................................. 17
“A” Axis Rotate Assembly .......................................................................................................... 17
Base Assembly .......................................................................................................................... 18
Gripper Rotate Assembly.................................................................................................................... 18
Gripper Jaw Assembly ........................................................................................................................ 18
Pneumatic Diagram -No Recommended Spare Parts Required. ...................................................... 18
Enclosure Mounting Bracket Assembly -No Recommended Spare Parts Required. ......................... 18
6.2 ELECTRICAL RECOMMENDED SPARE / W EAR PARTS ............................................................................ 19
Electrical 59-3056-55 .......................................................................................................................... 19
7. APPENDIX ............................................................................................................................................. 20
FIGURE 1 PICKER ASSEMBLY ................................................................................................................... 21
FIGURE 2 PICKER ASSEMBLY LIFTING EYE LOCATIONS ............................................................................... 22
FIGURE 3 PICKER SYSTEM PNEUMATIC CONNECTION POINT ....................................................................... 23
FIGURE 4 MOUNTING HOLE LOCATIONS OF FIXED PLATEN .......................................................................... 24
FIGURE 5 PICKER ASSEMBLY MOUNTING LOCATION ................................................................................... 25
FIGURE 6 “Y” AXIS PROFILE RAIL LOCATION AND BASE UNIT PROFILE RAIL LOCATIONS ................................. 26
FIGURE 7 “A” AXIS PILLOW BLOCK BEARING LOCATIONS ............................................................................ 27
FIGURE 8 “X” AXIS RACK SWITCH LOCATIONS............................................................................................ 28
FIGURE 9 “Y” AXIS BELT DRIVE SWITCH LOCATIONS ................................................................................... 29
FIGURE 10 GRIPPER ROTATE SWITCH LOCATIONS ...................................................................................... 30
FIGURE 11 GRIPPER JAW SWITCH LOCATIONS AND SET UP PROCEDURE ...................................................... 31
FIGURE 12 “A” AXIS ROTATE SWITCH LOCATIONS, SPEED CONTROLS, AND SHOCK ABSORBERS .................... 32
FIGURE 13 BASE ASSEMBLY SWITCH AND SPEED CONTROL LOCATIONS ....................................................... 33
7.2 MECHANICAL DRAWINGS LIST.............................................................................................................. 34
7.3 ELECTRICAL DRAWINGS LIST ................................................................................................................ 34
7.4 MECHANICAL SUB-ASSEMBLY BOM’S .................................................................................................. 34
4
 X-Axis Rack Assembly BOM 63-1265-1 (retrofit) ................................................................................ 35
Y-Axis Vertical Belt Drive Assembly BOM 63-1265-2 (retrofit)............................................................ 37
A-Axis Rotate Assembly 63-1265-3 (retrofit) ....................................................................................... 40
Base Assembly BOM 63-1265-4 (retrofit)........................................................................................... 44
Gripper Rotate Assembly BOM 63-1265-5 (retrofit) ............................................................................ 46
Gripper Jaw Assembly 63-1265-6 (retrofit).......................................................................................... 48
Enclosure Mounting Bracket Assembly 63-1265-8 (retrofit) ................................................................ 50
X-axis Rack Assembly 63-1268-1 (new).............................................................................................. 51
Y-Axis Vertical Belt Drive Assembly BOM refer to 63-1265-2 (retrofit) .............................................. 52
A-Axis Rotate Assembly 63-1268-3 (new).......................................................................................... 53
Base Assembly 63-1268-4 (new)........................................................................................................ 57
Gripper Rotate Assembly BOM refer to 63-1265-5 (new) ................................................................... 58
Gripper Jaw Assembly refer to 63-1265-6 (new) ................................................................................. 58
Enclosure Mounting Bracket Assembly refer to 63-1265-8 (retrofit) ................................................... 58
7.5 ELECTRICAL BOM ...................................................................................................................... 59
Electrical Components ......................................................................................................................... 59

The information contained in this document is subject to change without notice.

5
1. INTRODUCTION
How to Use This Manual
Thank you for purchasing a Sprue Picker. This reference manual is designed to guide and
assist you through the installation and operation of your Sprue Picker. To ensure that you have
information available to keep your Picker up and running, this manual provides maintenance
requirements, troubleshooting information, and a recommended spare parts list. Since you are
reading this, you are already aware of the importance of familiarizing yourself with how the
Picker is to be installed, operated, and maintained. Comptrol Incorporated strongly
recommends that before you install your Picker, you read this manual until you are thoroughly
familiar with the installation and operation of the Picker.

How to Contact Us
Although this manual contains the information you will need to install and operate your Picker,
you may have additional questions. If you need assistance, call Comptrol Incorporated
technical support at 1-800-743-1952.

Warranty and Limitations of Liability

Comptrol Incorporated warrants to the original buyer that the Sprue Picker will be free from
defect in material and workmanship for one (1) calendar year from the original date of shipment
from Comptrol Incorporated to the original buyer. Comptrol Incorporated' s only obligation with
respect to its warranty of the Sprue Picker, and the sole and exclusive remedy under this
warranty is limited to replacement or repair, at the option of Comptrol Incorporated, of the Picker
warranted, f.o.b. Cleveland, Ohio. In no event will Comptrol Incorporated be liable for incidental,
consequential, or special damages, or for transportation, installation, adjustment or other
expenses that may arise in connection with the Sprue Picker. NOTWITHSTANDING THE
FOREGOING WARRANTY AND REMEDIES, COMPTROL INCORPORATED WILL HAVE NO
WARRANTY OBLIGATION IF THE SPRUE PICKER IS NOT IN THE POSSESSION OF THE
ORIGINAL PURCHASER OR IF THE SPRUE PICKER BECOMES DEFECTIVE IN WHOLE OR
IN PART AS A RESULT OF MISUSE, IMPROPER INSTALLATION, REPAIRS NOT MADE,
REPAIRS NOT PROPERLY MADE, ALTERATION, NEGLECT, ACCIDENT, INUNDATION,
FIRE, OR OPERATION OUTSIDE PUBLISHED MAXIMUM RATINGS OF THE PICKER.
COMPTROL INCORPORATED DISCLAIMS ALL OTHER EXPRESS WARRANTIES,
STATUTORY WARRANTIES AND IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED
TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR USE OR PURPOSE.

Disassembly or modification of the Sprue Picker, except in strict compliance with the procedures
contained in this manual, and operating the Sprue Picker at speeds or loads that exceed Comptrol
Incorporated published specifications will void all warranties and may cause harm to personnel and/or the
Picker. Please call Comptrol Incorporated at 1-800-743-1952 if you have questions regarding speeds
and/or acceptable loads for your application.

All protective covers AND ELECTRICAL SAFETY DEVICES must be installed AND OPERATIONAL
during operation of this equipment.

You should understand that by your installation and use of the Sprue Picker, you agree
that the liability of Comptrol Incorporated for any claim of any kind for loss or damage
arising out of, connected with or resulting from the Sprue Picker, the design,
manufacture, sale, delivery, resale, inspection, repair, operation or use of the Sprue
Picker will in no event exceed price paid for the Picker and will terminate one (1) year
after the date of the shipment of the Picker.

6
 1.1 Machine Overview

The Sprue Picker unit is made up of several units and systems as described below and shown in Fig. 1.

NEW RETROFIT
1. “X” Axis Rack Assembly……………… Comptrol Drawing No. 63-1268-1 63-1265-1
2. “Y” Axis Vertical Drive Belt Assembly Comptrol Drawing No. 63-1265-2 63-1265-2
3. “A” Axis Rotate Assembly……………… Comptrol Drawing No. 63-1268-3 63-1265-3
4. Base Assembly……………………………Comptrol Drawing No. 63-1268-4 63-1265-4
5. Gripper Rotate Assembly……………… Comptrol Drawing No. 63-1265-5 63-1265-5
6. Gripper Jaw Assembly………………… Comptrol Drawing No. 63-1265-6 63-1265-6
7. Pneumatic System……………………… Comptrol Drawing No. 63-1268-7 63-1265-7
8. Electrical Controls System……………… Comptrol Drawing No. 59-3056-55 59-3056-55
9. Enclosure Mounting Bracket Assembly Comptrol Drawing No. 63-1265-8 63-1265-8

This system is designed to remove the scrap sprue from the injection-molding machine after the product
has been detached from the sprue. The picker deposits the scrap sprue into a customer supplied sprue
grinder for reprocessing.

5 8

4
6

6
2
7 not shown
9 not shown

7
2. SAFETY

2.1 Safety Depends on You!

The Sprue Picker System is designed and built with safety in mind. However, proper installation and
thoughtful operation on your part can increase your overall safety. DO NOT install, operate, or repair
the Sprue Picker System without reading this manual and the safety precautions contained
throughout it. In addition, and most importantly, think before you act and be careful.

Before installing, operating, or performing service on your Sprue Picker System it is extremely important
that you read this manual very thoroughly. To ensure that your system will deliver reliable, trouble-free,
and safe operation please heed the cautions and warnings presented in this manual.

2.2 Machine Usage

This machine is designed to remove sprues from injecting molding machine only. This machine is
designed to operate at a specified pneumatic pressure, travel rate of speed, part weight, ETC.
Operation of this machine beyond what is specified in this manual may cause equipment failure and/or
personal injury and would void any specified warranty.

See sections 3 for installation and machine settings.

2.3 Precautions

The following precautions must be taken by you to ensure safe installation and operation of your Sprue
Picker System, and to properly service and maintain the system. More specific precautions are included
in appropriate sections of this manual. As you read this manual, you should pay particular attention to all
cautions and warnings.

• Only qualified personnel who are thoroughly familiar with this manual should attempt
to install, operate, and service the Sprue Picker System.

• Dangerous voltages, currents, temperatures, and energy levels exist throughout the system.
Be certain that power has been removed for a minimum of five (5) minutes before servicing
the system. Caution should be exercised at all times when working with the picker system. It
is essential that proper electrical practices and applicable electrical codes be strictly followed
at all times.

• The Sprue Picker System contains motors that can develop high speed, high torque, and
high temperatures. Use extreme caution when working with or near the equipment. Serious
injury or death can result from improper operation or adjustments. Only qualified individuals
with proper training should attempt to install, operate, and service the Sprue Picker System.

• When operating the Sprue Picker System, all appropriate federal, state, and local electrical
and occupational safety codes for the installation, operation, and service of the system must
be strictly followed.

• NEVER wire, disassemble, or attempt to repair the system while powered! Serious injury,
death, or damage to the Sprue Picker System may result.

• The Sprue Picker System is an automated system and it can make sudden and unexpected
movements while it is under power. Use extreme caution when working around it. Only
properly trained individuals who are thoroughly familiar with this Manual should attempt to
operate the Sprue Picker System.

8
2.4 Safety Symbols
Please review the following warning symbols. These symbols are used throughout this manual for your
safety, and when used, indicate to you that you should exercise all appropriate caution.

DANGER
Danger is used to indicate the presence of a hazard which will cause
severe personal injury, death, or substantial property damage if the
warning is ignored.

WARNING
Warning is issued to indicate the presence of a hazard which can cause
severe personal injury, death or substantial property damage if the warning
is ignored.

ELECTRICAL POWER
Electrical power is used to indicate the presence of a hazard which will or
can cause severe personal injury, death or substantial property damage if
the warning is ignored.

CAUTION
Caution is used to indicate the presence of a hazard which will or can
cause minor injury or property damage if the warning is ignored.

NOTICE
Notice is used to notify people of installation, operation or maintenance
information which might be important but not hazard-related.

9
3. SPECIFICATIONS
“X” Axis Travel………………………………………………. 11.00” Maximum (Servo)
“Y” Axis Travel………………………………………………. 27.00” Maximum (Servo)
Gripper Rotation…………………………………………….. 90 Degrees
Pneumatic Operating Set Point……………………………. 70 PSI
Mech. and Electrical Operating Voltage………………….. 230VAC/3 Phase/60Hz
120VAC/1 Phase/60Hz
24VDC
Minimum Sprue Diameter……………………………………0.125”
EOAT Weight…………………………………………………1.5 Lbs. Maximum
Equipment Weight……………………………………………500 Lbs. Approx.
Machine Dimensions…………………………………………51.00” Width
52.00” Height
54.50” Depth Approx.

10
4. INSTALLATION

4.1 General Requirements

As with any equipment installation, safety procedures should always be used to protect workers and the
equipment.

NOTICE
NOTE: Remove any shipping material or bracing before applying main control
power and operating the machine. Failure to remove any shipping material or
bracing may result in physical equipment damage or operator injury.

4.2 Picker Mounting

The Sprue Picker comes completely assembled as one unit and is ready to be mounted directly to the
injection-molding machine.

The complete Sprue Picker unit is lifted into position on top of the fixed platen and fastened in place using
the mounting holes (M12 & M24 fasteners, torque to 85Nm & 730Nm min.) provided on the top surface of
the platen.
See Fig. 5

Two (2) lifting eyes have been provided on the electrical enclosure unit which are to be used to lift and
place the electrical enclosure into position. Chain and lift hooks or web straps may be used to connect to
the tilt shaft for lifting and placing the picker.
See Fig. 2.

See Fig. 2 for the lift point(s) to insure that no damage is done to the picker and to insure the safety of the
people involved with this installation.

WARNING
Keep the Sprue Picker assembly secured to whatever lifting mechanism is
used until the fasteners have been installed and the assembly is held
securely in place.

11
 4.3 Main Power and Control Connections

ELECTRICAL POWER

Make sure all power is off and locked out. Follow all company safety
practices.

Power Wiring. The Picker requires multiple power sources. The power sources are 230VAC three
phase, 120VAC single phase and 24VDC. The input power wiring must include an external disconnect
ahead of the Picker electrical enclosure. Refer to the 59-3056 electrical drawings for details.

Control Wiring. The Picker also requires interconnections to the injection mold machine. These
interconnections include the Emergency Stop circuit. The control signals to and from the Picker are
brought out to terminal strip 100TB and relays 406CR through 416CR. Refer to the 59-3056 electrical
drawings and appropriate injection mold machine documentation for details.

4.4 Check All Wire Connections

Before turning on the main power to the Sprue Picker system, check all wire terminal connections for
tightness. This check should include any multi-conductor cables that may be used in the Sprue Picker
control system. Verify that all cable connectors are tight.

WARNING
Make sure ALL energy sources are disconnected, contained
and locked out prior to performing this operation or other
service or maintenance. Follow all company safety practices.

WARNING
Before turning on the main power to this equipment, please
become familiar with all sections of this manual. Operation
of this equipment without proper instruction can result in
serious injury or equipment damage.

12
 4.5 Connection of Plant Air

WARNING
Before connecting the pneumatic line to the Sprue Picker, make
sure the Safety lock-out valve is off and locked out until after the
equipment installation is complete.

Plant air is to be provided to the Sprue Picker. Please refer to Fig. 3 for the connection point location.
Plant compressed air must be supplied at a minimum pressure of 80 PSI. The Sprue Picker is supplied
with a pressure regulator that has been preset at 70 PSI.

This equipment must be supplied with clean dry compressed air. Customer is to supply a 6” to 12” “drip
leg” with drain valve ahead of the pneumatic line connection point on the Sprue Picker.

13
 4.6 Start Up Check List

X Axis Rack - Check the adjustment of the over travel proximity switch targets so that the target position
will not cause the axis to damage itself. The targets should be positioned so that the over travel proximity
switches sense the targets and turn off before the axis runs outs of physical travel. Note that these
proximity switches are normally closed (NC) - they are normally on and turn off when a target is present.
See Fig. 8 for the location of the over travel and the home switches and targets.

Y Axis Vertical Belt Drive - Check the adjustment of the over travel proximity switches so that the position
of the switches will not cause the axis to damage itself. The switches should be positioned so that they
turn off before the axis runs out of physical travel. Note that these proximity switches are normally closed
(NC) - they are normally on and turn off when a target is present. See Fig. 9 for the location of the over
travel and the home switches.

Gripper Rotate Assembly - Check to make sure the end of travel sensors are on when the gripper is
rotated fully in both directions. Adjust the location of the end of travel sensors if necessary. Check the
speed of the rotation and adjust the flow controls if necessary. See Fig. 10 for the locations of the end of
travel switches.

Gripper Jaw Assembly - Check the jaw open switch and adjust if necessary. Check the part present
switch and adjust if necessary. See Fig. 11 for the location of these switches and the proper set up
dimensions.

A Axis Rotate Assembly - Check to make sure the end of travel sensors are on when the axis rotates fully
in both directions. Adjust the location of the end of travel sensors if necessary. Check the speed of the
rotation and adjust the flow controls if necessary. See Fig. 12 for the locations of the end of travel
switches and the flow controls.

Base Assembly - Check to make sure the end of travel sensors are on when the axis moves fully in both
directions. Adjust the location of the proximity switches if necessary. Check the speed of the motion and
adjust the flow controls if necessary. See Fig. 13 for the locations of the end of travel switches and the
flow controls.

14
5. MAINTENANCE
Before performing any maintenance to this equipment, the following points should be strictly observed to
ensure the safety of the operator and/or maintenance personal. Any applicable standard company safety
procedures shall be followed.

5.1 Lock-Out Tag

For the safety of all personnel and to prevent any damage to the machine, all energy sources must be
restrained. The external main disconnect switch should be turned off and a “lock out tag” and padlock
should be installed.

DANGER
All energy sources must be disconnected and restrained and locked out
prior to performing any service or maintenance work.

5.2 Mechanical Maintenance

Should mechanical maintenance be required on this equipment, additional safety procedures should be
utilized beside the electrical lock out and pneumatic lock out. The physical restraining or “blocking up” of
the vertical gripper unit when working on the picker will prevent any sudden accidental movement which
could cause personal injury or equipment damage.

DANGER
MAKE SURE YOU ARE FAMILIAR WITH THIS EQUIPMENT BEFORE
ATTEMPTING ANY MAINTENANCE OF THIS EQUIPMENT. SERIOUS
PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY
DAMAGE MAY OCCUR.

15
 5.3 Periodic Maintenance Requirements

1. Check all electrical connections for tightness. This includes all wire terminal connections inside the
control cabinet and any multi-conductor cable connectors internal or external to the control cabinet.
Retighten as necessary.
2. Inspect all timing belts for excessive wear. Replace as necessary.
3. Filter/Regulator: drain weekly and replace the filter cartridge yearly.
4. Inspect strike plate ( p/n: 63-1265-3-10 New/Retro) for excessive wear monthly.
5. Check all electrical multi-conductor cables for signs of excessive wear monthly.
6. Check CPU battery monthly.
7. Check fan and fan filters every three months. Clean fan filters as necessary.
8. Inspect the motor and seals for damage or wear every six months.
9. Inspect / test the safety circuit on a regular basis.
10. Inspect / test the overtravel limit switches on a regular basis.

5.4 Lubrication

This picker unit has been designed to minimize the maintenance of lubrication. All bearings that have
been included in the design are sealed for life and do not require re-lubrication.

The chart below lists any lubrication points, type of lubrication and frequency to maintain this equipment
in proper operating condition.

See Fig. No. No. Of Fitting Lubrication

Lubrication Point Frequency
For Location Points Type Type
X and Base Axis HDMP Dri-Slide
Grease 500 Hrs
Fig. 6 Profile Rail / 8 Fitting
Grease Code
or as required
Cassette #00343
HDMP Dri-Slide
Y Axis Profile Grease 500 Hrs
Fig. 6 2 Grease Code
Rail/Cassette Fitting or as required
#00343
HDMP Dri-Slide
A Axis Rotate Pillow Grease 500 Hrs
Fig. 7 2 Grease Code
Block Bearings Fitting or as required
#00343

16
6. RECOMMENDED SPARE / WEAR PARTS

6.1 Mechanical Recommended Spare / Wear Parts

RETROFIT 63-1265-1 NEW 63-1268-1

“X” Axis Rack Assembly “X” Axis Rack Assembly
Comptrol P/N Description Rec. Qty. Comptrol P/N Description Rec. Qty.
63-1265-1-04 20° Spur Rack 1 63-1265-1-04 20° Spur Rack 1
63-1265-1-B-04 Carriage 4 63-1268-1-B-04 Carriage 4
63-1265-1-B-05 Rail 2 63-1268-1-B-05 Rail 2

RETROFIT and NEW- 63-1265-2

“Y” Axis Vertical Drive Belt Assembly
Comptrol P/N Description Rec. Qty.
63-1254-2-16 Belt Drive Pulley 2
63-1254-2-17 Drive Pulley 2
63-1265-2-B-02 Timing Belt 1
63-1265-2-B-03 Timing Belt 1
63-1265-2-B-04 Bearing 4
63-1265-2-B-07 Prox Switch conn. 1
63-1265-2-B-08 Prox Switch conn. 2
63-1265-2-B-09 Cassette 2
63-1265-2-B-10 Rail 1
63-1265-2-B-12 ERS-26 Brake, 90V 1
63-1265-2-B-13 Splined Hub, 3/8" Bore 1
63-1265-2-B-01 Servo Motor 1
63-1265-2-B-11 Planetary Gearbox 1

RETROFIT 63-1265-3 NEW 63-1268-3

“A” Axis Rotate Assembly “A” Axis Rotate Assembly
Rec. Rec.
Comptrol P/N Description Comptrol P/N Description
Qty. Qty.
63-1265-3-13 Spur Gear 1 63-1265-3-13 Spur Gear 1
Adjustable Shock
63-1265-3-B-02 2 63-1268-3-B-02 Adjustable Shock Absorber 2
Absorber
63-1265-3-C-02 Pillow Block 2 63-1268-3-B-04 Pillow Block 2
63mm Bore Cylinder, 63mm Bore Cylinder,
63-1265-3-C-03 125mm Stroke, 1 63-1268-3-B-10 125mm Stroke, Trunnion 1
Trunnion Mount Mount
5 Station Manifold with 3
Prox Switch PNP NO 4mm & 2 6mm push in
63-1265-3-B-04 1 63-1268-3-B-09 1
8mm / conn. fittings, 25 pin connector,
valves 2 pos dbl solenoid.
Prox Switch PNP NC Prox Switch PNP NO 8mm
63-1265-3-B-05 2 63-1268-3-B-08 1
8mm / conn. / conn.
Prox Switch PNP NC 8mm
63-1265-3-B-08 Planetary Gearbox 1 63-1268-3-B-07 2
/ conn.
63-1265-3-B-01 Servo Motor 1 63-1268-3-B-13 Planetary Gearbox 1
63-1265-3-C-08 PNP Switch 2 63-1268-3-B-01 Servo Motor 1
Switch, PNP , M8
63-1268-3-B-12 2
Connector with pigtail

17
 RETROFIT 63-1265-4 NEW 63-1268-4
Base Assembly Base Assembly
Rec. Rec.
Comptrol P/N Description Comptrol P/N Description
Qty. Qty.
63-1265-4-C-04 32mm Bore Cylinder, 1 63-1268-4-B-16 32mm Bore Cylinder, 1
600mm Stroke 600mm Stroke
63-1265-4-B-01 Cassette 4 63-1268-4-B-01 Cassette 4
63-1265-4-B-02 Rail 2 63-1268-4-B-02 Rail 2
2 63-1268-4-B-17 Prox Switch PNP NO 2
63-1265-4-C-05 Proximity Switch
8mm / conn.

RETROFIT and NEW- 63-1265-5

Gripper Rotate Assembly
Comptrol Part Rec.
Description
No. Quantity
90° Rotary Cyl. W / PNP switches /
63-1265-5-B-07
2.5m cbl, Flange Mtg.
1

RETROFIT and NEW- 63-1265-6

Gripper Jaw Assembly
Comptrol Part Rec.
Description
No. Quantity
63-1254-6-01 RH Gripper 1
63-1254-6-02 LH Gripper 1
63-1265-B-02 Pneumatic Gripper 1
63-1265-B-01 Proximity Sensor with cable 1
63-1265-B-04 Connector, Straight Plug, Pin 1
63-1265-B-05 Sensor 1
63-1265-B-03 Compression Spring 1

Pneumatic Diagram 63-1265-7 and 63-1268-7 -No Recommended Spare Parts Required.

Enclosure Mounting Bracket Assembly 63-1265-8 -No Recommended Spare parts

Required.

18
6.2 Electrical Recommended Spare / Wear Parts
Electrical 59-3056-55
Rec.
Comptrol Part No. Description
Quantity
59-3056-B-04 Fan, PF 2000, Nema 12 1
59-3056-B-13 Fuse, 2A, Class CC 2
59-3056-B-14 Fuse, 20A, Class CC 3
59-3056-B-15 Fuse, 3A, Class CC 1
59-3056-B-16 Fuse, 2A, Class CC 1
59-3056-B-17 Relay, Safety, UE43-2MF3D2, (2) Contacts, 24VDC 1
59-3056-B-18 Contactor, Servo, 24VDC, N.C. Auxiliary 1
59-3056-B-20 Chasis, PLC, ControLogix, (7) Slot 1
59-3056-B-21 Power Supply , PLC, 120/240VAC, 75W 1
59-3056-B-22 CPU, Integral (3) Axis SERCOS 1
59-3056-B-23 Module, Communication, DH+ and Remote I/O 1
59-3056-B-24 Module, Input, 32Pt, 12/24VDC 1
59-3056-B-25 Module, Output, 32Pt, 12/24VDC, Source 1
59-3056-B-27 Power Rail, Slim, (2) Axis, Kinetix 6000 1
59-3056-B-28 Integrated Axis Module, 230VAC, 6KW 1
59-3056-B-29 Axis Module, 230VAC 1
59-3056-B-32 Brake, Control, CBC-801-1 1
59-3056-B-34 Relay, PLC-RSC-24DC/21 1
59-3056-B-35 Relay, PLC-RSC-24DC/21HC 1
59-3056-B-47 Box, Sensor, SACB-8/8-M23 1
59-3056-B-48 Connector, 12 Pos, Solder, M23 1
59-3056-B-51 Cable Assembly, TL Motor, Power, Flex Duty, 30' 1
59-3056-B-53 Cable Assembly, TL Motor, Encoder, Flex Duty, 30' 1
59-3056-055Ton-B-54 Cable, 2/18AWG, Flex Duty 50'
59-3056-055Ton-B-55 Cable, 12/20AWG, Flex Duty 50'
59-3056-B-56 Cable, Sensor, M8, Straight, Flex Duty 1
59-3056-B-57 Cable, Sensor, M8, Right Angle, Flex Duty 1
59-3056-B-59 Cable, 3/24AWG, Flex Duty 25'
59-3056-B-60 Connector, Male, M12, Straight 1
59-3056-B-61 Connector, Male, M8, Straight 1
59-3056-B-62 Connector, Female, M8, Straight 1
59-3056-B-66 Connector, DB25, Female 1

19
7. APPENDIX
Figure 1 Picker assembly
Figure 2 Picker assembly lifting eye locations
Figure 3 Picker system pneumatic connection point
Figure 4 Mounting hole locations of fixed platen
Figure 5 Picker assembly mounting location
Figure 6 “Y” axis profile rail location and base unit profile rail locations
Figure 7 “A” axis pillow block bearing locations
Figure 8 “X” axis rack switch locations
Figure 9 “Y” axis belt drive switch locations
Figure 10 Gripper rotate switch locations
Figure 11 Gripper jaw switch locations and set up procedure
Figure 12 “A” axis rotate switch locations, speed controls, and shock absorbers
Figure 13 Base assembly switch and speed control locations

20
Figure 1 Picker assembly

21
Figure 2 Picker assembly lifting eye locations

Lifting Eyes

Lift Picker by
the shaft.

22
 Figure 3 Picker system pneumatic connection point

MAIN SYSTEM PRESSURE

REGULATOR. SET AT 70 PSI

CUSTOMERS PNEUMATIC
CONNECTION POINT. 1/4” NPT

23
Figure 4 Mounting hole locations of fixed platen

24
Figure 5 Picker assembly mounting location

This mounting pad is

located on top face of
fixed platen.

25
Figure 6 “Y” axis profile rail location and base unit profile rail locations

(2) Profile Rails

Base Unit

Profile Rail “Y”

26
Figure 7 “A” axis pillow block bearing locations

“A” Axis Rotate Pillow

Blocks

27
Figure 8 “X” axis rack switch locations

HOME
SWITCH
OVER TRAVEL SWITCH
TARGET AT EACH END

HOME
SWITCH
OVER TARGET
TRAVEL
SWITCHES

28
Figure 9 “Y” axis belt drive switch locations

OVER TRAVEL SWITCH

HOME SWITCH

OVER TRAVEL SWITCH

29
Figure 10 Gripper rotate switch locations

GRIPPER ROTATE END OF

TRAVEL SWITCHES

GRIPPER ROTATE FLOW

CONTROL

30
Figure 11 Gripper jaw switch locations and set up procedure

GRIND LENGTH OF STOP

PIN UNTIL .07
DIMENSION BETWEEN 1. BEFORE ASSEMBLING THE SET SCREW (ITEM 13), COAT
GRIPPERS IS OBTAINED. THREADS WITH ND INDUSTRIES VIBRA-TITE FORMULA 3 THREAD
JAWS SHOULD BE LOCKER OR EQUIV.
PARALLEL.
2. TO SET THE SENSING DISTANCE OF THE SET SCREW (ITEM 13)
………TO THE PROXIMITY SWITCH, COMPRESS THE COMPRESSION
………PLATE (ITEM 16) UNTIL IT IS FLUSH WITH THE GRIPPER TEETH.
THREAD IN THE SET SCREW (ITEM 13) UNTIL IT TOUCHES THE
PROXIMITY SWITCH, BACK OFF THE SET SCREW ¼ TURN.

31
Figure 12 “A” axis rotate switch locations, speed controls, and shock absorbers

ADJUSTABLE SHOCK
ABSORBER

END OF TRAVEL
EXTEND SWITCH

ADJUSTABLE
SHOCK ABSORBER

FLOW CONTROLS

32
Figure 13 Base assembly switch and speed control locations

SPEED CONTROLS AT
EACH END OF CYLINDER

END OF TRAVEL
SWITCH TARGET AT
END OF TRAVEL EACH END
SWITCHES

33
 7.2 Mechanical Drawings List

The following is a listing of mechanical drawings supplied on CD.

NEW
Sprue Picker Assembly Drawing No. 63-1268
“X” Axis Rack Assembly Drawing No. 63-1268-1
“Y” Axis Vertical Belt Drive Assembly Drawing No. 63-1265-2
“A” Axis Rotate Assembly Drawing No. 63-1268-3
Base Assembly Drawing No. 63-1268-4
Gripper Rotate Assembly Drawing No. 63-1265-5
Gripper Jaw Assembly Drawing No. 63-1265-6
Pneumatic Diagram Drawing No. 63-1268-7
Enclosure Mounting Bracket Assembly Drawing No. 63-1265-8

RETROFIT
Sprue Picker Assembly Drawing No. 63-1265
“X” Axis Rack Assembly Drawing No. 63-1265-1
“Y” Axis Vertical Belt Drive Assembly Drawing No. 63-1265-2
“A” Axis Rotate Assembly Drawing No. 63-1265-3
Base Assembly Drawing No. 63-1265-4
Gripper Rotate Assembly Drawing No. 63-1265-5
Gripper Jaw Assembly Drawing No. 63-1265-6
Pneumatic Diagram Drawing No. 63-1265-7
Enclosure Mounting Bracket Assembly Drawing No. 63-1265-8

7.3 Electrical Drawings List

The following is a listing of electrical controls drawings supplied on CD

Electrical Controls Drawing No. 59-3056 -55 Sht. 1 through Sht. 11

7.4 Mechanical Sub-Assembly BOM’S

34
 X-Axis Rack Assembly BOM
63-1265-1 (Retrofit)
Part Number Description Qty.
63-1254-1-02 Extension Plate – Rear 1
63-1254-1-05 Overtravel Target 2
63-1254-1-06 Ext. Home Target 1
63-1254-1-11 Mounting Plate Adapter 2
63-1254-1-14 Support Plate 1
63-1265-1-01 Extrusion Extension 1
63-1265-1-03 Spur Rack Mount Plate 1
63-1265-1-04 20° Spur Rack 1
63-1265-1-07 Belt Drive Mount Plate 1
63-1265-1-08 Ext. Support Leg 2
63-1265-1-09 Extension Support Plate 1
63-1265-1-12 Extension Scale 1
63-1265-1-13 Lower Vertical Track Support 1
63-1265-1-B-03 Groove Profile 8 AL M4-60 cut to 573mm length, 25mm to first hole 2
63-1265-1-B-04 Carriage 4
63-1265-1-B-05 Rail 2
63-1265-1-B-20 Vertical Separator 30
63-1265-1-B-21 Center Shelf - Top Slot 10
63-1265-1-C-01 Energy Chain 1
63-1265-1-C-02 Mount Bracket Set – Locking 1

35
 63-1254-1-02 63-1254-1-05 63-1254-1-06 63-1254-1-11 63-1254-1-14

63-1265-1-01 63-1265-1-03 63-1265-1-04 63-1265-1-07 63-1265-1-08

63-1265-1-09 63-1265-1-12 63-1265-1-13 63-1265-1-B-03 63-1265-1-B-04

63-1265-1-B-05 63-1265-1-B-20 63-1265-1-B-21 63-1265-1-C-01 63-1265-1-C-02

36
 Y-Axis Vertical Belt Drive Assembly BOM
63-1265-2 (Retrofit)
Part Number Description Qty.
63-1254-2-01 Clamp 2
63-1254-2-02 Drive End Pulley Housing 1
63-1254-2-04 Drive Shaft 1
63-1254-2-05 Idler Shaft 1
63-1254-2-06 Cassette Mounting Plate 1
63-1254-2-07 Belt Clamp Block 1
63-1254-2-08 Belt Clamp Adjust Block 1
63-1254-2-09 Adjustment Block 1
63-1254-2-10 Adjust Rod 1
63-1254-2-11 Prox Target 1
63-1254-2-12 Brake Cover 1
63-1254-2-14 Trailing End Pulley Housing 1
63-1254-2-16 Belt Drive Pulley 2
63-1254-2-17 Drive Pulley 1
63-1254-2-19 Upper Proximity Bracket 1
63-1254-2-20 Lower Proximity Bracket 1
63-1265-2-03 Base Mounting Plate 1
63-1265-2-13 Gearbox Mount Plate 1
63-1265-2-15 Belt Cover 1
63-1265-2-18 Vertical Scale 1
63-1265-2-21 Gearbox Pulley 1
63-1265-2-B-01 Servo Motor 1
63-1265-2-B-02 Timing Belt 1
63-1265-2-B-03 Timing Belt 1
63-1265-2-B-04 Bearing 4
63-1265-2-B-07 Proximity Switch, PNP, NO, 8mm / conn. 1
63-1265-2-B-08 Proximity Switch, PNP, NC, 8mm / conn. 2
63-1265-2-B-09 Cassette 2
63-1265-2-B-10 Rail 1
63-1265-2-B-11 Planetary Gearbox 1
63-1265-2-B-12 ERS-26 Brake, 90V 1
63-1265-2-B-13 Splined Hub, 3/8" Bore 1

37
63-1254-2-01 63-1254-2-02 63-1254-2-04 63-1254-2-05 63-1254-2-06

63-1254-2-07 63-63-1254-2-08 63-1254-2-09 63-1254-2-10 63-1254-2-11

63-1254-2-12 63-1254-2-14 63-1254-2-16 63-1254-2-17 63-1254-2-19

63-1254-2-20 63-1265-2-03 63-1265-2-13 63-1265-2-15 63-1265-2-18

63-1265-2-21 63-1265-2-B-01 63-1265-2-B-02 63-1265-2-B-03 63-1265-2-B-04

38
63-1265-2-B-07 63-1265-2-B-08 63-1265-2-B-09 63-1265-2-B-10 63-1265-2-B-11

63-1265-2-B-12 63-1265-2-B-13

39
 A-Axis Rotate Assembly
63-1265-3 (Retrofit)

Part Number Description Qty.

63-1254-3-15 DB Clamp 1
63-1254-3-16 Spur Gear Cover 1
63-1254-3-18 Ext. Axis Home/Overtravel Prox Mount 1
63-1254-3-20 Pneumatic Label 1
63-1265-3-01 Tilt Shock Mount Plate 1
63-1265-3-02 Trunnion Block 2
63-1265-3-03 Trunnion Block Clamp 2
63-1265-3-04 Tilt Shaft 1
63-1265-3-05 Tilt Base – Middle 1
63-1265-3-06 Tilt Base – Upper 1
63-1265-3-07 Tilt Base – Lower 1
63-1265-3-08 Tilt Clevis Mount Bracket 1
63-1265-3-10 Strike Plate 2
63-1265-3-11 Vertical Shock Mount 1
63-1265-3-13 Spur Gear 1
63-1265-3-14 Extension Servo Mount Plate 1
63-1265-3-17 Pin 1
63-1265-3-19 Support Plate – Upper 1
63-1265-3-21 Rotation Stop 1
63-1265-3-23 X-axis Cable Track Bracket 1
63-1265-3-24 SMC Valve Modification 1
63-1265-3-25 Upper Cable Track Mount 1
63-1265-3-26 Lower Cable Track Support 1
63-1265-3-B-01 Servo Motor 1
63-1265-3-B-02 Adjustable Shock Absorber 2
63-1265-3-B-04 Proximity Switch, PNP, NO, 8mm / conn. 1
63-1265-3-B-05 Proximity Switch, PNP, NC, 8mm / conn. 2
63-1265-3-B-08 Planetary Gearbox 1
63-1265-3-B-41 Energy Chain 1
63-1265-3-B-42 Slot Separator 44
63-1265-3-B-43 75mm Width Shelf 11
63-1265-3-B-44 Mount Bracket Set – Locking 1

40
 A-Axis Rotate Assembly (cont.)
63-1265-3-C-01 Bushing 2
63-1265-3-C-02 Pillow Block 2
63-1265-3-C-03 63mm Bore Cylinder, 125mm Stroke, Trunnion Mount 1
63-1265-3-C-04 Piston Rod Ball Joint 1
63-1265-3-C-05 Fixing Clamp 1
63-1265-3-C-06 Silencer 2
63-1265-3-C-07 Reed Switch 1
63-1265-3-C-08 Proximity Switch 1
63-1265-3-C-09 Steel Shim 2

41
63-1254-3-15 63-1254-3-16 63-1254-3-18 63-1254-3-20 63-1265-3-01

63-1265-3-02 63-1265-3-03 63-1265-3-04 63-1265-3-05 63-1265-3-06

63-1265-3-07 63-1265-3-08 63-1265-3-10 63-1265-3-11 63-1265-3-13

63-1265-3-14 63-1265-3-17 63-1265-3-19 63-1265-3-21 63-1265-3-23

63-1265-3-24 63-1265-3-25 63-1265-3-26 63-1265-3-B-01 63-1265-3-B-02

42
63-1265-3-B-04 63-1265-3-B-05 63-1265-3-B-08 63-1265-3-B-41, 42, 43, 44 63-1265-3-C-01

63-1265-3-C-02 63-1265-3-C-03 63-1265-3-C-04 63-1265-3-C-05 63-1265-3-C-06

63-1265-3-C-07 63-1265-3-C-08 63-1265-3-C-09

43
 Base Assembly BOM
63-1265-4 (Retrofit )

Part Number Description Qty.

63-1265-4-01 Base Weldment 1
63-1265-4-02 Main Slide Plate 1
63-1265-4-03 Tilt Support Plate - Left Hand 1
63-1265-4-04 Tilt Support Plate - Right Hand 1
63-1265-4-05 Cross Slide Mount Clevis 1
63-1265-4-06 Shift Proximity Mount 1
63-1265-4-08 Shift Support Bracket 1
63-1265-4-10 Shift Prox Target 2
63-1265-4-11 Base Adapter Extension 1
63-1265-4-B-01 Cassette 4
63-1265-4-B-02 Rail 2
63-1265-4-C-01 Pressure Gauge 1
63-1265-4-C-02 Angle Bracket 1
63-1265-4-C-03 Filter/Regulator Unit 1
63-1265-4-C-04 32mm Bore Cylinder, 600mm Stroke 1
63-1265-4-C-05 Proximity Switch 2
63-1265-4-C-06 Floating Joint 1
63-1265-4-C-12 Rubber Bumper for M12 Hex Head Bolt 1

44
 63-1265-4-01 63-1265-4-02 63-1265-4-03 63-1265-4-04 63-1265-4-05

63-1265-4-06 63-1265-4-08 63-1265-4-10 63-1265-4-11 63-1265-4-B-01

63-1265-4-B-02 63-1265-4-C-01, 02, 03 63-1265-4-C-04 63-1265-4-C-05 63-1265-4-C-06

63-1265-4-C-12

45
 Gripper Rotate Assembly BOM
63-1265-5 (Retrofit)

Part Number Description Qty.

63-1254-5-03 Arm - Lower Cap Plate 1
63-1254-5-05 Key Stopper 1
63-1254-5-06 Gripper Key 1
63-1254-5-07 Thrust Washer 1
63-1254-5-11 Vertical Track Mount 1
63-1254-5-13 Vertical Scale Pointer 1
63-1254-5-15 Bracket 1
63-1265-5-01 Arm 1
63-1265-5-02 Rotary Cylinder Mount Plate 1
63-1265-5-04 Gripper Mount 1
63-1265-5-08 Rotary Coupling 1
63-1265-5-09 Arm Plate 1
63-1265-5-10 Arm Plate Adapter 1
63-1265-5-12 Bulkhead Mount Angle 1
63-1265-5-B-01 Mount Bracket Set 1
63-1265-5-B-02 Horizontal Shelf 11
63-1265-5-B-03 Vertical Separator 22
63-1265-5-B-04 Energy Chain 1
63-1265-5-B-05 T-Slot Nut 5 St M5 14
63-1265-5-B-06 3/8" shaft collar. 1
63-1265-5-B-07 90° Rotary Cyl. W / PNP switches / 2.5m cbl, Flange Mtg. 1
63-1265-5-B-08 Sintered Bronze Bushing 3/8" thru 7/16" dia. x 3/8" long 1

46
63-1254-5-03 63-1254-5-05 63-1254-5-06 63-1254-5-07 63-1254-5-11

63-1254-5-13 63-1254-5-15 63-1265-5-01 63-1265-5-02 63-1265-5-04

63-1265-5-08 63-1265-5-09 63-1265-5-10 63-1265-5-12 63-1265-5-B-01, 02, 03, 04

63-1265-5-B-05 63-1265-5-B-06 63-1265-5-B-07 63-1265-5-B-08

47
 Gripper Jaw Assembly
63-1265-6 (Retrofit)

Part Number Description Qty.

63-1254-6-01 RH Gripper 1
63-1254-6-02 LH Gripper 1
63-1254-6-03 Compression Plate 1
63-1254-6-04 Stop Pin 1
63-1265-6-01 Gripper Sensor Electrical Connections 1
63-1265-B-01 Proximity Sensor with M8 Plug, .3m cable, SMT-8-PS-S-LED-24-B. 1
63-1265-B-02 HGW-25-A, Gripper 1
63-1265-B-03 Compression Spring 1
63-1265-B-04 Connector, Straight Plug, Pin 1
63-1265-B-05 Sensor 1
63-1265-B-13 Connector Cable, SIM-M8-3GD-2.5-PU 1
63-1265-B-14 Connector, Male M8, Straight 1
63-1265-B-15 Connector, Female M8, Straight 1

48
63-1254-6-01 63-1254-6-02 63-1254-6-03 63-1254-6-04 63-1265-B-01

63-1265-B-02 63-1265-B-03 63-1265-B-04 63-1265-B-05 63-1265-B-13

63-1265-B-14 63-1265-B-15

49
 Enclosure Mounting Bracket Assembly
63-1265—8 (Retrofit)

Part Number Description Qty.

63-1265-8-01 R. H. Vertical Bracket 1
63-1265-8-02 L. H. Vertical Bracket 1
63-1265-8-03 Horizontal Support 2

63-1265-8-01 63-1265-8-02 63-1265-8-03

50
 X-Axis Rack Assembly
63-1268-1 (New)

Part Number Description Qty.

63-1254-1-02 Extension Plate – Rear 1
63-1254-1-05 Overtravel Target 2
63-1254-1-06 Ext. Home Target 1
63-1254-1-11 Mounting Plate Adapter 2
63-1254-1-14 Support Plate 1
63-1265-1-01 Extrusion Extension 1
63-1265-1-03 Spur Rack Mount Plate 1
63-1265-1-04 20° Spur Rack 1
63-1265-1-07 Belt Drive Mount Plate 1
63-1265-1-08 Ext. Support Leg 2
63-1265-1-09 Extension Support Plate 1
63-1265-1-12 Extension Scale 1
63-1265-1-13 Lower Vertical Track Support 1
63-1268-1-B-03 Groove Profile 8 AL M4-60 cut to 573mm length, 25mm To First Hole 2
63-1268-1-B-04 Carriage 4
63-1268-1-B-05 Rail 2
63-1268-1-B-20 Vertical Separator 30
63-1268-1-B-21 Center Shelf - Top Slot 10
63-1268-1-B-22 Energy Chain 1
63-1268-1-B-23 Mount Bracket Set – Locking 1

51
63-1254-1-02 63-1254-1-05 63-1254-1-06 63-1254-1-11 63-1254-1-14

63-1265-1-01 63-1265-1-03 63-1265-1-04 63-1265-1-07 63-1265-1-08

63-1265-1-09 63-1265-1-12 63-1265-1-13 63-1268-1-B-03 63-1268-1-B-04

63-1268-1-B-05 63-1268-1-B-20, 21, 22, 23

Y-Axis Vertical Belt Drive Assembly BOM

REFER TO 63-1265-2 (Retrofit) Pages 38-40

52
 A-Axis Rotate Assembly
63-1268-3 (New)

Part Number Description Qty.

63-1254-3-15 DB Clamp 1
63-1254-3-16 Spur Gear Cover 1
63-1254-3-18 Ext. Axis Home/Overtravel Prox Mount 1
63-1254-3-20 Pneumatic Label 1
63-1265-3-01 Tilt Shock Mount Plate 1
63-1265-3-06 Tilt Base – Upper 1
63-1265-3-07 Tilt Base – Lower 1
63-1265-3-10 Strike Plate 2
63-1265-3-11 Vertical Shock Mount 1
63-1265-3-13 Spur Gear 1
63-1265-3-14 Extension Servo Mount Plate 1
63-1265-3-19 Support Plate – Upper 1
63-1265-3-21 Rotation Stop 1
63-1265-3-23 X-axis Cable Track Bracket 1
63-1265-3-25 Upper Cable Track Mount 1
63-1265-3-26 Lower Cable Track Support 1
63-1268-3-02 Trunnion Block 2
63-1268-3-03 Trunnion Block Clamp 2
63-1268-3-04 Tilt Shaft 1
63-1268-3-05 Tilt Base – Middle 1
63-1268-3-08 Tilt Clevis Mount Bracket 1
63-1268-3-17 Pin 1
63-1268-3-22 Proximity Clamp 1
63-1268-3-B-01 Servo Motor 1
63-1268-3-B-02 Adjustable Shock Absorber 2
63-1268-3-B-03 Bushing 2
63-1268-3-B-04 Pillow Block 2
63-1268-3-B-07 Proximity Switch, PNP, NC, 8mm / conn. 2
63-1268-3-B-08 Proximity Switch, PNP, NO, 8mm / conn. 2
63-1268-3-B-09 5 Station Manifold with 3 4mm and 2 6mm push in fittings, 25 pin connector, valves 2 pos dbl solenoid. 1
Banks 2 & 3 to have 6mm fittings.
63-1268-3-B-10 63mm Bore Cylinder, 125mm Stroke, Trunnion Mount 1
63-1268-3-B-11 Piston Rod Ball Joint 1
63-1268-3-B-12 Switch, PNP, M8 Connector w/Pigtail 1

53
 A-axis Rotate Assembly
63-1268-3 (New)
Part Number Description Qty.
63-1268-3-B-13 Planetary Gearbox 1
63-1268-3-B-14 Switch Bracket 1
63-1268-3-B-48 Energy Chain 1
63-1268-3-B-49 Slot Separator 44
63-1268-3-B-50 75mm Width Shelf 11
63-1268-3-B-51 Mount Bracket Set - Locking 1

54
63-1254-3-15 63-1254-3-16 63-1254-3-18 63-1254-3-20 63-1265-3-01

63-1265-3-06 63-1265-3-07 63-1265-3-10 63-1265-3-11 63-1265-3-13

63-1265-3-14 63-1265-3-19 63-1265-3-21 63-1265-3-23 63-1265-3-25

63-1265-3-26 63-1268-3-02 63-1268-3-03 63-1268-3-04 63-1268-3-05

63-1268-3-08 63-1268-3-17 63-1268-3-22 63-1268-3-B-01 63-1268-3-B-02

55
63-1268-3-B-03 63-1268-3-B-04 63-1268-3-B-07 63-1268-3-B-08 63-1268-3-B-09

63-1268-3-B-10 63-1268-3-B-11 63-1268-3-B-12 63-1268-3-B-13 63-1268-3-B-14

63-1268-3-B-48, 49, 50, 51

56
 Base Assembly
63-1268-4 (New)
Part Number Description Qty.
63-1265-4-06 Shift Proximity Mount 1
63-1265-4-08 Shift Support Bracket 1
63-1265-4-11 Base Adapter Extension 1
63-1268-4-01 55 Ton / 120 Ton Base Weldment 1
63-1268-4-02 Main Slide Plate 1
63-1268-4-03 Tilt Support Plate - Left Hand 1
63-1268-4-04 Tilt Support Plate - Right Hand 1
63-1268-4-05 Cross Slide Mount Clevis 1
63-1268-4-B-01 Cassette 4
63-1268-4-B-02 Rail 2
63-1268-4-B-15 Filter/Regulator Unit with Bracket & Gauge 1
63-1268-4-B-16 32mm Bore Cylinder, 600mm Stroke 1
63-1268-4-B-17 Proximity Switch, PNP, NO, 8mm / conn. 2
63-1268-4-B-18 Floating Joint 1
63-1268-4-B-24 Urethane Bumper, 1/2-13 Female Thread 1

57
 63-1265-4-06 63-1265-4-08 63-1265-4-11 63-1268-4-01 63-1268-4-02

63-1268-4-03 63-1268-4-04 63-1268-4-05 63-1268-4-B-01 63-1268-4-B-02

63-1268-4-B-15 63-1268-4-B-16 63-1268-4-B-17 63-1268-4-B-18 63-1268-4-B-24

Gripper Rotate Assembly BOM

REFER TO 63-1265-5 (Retrofit) Pages 47-48

Gripper Jaw Assembly

REFER TO 63-1265-6 (Retrofit) Pages 49-50

Enclosure Mounting Bracket Assembly

REFER TO 63-1265-8 (Retrofit) Page 51

58
 7.5 ELECTRICAL BOM

Electrical Components
59-3056-55 Ton
Part Number Description Qty.
59-3056-B-01 Enclosure, 30" x 24" x 12" 1
59-3056-B-03 Insert, Key 2
59-3056-B-04 Fan, PF 2000, Nema 12 1
59-3056-B-05 Grille, PFA 2000, Nema 12 1
59-3056-B-10 Fuseholder, Two Pole, Class CC 1
59-3056-B-11 Fuseholder, Three Pole, Class CC 1
59-3056-B-12 Fuseholder, Single Pole, Class CC 2
59-3056-B-13 Fuse, 2A, Class CC 2
59-3056-B-14 Fuse, 20A, Class CC 3
59-3056-B-15 Fuse, 3A, Class CC 1
59-3056-B-16 Fuse, 2A, Class CC 1
59-3056-B-17 Relay, Safety, UE43-2MF3D2, (2) Contacts, 24VDC 1
59-3056-B-18 Contactor, Servo, 24VDC, N.C. Auxiliary 1
59-3056-B-20 Chasis, PLC, ControLogix, (7) Slot 1
59-3056-B-21 Power Supply , PLC, 120/240VAC, 75W 1
59-3056-B-22 CPU, Integral (3) Axis SERCOS 1
59-3056-B-23 Module, Communication, DH+ and Remote I/O 1
59-3056-B-24 Module, Input, 32Pt, 12/24VDC 1
59-3056-B-25 Module, Output, 32Pt, 12/24VDC, Source 1
59-3056-B-26 Module, Removable Terminal Block 2
59-3056-B-27 Power Rail, Slim, (2) Axis, Kinetix 6000 1
59-3056-B-28 Integrated Axis Module, 230VAC, 6KW 1
59-3056-B-29 Axis Module, 230VAC 1
59-3056-B-30 Cable, Fiber Optic, SERCOS, 1m 2
59-3056-B-31 Cable, Fiber Optic, SERCOS, 4" 1
59-3056-B-32 Brake, Control, CBC-801-1 1
59-3056-B-33 Socket, Octal, DIN Mount 1
59-3056-B-34 Relay, PLC-RSC-24DC/21 6
59-3056-B-35 Relay, PLC-RSC-24DC/21HC 1
59-3056-B-36 Terminal, UTTB 4 48
59-3056-B-41 End, Bracket, E/UK 9
59-3056-B-42 Rail, Perforated, NS 35/7.5 A/R
59-3056-B-43 Bar, Ground 1
59-3056-B-47 Box, Sensor, SACB-8/8-M23 2
59-3056-B-48 Connector, 12 Pos, Solder, M23 2
59-3056-B-49 Connector, Wall Mount Receptacle, Socket 1
59-3056-B-51 Cable Assembly, TL Motor, Power, Flex Duty, 30' 1
59
59-3056-B-53 Cable Assembly, TL Motor, Encoder, Flex Duty, 30' 1
59-3056-055Ton-B-54 Cable, 2/18AWG, Flex Duty 28'
59-3056-055Ton-B-55 Cable, 12/20AWG, Flex Duty 61'
59-3056-B-56 Cable, Sensor, M8, Straight, Flex Duty 2
59-3056-B-57 Cable, Sensor, M8, Right Angle, Flex Duty 2
59-3056-B-59 Cable, 3/24AWG, Flex Duty 20m
59-3056-B-60 Connector, Male, M12, Straight 16
59-3056-B-61 Connector, Male, M8, Straight 2
59-3056-B-62 Connector, Female, M8, Straight 2
59-3056-B-63 Connector, Auxiliary Feedback 1
59-3056-B-64 Connector, Motor Feedback 2
59-3056-B-65 Connector, I/O 2
59-3056-B-66 Connector, DB25, Female 1
59-3056-B-67 Hood, 25 Position 1

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59-3056-B-10, 13 59-3056-B-11, 14

61
59-3056-B-31 59-3056-B-30

59-3056-B-05

59-3056-B-28

59-3056-B-29

59-3056-B-65

59-3056-B-53, 64

59-3036-B-27

62
59-3056-B-18

59-3036-B-32

59-3056-B-42

59-3056-B-33

63
59-3056-B-21

59-3056-B-22

59-3056-B-23

59-3056-B-24

59-3056-B-25

59-3056-B-20 59-3056-B-43

64
59-3056-B-04

59-3056-B-12

59-3056-B-15

59-3056-B-16

59-3056-B-36 59-3056-B-34 59-3056-B-35 59-3056-B-17

65
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