Climax FF1200 User manual

P/N 95936
July 2019
Revision 0
FF1200
FF2400
FF3600
COMPACT FLANGE FACER
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
FF1200 FF2400
FF3600

P/N 95936, Rev. 0 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
inated, downloaded, or stored in any storage medium, without the express prior written consent of CLIMAX.
CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto
an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-
vided that such electronic or printed copy of this manual or revision must contain the complete text of this
copyright notice and provided further that any unauthorized commercial distribution of this manual or any
revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[e-mail].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]. For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street
Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate
Bredbury Industrial Park
Horsfield Way
Stockport SK6 2SU, UK
Telephone: [phone]
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [e-mail]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East Headquarters)
Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B FF1200-FF2400-FF3600 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 95936, Rev. 0 Page C
CE DOCUMENTATION

Page D FF1200-FF2400-FF3600 Operating Manual
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new machines
are free from defects in materials and workmanship. This warranty is available to the original purchaser for a
period of after delivery. If the original purchaser finds any defect in materials or workmanship within the
warranty period, the original purchaser should contact its factory representative and return the entire
machine, shipping prepaid, to the factory. CLIMAX will, at its option, either repair or replace the defective
machine at no charge and will return the machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has
been performed properly. This warranty is available to the customer purchasing parts or labor for a period of
90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the
customer purchasing parts or labor finds any defect in materials or workmanship within the warranty period,
the purchaser should contact its factory representative and return the part or repaired machine, shipping pre-
paid, to the factory. CLIMAX will, at its option, either repair or replace the defective part and/ or correct any
defect in the labor performed, both at no charge, and return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
• Damage after the date of shipment not caused by defects in materials or workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability and
fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and
limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot
guarantee that the information contained in this manual is correct for applications other than the application
described in this manual. Product specifications are subject to change without notice.

P/N 95936, Rev. 0 Page 1
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.2 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.3 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.4 DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.5 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 RECEIPT AND INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
3.2 LIFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
3.3 MACHINE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.3.1 FF1200: Determining the chucking range - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.3.2 FF2400: Determining the chucking range - - - - - - - - - - - - - - - - - - - - - - - - - 29
3.3.3 FF3600: Determining the chucking range - - - - - - - - - - - - - - - - - - - - - - - - - 30
3.3.4 Attaching the chucking feet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
3.3.5 Mount the chuck to the workpiece - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32
3.3.6 Install the slide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41
3.3.7 Install or replace the cutting tool- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
3.3.8 Install the motor- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
3.3.9 Set up the PCU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
3.4 MACHINE CONFIGURATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44
3.4.1 Set the tool cutting depth - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
3.4.2 Tilt the axial slide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
3.4.3 Tilt the radial slide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 OPERATION MODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.1.1 Configure for machining on a flat flange - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.1.2 Configure for machining on a tapered flange- - - - - - - - - - - - - - - - - - - - - - - - 54
4.2 PRE-OPERATION CHECKS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

Page 2 FF1200-FF2400-FF3600 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
4.3 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.3.1 Start the machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.3.2 Stop the machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.3.3 Adjust the machine settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
5.1 MAINTENANCE CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
5.2 APPROVED LUBRICANTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
5.3 MAINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
5.3.1 Check the PCU oil reservoir and particulate filter trap - - - - - - - - - - - - - - - - - - - 61
5.3.2 PCU drop-out circuit check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
5.3.3 Emergency stop test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
5.3.4 Dovetail ways - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61
5.3.5 Lubricate the RDU bearing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.4 RESETTING THE CAM ARM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
5.5 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.5.1 The machine isn’t turning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.5.2 The machine bearing is overheating - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.3 The machine isn’t feeding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.4 The machine is performing poorly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.5 The machine isn’t cutting flat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.1 SHORT-TERM STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
6.2 LONG-TERM STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
6.3 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
6.4 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
APPENDIX B SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
APPENDIX C SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

P/N 95936, Rev. 0 Page 1
LIST OF FIGURES
FIGURE PAGE
1-1 Tool head holder label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-2 FF1200 radial slide assembly label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-3 FF2400 and FF3600 radial slide assembly label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-4 RDU top label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1-5 RDU side label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-6 Pneumatic motor label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-1 FF1200 principal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-2 FF2400 principal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-3 FF3600 principal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-4 Feed engagement and feed rate adjustment controls (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . 13
2-5 Feed controls (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-6 PCU controls and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-7 FF1200 machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-8 FF2400 machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-9 FF3600 machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-10 FF1200 machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-11 FF2400 machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-12 FF3600 right-angle pneumatic motor machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2-13 FF1200 sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-14 FF2400 sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-15 FF3600 sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-1 Lifting point identification label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-2 Lifting points on RDU for the FF2400 and FF3600 (FF2400 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-3 Lifting points on FF1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-4 FF1200 chucking foot components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-5 FF2400 Chucking foot components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-6 FF3600 Chucking foot components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-7 RDU inverted (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-8 RDU with all chucking feet attached (FF1200 shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-9 Chucking foot assembly attached to RDU (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3-10 Mount the machine to the workpiece (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3-11 Vertical example with tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-12 Vertical example with setup fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-13 Upside-down example with tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-14 Upside-down example with setup fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-15 Horizontal example with tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-16 Horizontal example with setup fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-17 Level the RDU (FF3600 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-18 5/16" rods for manually rotating the RDU bearing (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-19 Center the RDU (FF3600 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-20 Align the slide body over the cam slot (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-21 Holding cam release key while inserting (FF3600 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-22 Attach the slide assembly to the RDU (FF3600 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3-23 Install the tool horizontally (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Page 2 FF3600 Operating Manual
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
3-24 Align the air motor (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-25 Motor installed (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-26 Turn the axial feed drive shaft to adjust tool height (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . 45
3-27 Axial gib lock screw (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3-28 Loosen the swivel lock setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-29 Tighten the swivel release setscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-30 Swivel the tool head (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3-31 Loosen the slide pin backing setscrew (FF1200 shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3-32 Support the radial slide (FF1200 shown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-33 Feed controls (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-34 Remove the plug screw (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3-35 Position the dial indicator (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3-36 Loosen the radial slide screws (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-37 Set the radial slide tilt (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-1 Feed controls (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4-2 Radial gib lock screw (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4-3 Axial gib lock screw (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4-4 PCU components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4-5 Feed engagement and feed rate adjustment controls (FF1200 shown) . . . . . . . . . . . . . . . . . . . . . . . . 58
5-1 RDU bearing grease fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5-2 Cam arm clamp screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-3 Cam arm and key position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-4 Adjusting cam arm screw to correct torque value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5-5 Cam arm and key operational alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6-1 FF1200 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6-2 FF2400 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6-3 FF3600 shipping container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
A-1 FF1200 principal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
A-2 FF2400 principal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
A-3 FF3600 principal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
A-4 FF1200 rotational drive unit assembly (P/N 79752) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
A-5 FF1200 rotational drive unit assembly parts list (P/N 79752) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
A-6 FF2400 Rotational drive unit assembly (P/N 79903) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
A-7 FF2400 rotational drive unit assembly parts list (P/N 79903) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
A-8 FF3600 rotational drive unit assembly (P/N 80017) ............................................... 79
A-9 FF3600 rotational drive unit assembly parts list (P/N 80017) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
A-10 RDU drive with feed control assembly (P/N 79749) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
A-11 FF1200 radial and axial slide assembly (P/N 79192) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
A-12 FF1200 radial and axial slide assembly parts list (P/N 79192). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
A-13 FF2400 radial and axial slide assembly (P/N 80683) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
A-14 FF2400 radial and axial slide assembly parts list (P/N 80683). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
A-15 FF3600 radial and axial slide assembly (P/N 80702) ............................................ 86
A-16 FF3600 radial and axial slide assembly parts list (P/N 80702). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A-17 Feed box assembly (P/N 79194). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
A-18 Feed box assembly parts list (P/N 79194) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

P/N 95936, Rev. 0 Page 3
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
A-19 Tool head assembly (P/N 80407) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A-20 Tool head assembly parts list (P/N 80407) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A-21 FF1200 chucking foot assembly (P/N 78911) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A-22 FF2400 chucking foot assembly (P/N 78979) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A-23 FF3600 chucking foot assembly (P/N 80097) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A-24 Pneumatic drive assembly (P/N 76027) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A-25 Pneumatic conditioning unit (PCU) assembly (P/N 78264). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A-26 PCU assembly parts list (P/N 78264) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A-27 FF1200 1.07 hp straight air motor (P/N 80570) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
A-28 FF2400 and FF3600 2.2 hp straight air motor (P/N 80632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A-29 2.2 hp right angle air motor (P/N 80618). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
B-1 Pneumatic schematic (P/N 78264) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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P/N 95936, Rev. 0 Page 1
LIST OF TABLES
TABLE PAGE
1-1 Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 Outside diameter ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1 FF1200-FF2400-FF3600 component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-2 PCU control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3 FF1200 sub-component mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-4 FF2400 sub-component mass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-5 FF3600 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-1 Chucking foot component identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-2 FF1200 chucking range chart (P/N 80083) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-3 FF2400 chucking range chart (P/N 79901) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-4 FF3600 chucking range chart (P/N 80088) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-5 Vertical tether identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-6 Vertical example with setup fingers identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-7 Upside-down tether identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-8 Upside-down example with setup fingers identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-9 Horizontal tether identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-10 Horizontal example with setup fingers identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-11 Feed control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-12 FF1200 radial slide tilt angle conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-13 FF2400 and FF3600 radial slide tilt angle conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4-1 Feed control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4-2 PCU control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4-3 Feed rate control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
A-1 FF1200 Spare parts kit (P/N 78263) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A-2 FF2400 spare parts kit (P/N 81453) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A-3 FF3600 Spare parts kit (P/N 81454) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A-4 Tool kit P/N 78262. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Page 2 FF1200-FF2400-FF3600 Operating Manual
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P/N 95936, Rev. 0 Page 1
1 INTRODUCTION
IN THIS CHAPTER:
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the setup, operation, mainte-
nance, storage, shipping, and decommissioning of the FF1200-FF2400-FF3600.
The first page of each chapter includes a summary of the chapter contents to help
you locate specific information. The appendices contain supplemental product
information to aid in setup, operation, and maintenance tasks.
Read this entire manual to familiarize yourself with the FF1200-FF2400-FF3600
before attempting to set it up or operate it.
1.2 SAFETY ALERTS
Pay careful attention to the safety alerts printed throughout this manual. Safety
alerts will call your attention to specific hazardous situations that may be encoun-
tered when operating this machine. Examples of safety alerts used in this manual
are defined here1:
DANGER
indicates a hazardous situation which, if not avoided, WILL result in
death or severe injury.
WARNING
indicates a hazardous situation which, if not avoided, COULD result in
death or severe injury.
1. Formoreinformationonsafetyalerts,refertoANSI/NEMA Z535.6-2011, Product
safety Information in Product Manuals, Instructions, and Other Collateral Materials.

General safety precautions
Page 2 FF1200-FF2400-FF3600 Operating Manual
CAUTION
indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
indicates a hazardous situation which, if not avoided, could result in
property damage, equipment failure, or undesired work results.
1.3 GENERAL SAFETY PRECAUTIONS
CLIMAX leads the way in promoting the safe use of portable machine tools.
Safety is a joint effort. You, the end user, must do your part by being aware of your
work environment and closely following the operating procedures and safety pre-
cautions contained in this manual, as well as your employer’s safety guidelines.
Observe the following safety precautions when operating or working around the
machine.
Training – Before operating this or any machine tool, you should receive
instruction from a qualified trainer. Contact CLIMAX for machine-specific
training information.
Risk assessment – Working with and around this machine poses risks to
your safety. You, the end user, are responsible for conducting a risk assess-
ment of each job site before setting up and operating this machine.
Intended use – Use this machine in accordance with the instructions and
precautions in this manual. Do not use this machine for any purpose other
than its intended use as described in this manual.
Personal protective equipment – Always wear appropriate personal pro-
tective gear when operating this or any other machine tool. Flame-resistant
clothing with long sleeves and legs is recommended when operating the
machine. Hot chips from the workpiece may burn or cut bare skin.
Work area – Keep the work area around the machine clear of clutter. Restrain
cords and hoses connected to the machine. Keep other cords and hoses
away from the work area.
Lifting – Many CLIMAX machine components are very heavy. Whenever
possible, lift the machine or its components using proper hoisting equip-
ment and rigging. Always use designated lifting points on the machine.
Follow lifting instructions in the setup procedures of this manual.
Lock-out/tag-out – Lock-out and tag-out the machine before performing
maintenance.
Moving parts – CLIMAX machines have numerous exposed moving parts
and interfaces that can cause severe impact, pinching, cutting, and other

Machine-specific safety precautions
P/N 95936, Rev. 0 Page 3
injuries. Except for stationary operating controls, avoid contact with mov-
ing parts by hands or tools during machine operation. Remove gloves and
secure hair, clothing, jewelry, and pocket items to prevent them from
becoming entangled in moving parts.
Sharp edges – Cutting tools and workpieces have sharp edges that can eas-
ily cut skin. Wear protective gloves and exercise caution when handling a
cutting tool or workpiece.
Hot surfaces – During operation, motors, pumps, HPUs, and cutting tools
can generate enough heat to cause severe burns. Pay attention to hot sur-
face labels, and avoid contact with bare skin until the machine has cooled.
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS
Eye hazard – This machine produces metal chips during operation. Always
wear eye protection when operating the machine.
Sound level – This machine produces potentially harmful sound levels.
Hearing protection is required when operating this machine or working
around it. During testing, the machine produced the sound levels1 listed in
Table 1-1.
Hazardous environments – Do not operate the machine in environments
where potentially explosive materials, toxic chemicals, or radiation may be
present.
Machine mounting – Do not operate the machine unless mounted to a
workpiece in accordance with this manual. If mounting the machine in an
overhead or vertical position, do not remove hoist rigging until the machine
is mounted to the workpiece in accordance with this manual. In any mount-
ing position, verify that the machine is tethered and mounted so that if the
machine slips or rotates, no injury or damage will occur.
1. Machine sound testing was conducted in accordance with European Harmonized
Standards EN ISO 3744:2010 and EN 11201:2010.
TABLE 1-1. SOUND LEVELS
Sound power 91.8 dBA
Operator sound pressure 84.0 dBA
Bystander sound pressure 89.7 dBA

Risk assessment and hazard mitigation
Page 4 FF1200-FF2400-FF3600 Operating Manual
1.5 RISK ASSESSMENT AND HAZARD MITIGATION
Machine Tools are specifically designed to perform precise material-removal oper-
ations.
Stationery Machine Tools include lathes and milling machines and are typically
found in a machine shop. They are mounted in a fixed location during operation
and are considered to be a complete, self-contained machine. Stationery Machine
Tools achieve the rigidity needed to accomplish material-removal operations from
the structure that is an integral part of the machine tool.
Portable Machine Tools are designed for on-site machining applications. They typ-
ically attach directly to the workpiece itself, or to an adjacent structure, and
achieve their rigidity from the structure to which it is attached. The design intent is
that the Portable Machine Tool and the structure to which it is attached become
one complete machine during the material-removal process.
To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, set-up, and operation practices that are unique
to Portable Machine Tools.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of portable machining applications,
identifying one or more hazards that must be addressed is typical.
When performing the on-site risk assessment, it is important to consider the Porta-
ble Machine Tool and the workpiece as a whole.

Risk assessment checklist
P/N 95936, Rev. 0 Page 5
1.6 RISK ASSESSMENT CHECKLIST
The following checklist is not intended to be an all inclusive list of things to watch
out for when setting up and operating this Portable Machine Tool. However these
checklists are typical of the types of risks the assembler and operator should be
considering. Use these checklists as part of your risk assessment:
TABLE 1-2. RISK ASSESSMENT CHECKLIST BEFORE SET-UP
I took note of all the warning labels on the machine.
I removed or mitigated all identified risks (such as tripping, cutting, crushing,
entanglement, shearing, or falling objects).
I considered the need for personnel safety guarding and installed any neces-
sary guards.
I read the machine assembly instructions (Section 3).
I took inventory of all the items required but not supplied (Section 2.3).
I considered how this machine operates and identified the best placement for
the controls, cabling, and the operator.
 I have assessed for additional risks unique to this application of the Portable
Machine tool.
TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After Set-up
I checked that the machine is safely installed (according to Section 3) and the
potential fall path is clear. If the machine is installed at an elevated position, I
checked that the machine is safeguarded against falling.
I identified all possible pinch points, such as those caused by rotating parts,
and informed the affected personnel.
I planned for containment of any chips or swarf produced by the machine.
I followed the required maintenance checklist (Section 5.1) with the recom-
mended lubricants (Section 5.2).
I checked that all affected personnel have the recommended personal protec-
tive equipment, as well as any equipment required by the site or other regula-
tions.
I checked that all affected personnel understand the danger zone and are clear
of it.
I have assessed for additional risks unique to this application of the Portable
Machine tool.

Labels
Page 6 FF1200-FF2400-FF3600 Operating Manual
1.7 LABELS
Label identification
The following warning labels should be on your machine. If any are defaced or
missing, contact CLIMAX immediately for replacements.
TABLE 1-4. LABELS
P/N 29152
Mass plate
P/N 46902
Warning
label: hot
surface
P/N 59035
Warning label:
wear eye pro-
tection
P/N 59037
Wear ear
protection
warning label
P/N 59039
Lift point warn-
ing label
P/N 59042
Warning
label: hand
crunch/mov-
ing parts
P/N 59044
Read opera-
tors manual
warning label
P/N 81132
Warning
label: lock-
out/tag out