Climax FF5000 User manual

FF5000
FLANGE FACER MACHINE
OPERATING MANUAL
P/N 36668
December 2015
Revision 4

P/N 36668, Rev. 4 Page A
©2015 Climax Portable Machining and Welding Systems or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied,
transmitted, disseminated, 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, provided 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 Portable Machining and Welding Systems, we value your opinion.
For comments or questions about this manual or other Climax documentation, please e-
mail [email protected].
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 factory
representative with the following:
Your name
Shipping address
Telephone number
Machine model
Serial number (if applicable)
Date of purchase.
Climax World Headquarters
Climax Portable Machining and Welding Systems
2712 South Second Street
Newberg, Oregon 97132 USA
Telephone (worldwide): [phone]
Toll-free (North America):1-800-333-8311
Fax: [phone]
E-mail: [email protected]
Climax European Headquarters
Climax GmbH
Am Langen Graben 8
52353 Düren, Germany
Telephone: [phone]
E-mail: [email protected]

Page B FF5000 Operating Manual
CLIMAX WORLDWIDE LOCATIONS

P/N 36668, Rev. 4 Page C
CE

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P/N 36668, Rev. 4 Page E
TABLE OF CONTENTS
1INTRODUCTION ...........................................................................................................................1
1.1 LIMITED WARRANTY.................................................................................................................1
TERMS OF SALE 1
ABOUT THIS MANUAL..............................................................................................................................1
1.2 HOW TO USE THIS MANUAL.......................................................................................................2
ALERTS 2
1.3 SAFETY PRECAUTIONS ............................................................................................................3
1.4 RISK ASSESSMENT CHECKLIST .................................................................................................3
1.5 ITEMS REQUIRED BUT NOT SUPPLIED.........................................................................................4
1.6 NOISE LEVEL 4
1.7 LABELS 5
2OVERVIEW ...................................................................................................................................7
2.1 ABOUT THIS MANUAL ...............................................................................................................7
2.2 ABOUT THE FF5000 ...............................................................................................................7
2.3 FF5000 SPECIFICATIONS ........................................................................................................8
2.4 PNEUMATIC MOTOR OPTION PERFORMANCE SPECIFICATIONS......................................................8
3SETUP.........................................................................................................................................11
3.1 RECEIPT AND INSPECTION .....................................................................................................11
3.2 SETUP AND ALIGN THE MACHINE.............................................................................................11
TO SETUP AND ALIGN THE MACHINE ......................................................................................................11
3.3 MOUNTING THE INTERFACE PLATE..........................................................................................12
3.4 LEVELING THE MACHINE.........................................................................................................13
3.5 TO PRECISION LEVEL AND CENTER THE MACHINE .....................................................................13
3.6 TOOL HEAD SETUP AND ADJUSTMENT......................................................................................14
3.7 ADJUSTING THE TOOL HEAD...................................................................................................15
4OPERATION ...............................................................................................................................17
4.1 STARTING AND STOPPING ......................................................................................................17
4.1.1 PREPARING THE MACHINE FOR START-UP...................................................................................18
4.1.2 STOPPING THE MACHINE ...........................................................................................................18
4.2 SETTING VERTICAL AND RADIAL TOOL FEED .............................................................................19
4.2.1 SETTING THE DRAG...................................................................................................................19
4.2.2 TO SET THE FEED .....................................................................................................................21
4.2.3 AUTOMATIC FEED .....................................................................................................................21
4.3 SETTING TOOL FEED SPEED AND DIRECTION ............................................................................22
4.3.1 SETTING THE FEED DIRECTION:..................................................................................................22
4.3.2 TO SET THE FEED SPEED/DIRECTION WHEN FLAT FACING.............................................................23
4.4 CUTTING ANGLES,GROOVES AND CHAMFERS ..........................................................................24
4.4.1 TO ADJUST THE TOOL HEAD.......................................................................................................24
5DISASSEMBLY...........................................................................................................................27
5.1 POST-OPERATION CHECKS ....................................................................................................27
5.2 TO DISASSEMBLE THE MACHINE..............................................................................................27
6MAINTENANCE ..........................................................................................................................29

Page F FF5000 Operating Manual
RECOMMENDED LUBRICANTS................................................................................................................29
6.1 CHUCK ASSEMBLY ................................................................................................................29
6.2 ALIGNMENT ASSEMBLY ..........................................................................................................29
6.3 MAIN BODY ASSEMBLY...........................................................................................................29
6.4 TOOL HEAD ASSEMBLY ..........................................................................................................29
6.5 AIR MOTOR AND PNEUMATIC ASSEMBLY MAINTENANCE.............................................................30
7STORAGE...................................................................................................................................31
7.1 SHORT-TERM STORAGE.........................................................................................................31
7.2 LONG-TERM STORAGE...........................................................................................................31
7.3 SHIPPING 31
APPENDIX A SPARE PARTS ..................................................................................................33
APPENDIX B EXPLODED VIEWS AND PARTS......................................................................35
APPENDIX A MSDS .................................................................................................................51

P/N 36668, Rev. 4 Page G
LIST OF FIGURES
FIGURE 1. CLIMAX MODEL FF5000 PORTABLE FLANGE FACER .......................................................................................................7
FIGURE 2. P/N 59246 PNEUMATIC SCHEMATIC .........................................................................................................................9
FIGURE 3. CHUCKS AND JAWS............................................................................................................................................... 12
FIGURE 4. MOUNTING INTERFACE PLATE ................................................................................................................................ 12
FIGURE 5. LEVELING THE MACHINE ........................................................................................................................................ 13
FIGURE 6. PRECISION LEVEING AND CENTERING THE MACHINE.................................................................................................... 14
FIGURE 7. PNEUMATIC AIR CONTROL VALVE SHUT OFF............................................................................................................... 18
FIGURE 8. SETTING TOOL FEED.............................................................................................................................................. 19
FIGURE 9. CAP SCREW LOCATIONS......................................................................................................................................... 20
FIGURE 10. SET SCREW LOCATIONS ....................................................................................................................................... 20
FIGURE 11. REMOVE CRANK HANDLE ..................................................................................................................................... 21

Page H FF5000 Operating Manual
LIST OF TABLES
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP.................................................................................................................3
TABLE 2. RISK ASSESSMENT CHECKLIST AFTER SET-UP ...................................................................................................................4
TABLE 3. RECOMMENDED LUBRICANTS .................................................................................................................................. 29
TABLE 4. SPARE PARTS LIST .................................................................................................................................................. 33
TABLE 5. TOOL KIT –P/N 29116 ......................................................................................................................................... 35

P/N 36668, Rev. 4 Page 1
1 INTRODUCTION
1.1 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 one year 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 prepaid, 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.

Page 2 FF5000 Operating Manual
1.2 How to use this manual
Alerts
Pay careful attention to the alertsappearing in this manual. Alert types are defined in the
following examples.
DANGER
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, WILL result in injury or loss of life.
WARNING
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, COULD result in injury or loss of life.
CAUTION
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, could result in minor or moderate injury.
NOTICE
concerns a condition, procedure, or practice worthy of special
attention.
TIP: A tip provides additional information that can aid in completion of a
task.

P/N 36668, Rev. 4 Page 3
1.3 Safety precautions
Climax Portable Machining and Welding Systems leads the way in promoting the safe
use of portable machine tools. Safety is a joint effort. You, the machine operator, must do
your part by being aware of your work environment and closely following the operating
procedures and safety precautions 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.
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 the appropriate personal protective gear
when operating this or any other machine tool. Eye and ear protection are required when
operating or working around the machine. Flame-resistant clothing with long sleeves and
legs is recommended when operating the machine, as hot flying chips from the workpiece
may burn or cut bare skin.
Work area –Keep the work area around the machine clear of clutter. Keep all cords and
hoses away from the work area when operating the machine.
Moving parts –Except for operating controls, avoid contact with moving parts by hands or
tools during machine operation. Secure hair, clothing, jewelry, and pocket items to
prevent them from becoming entangled in moving parts.
1.4 Risk assessment checklist
Use these checklists as part of your on-site risk assessment and include any additional
considerations that may pertain to your specific application.
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP
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 necessary
guards.

I read the machine assembly instructions (Section 3.2).

I considered how this machine operates and the best placement for the controls,
cabling, and the operator.

I have evaluated and mitigated any other potential risks specific to my work area.

Page 4 FF5000 Operating Manual
TABLE 2. 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 elevated, 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 maintenance guidelines (Section 6Error! Reference source not found.)
ith the recommended lubricants.

I checked that all affected personnel have the recommended personal protective
equipment, as well as any equipment required by the site or other regulations.

I checked that all affected personnel understand the danger zone and are clear of it.

I have evaluated and mitigated any other potential risks specific to my work area.
1.5 Items required but not supplied
There are no items required but not supplied with the FF5000 machine.
1.6 Noise level
Sound power level is 80.3 dB(A)
Operator Sound Pressure Level is 86.2 dB(A)
Bystander Sound Pressure level is 80.0 dB(A)

P/N 36668, Rev. 4 Page 5
1.7 Labels
The following labels should be on yhour machine. If any are defaced or missing, contact
Climax immediately for replacements.
P/N 35772
Plus or minus direction
indicator
P/N 59044
Lable safety warning
read manual
P/N 80510 label safety
warning cutting of
fingers, or rotating blade
P/N 81008
Label safety warnign eye
and ear protection
required

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P/N 36668, Rev. 4 Page 7
2 OVERVIEW
Information in this manual is up-to-date at the time of going to print. However, because
of the Climax commitment to ongoing product improvement, the machine you receive
may differ slightly from the one described herein.
2.1 About this manual
This manual describes how to use your Model FF5000 Portable Flange Facer. For
maximum safety and performance, read the entire instruction manual before operating the
machine.
2.2 About the FF5000
The Model FF5000 Portable Flange Facer is an (Inside Diameter) ID-mounted flange re-
facer. Its compact design makes it an ideal on-site maintenance tool. The machine fits
into bores with ID's from 5.0" to 14.0" (127.0 to 355.6 mm). With the optional larger
chuck, the mounting range is increased to 24” (610 mm) and I.D. flanges from 5" to 24"
(127 to 610 mm) can be machined. Call Climax if you have special requirements outside
of this range.
The FF5000 components are shown in Figure 1.
FIGURE 1. CLIMAX MODEL FF5000 PORTABLE FLANGE FACER

Page 8 FF5000 Operating Manual
2.3 FF5000 specifications
Facing diameter:
5.0 –24.0 inch (127 –609.6 mm)
ID mounting range:
5-14 inch standard
5.0 –18 inch (127 –457.2 mm) using three chucks, optionally
up to 24”
Maximum axial travel:
2.8 inch (71.1 mm) (.10 inch/turn (2.5 mm/turn) effective lead)
Axial travel feed rate:
0 -0.030 inch/rev (0 - .76 mm/rev) fully adjustable
(approximate range)
Maximum down-feed travel:
2.0 inch (50.8 mm)
Down feed rate:
0- 0.020 inch/rev (0 - 0.51 mm/rev) fully adjustable
(approximate range)
Tool holder rotation:
45 degrees counter-clockwise, 85 degrees clockwise (facing
tool head)
Right angle drive ratio:
4:1
Main drive gear ratio:
7.05:1
Overall gear ratio:
28.2:1
Machine weight without
chuck:
60 lbs (28 kg)
Shipping weight:
175 lbs (80 kg)
Shipping dimensions:
25” x 25” x 18” (635mm x 635mm x 460mm)
2.4 Pneumatic motor option performance specifications
Maximum rated horsepower:
1.07 hp (800 W)
Cutter head speed:
20 rpm free speed
Torque at cutter:
170 ft-lb (230 Nm) at maximum rated power (assumes .85
efficiency each gearbox)
Air requirements
60 scfm (1700 SLPM) at 90 psi
Air motor torque:
8.25 ft-lbs (11.25 Nm) at maximum power
13.75 ft-lbs (18.75 Nm) stall

P/N 36668, Rev. 4 Page 9
FIGURE 2. P/N 59246 PNEUMATIC SCHEMATIC
NOTICE
Contact Climax right away if there are any errors or questions about
this equipment.

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