Climax FF6300 User manual

FF6300
FLANGE FACER
FF6300 OPERATING MANUAL
SERIAL NUMBER RANGE: 15000834–
ORIGINAL INSTRUCTIONS
P/N 80679
July 2019
Revision 10

P/N 80679, Rev. 10 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 FF6300 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 80679, Rev. 10 Page C
CE DOCUMENTATION

Page D FF6300 Operating Manual
LIMITED WARRANTY
Climax Portable Machining & Welding Systems, 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.

P/N 80679, Rev. 10 Page i
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.8 LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 ITEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.1 ID chuck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 ID chuck assembly dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.3 OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.4 OD mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.5 Surface mount assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1.6 Surface mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 RIGGING AND LIFTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.1 Pneumatic conditioning unit controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.3.2 Hydraulic power unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4.2 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.3 Rotational speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.4 Feed rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 PREPARING THE MACHINE FOR USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Pre-setup check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.2 Assessing the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 LIFTING AND RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 SETUP OVERVIEW FOR THE ID CHUCK MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.5 INSTALLATION HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.6 INSTALLING THE ID CHUCK IN THE WORKPIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Page ii FF6300 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
3.7 OD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.7.1 Setup overview for the OD mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7.2 Assembling the OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.7.3 OD mounting arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.7.4 Attaching the OD mount assembly to the workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.7.5 Centering and leveling the OD mount assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.8 SURFACE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.8.1 Setup overview for the surface mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.8.2 Assembling the surface mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.8.3 Centering and leveling the surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.9 POSITIONING THE MACHINING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.10 POSITIONING THE COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.11 ROTATING THE TOOL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.12 ADJUSTING THE FEED BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.12.1 Adjusting the feed rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.12.2 Conducting feed actuation measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.12.3 Reversing the feed direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.12.4 Disconnecting feed hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.13 BACKFACING ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.1 PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 PRE-START CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3 MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3.1 Pneumatic-powered machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3.2 Hydraulic-powered machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.3.3 Adjusting the machine when the cut is completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.1 Check the pneumatic conditioning unit oil reservoir levels . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.2 Empty the air filter water trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.3 Pneumatic conditioning unit emergency stop check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.4 Pneumatic conditioning unit drop-out circuit check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.3.5 Hydraulic power unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

P/N 80679, Rev. 10 Page iii
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5.3.6 Dovetail and square ways maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.3.7 Leadscrew maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.3.8 Adjust the dovetail and square ways gib screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.9 Adjust the radial slide lead nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.10 Tram the turning arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.4 LUBRICATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.5.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.5.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.5.3 The feed is slow or unresponsive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.5.4 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.5.5 The machine is not cutting flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.6 DECOMMISSIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
APPENDIX A EXPLODED VIEWS AND PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
APPENDIX C SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Page iv FF6300 Operating Manual
This page intentionally left blank

P/N 80679, Rev. 10 Page v
LIST OF FIGURES
FIGURE PAGE
1-1. Warning label placement FF6300 ID chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-2. Warning label placement FF6300 ID chuck (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-3. Warning label placement FF6300 OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1-4. Warning label placement FF6300 pneumatic conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-1. ID chuck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-2. ID chuck assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-3. OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-4. OD mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-5. Surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-6. Surface mount assembly dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2-7. Detail of pneumatic conditioning unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2-8. Detail of hydraulic power unit controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-1. M10 lifting eye (P/N 70483) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-2. Measure the flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-3. Assemble the ID chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-4. Adjust the turning arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-5. Place the ID chuck in the flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-6. Level and center the ID chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-7. Install a tool bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-8. Connect the hoses (hydraulic version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-9. Vertical hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3-10. Attaching the ID chuck to the main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3-11. Vertical installation fall danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-12. Applying anti-seize compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-13. Detail of ID chuck legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3-14. Adjusting the setup fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-15. Location of the 10-mm hex for manual rotation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-16. OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-17. Centering plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-18. Attaching the OD mount assembly to the main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-19. OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-20. Distance for OD mount measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-21. Measurement points for each arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-22. Attaching the OD mount with a tack-weld nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-23. Attaching the OD mount using the CLIMAX chain clamp kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-24. OD mount adjustment points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-25. Surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3-26. Location of securing clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3-27. Detail of machining arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3-28. Location of clamping screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-29. Location of locking screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3-30. Detail of tool holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3-31. Location of swivel clamping screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3-32. Feed box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Page vi FF6300 Operating Manual
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
3-33. Detail of feed box positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3-34. Knob revolutions marked on the machined flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3-35. Feed rate adjustment knob and feed box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-36. Pneumatic valve location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3-37. Dial indicator used for precise adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-38. Location of feed box bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3-39. Location of feed box direction arrow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-40. Feed adjustment knob positioned down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-41. Location of feed hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3-42. Backfacing attachment on surface mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3-43. Installing the backfacing attachment to the turning arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3-44. Backfacing attachment dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4-1. Detail of hose guide bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4-2. Pneumatic powered machining valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4-3. Location of hydraulic powered rotation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5-1. Location of lead nut adjustment screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5-2. Lubrication locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5-3. Location of feed box filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6-1. FF6300 in containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6-2. Packing the FF6300 with ID chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6-3. Packing the FF6300 with OD mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
A-1. Feed box pneumatic manual feed adjust (P/N 87326). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
A-2. Air control assembly for pneumatic feed (P/N 87941) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
A-3. Pneumatic filter and valve with stand assembly (P/N 59329) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
A-4. Pneumatic conditioning unit 1/2" (13 mm) low-pressure drop-out (P/N 78264) . . . . . . . . . . . . . . . . . . 84
A-5. Pneumatic conditioning unit 1/2" (13 mm) low-pressure drop-out parts list (P/N 78264). . . . . . . . . . . 85
A-6. Slide tool holder assembly (P/N 79790). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
A-7. Slide tool holder assembly parts list (P/N 79790) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A-8. Main body assembly (P/N 87913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
A-9. Main body assembly parts list (P/N 87913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
A-10. Turning arm assembly 38" (965 mm) (P/N 80304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A-11. Turning arm assembly 38" (965 mm) parts list (P/N 80304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
A-12. Counterweight arm assembly (P/N 80324) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
A-13. Backface attachment assembly (P/N 80362). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A-14. OD mount assembly 38–63” (965–1,600 mm) (P/N 80477). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
A-15. OD mount assembly 38–63" (965–1,600 mm) parts list (P/N 80477) . . . . . . . . . . . . . . . . . . . . . . . . 95
A-16. OD mount clamp kit (P/N 80622) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A-17. FF6300 pneumatic kit (P/N 80969) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A-18. FF6300 hydraulic kit (6.2 cu.in. motor with QD FTG) (P/N 80970) . . . . . . . . . . . . . . . . . . . . . . . . . . 98
A-19. Air valve assembly (P/N 87916). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A-20. ID chuck assembly 4 leg 12–57" (305–1,448 mm) (P/N 81971) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A-21. Leveling foot 4" (102 mm) assembly (P/N 81977) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A-22. Surface mount assembly (P/N 82309) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A-23. Air control assembly for pneumatic feed and 1/2" (13 mm) drive supply (P/N 87917). . . . . . . . . . . 103

P/N 80679, Rev. 10 Page vii
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
A-24. Hydraulic kit 6.2 cubic motor (P/N 82555) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A-25. Bypass assembly for set up of hydraulic machine (P/N 83154). . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A-26. Bypass assembly for set up of hydraulic machine (P/N 83166). . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
B-1. Pneumatic schematic (P/N 87917). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
B-2. Assembly schematic for pneumatic feed only (used with hydraulic machines) (P/N 87941) . . . . . . . 111
B-3. Hydraulic kit 6.2 cubic in motor with QD FTG FF6300 (P/N 80970) . . . . . . . . . . . . . . . . . . . . . . . . . 112

Page viii FF6300 Operating Manual
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P/N 80679, Rev. 10 Page ix
LIST OF TABLES
TABLE PAGE
1-1. Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
1-1. Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2. Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-3. Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1-4. Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-1. Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-2. Shipping weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-3. Shipping dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-1. ID chuck setup table for standard ID chuck hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3-2. Feed rate adjustment knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5-1. Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5-2. Recommended lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
A-1. Tool kit (P/N 80327) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A-2. Recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Page x FF6300 Operating Manual
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P/N 80679, Rev. 10 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
1.8 LABEL LOCATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
1.9 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11
1.1 HOW TO USE THIS MANUAL
This manual describes the setup, operation, maintenance, storage, shipping, and
decommissioning of the FF6300 Flange Facer Machine.
NOTICE
For maximum safety and performance, read this entire manual before
attempting to set up or operate the machine.
The first page of each chapter includes a list of the chapter contents to help you locate
specific information.
The appendices contain supplemental product information to aid in setup, operation,
and maintenance tasks.
1.2 SAFETY ALERTS
Pay careful attention to the safety alerts in this manual. Safety alerts call your attention
to dangerous situations that you may encounter when operating this machine. This
manual uses the following types of safety alerts:1
DANGER
indicates a dangerous situation that, if not avoided, WILL result in death or
serious injury.
1. For more information on safety alerts, see ANSI/NEMA Z535.6-2011, Product safety Infor-
mation in Product Manuals, Instructions, and Other Collateral Materials.

Page 2 FF6300 Operating Manual
WARNING
indicates a dangerous situation that, if not avoided, COULD result in
death or serious injury.
CAUTION
indicates a dangerous situation that, if not avoided, could result in minor
or moderate injury.
NOTICE
indicates a dangerous situation that, if not avoided, could result in
property damage, equipment failure, or undesirable 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 must do your part by:
• Being aware of your work environment
• Closely following the operating procedures and safety precautions con-
tained in this manual
• Closely following your employer’s safety guidelines
When operating or working around the machine, observe the safety precautions
below.
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. Conduct a risk assessment (Section 1.5 and Section 1.5 on
page 6) 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. Wear
flame-resistant clothing with long sleeves and legs 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. Restrain
cords and hoses connected to the machine. Keep other cords and hoses
away from the work area.
Danger zone – The danger zone of this machine is defined as being inside
the turning radius of the machine, or as being outside the diameter of the

P/N 80679, Rev. 10 Page 3
machine when using the OD mount assembly.
Lifting – Many CLIMAX machine components are very heavy. Whenever
possible, use proper hoisting equipment and rigging to lift the machine or
its components. Always use the lifting points designated on the machine.
Follow the lifting instructions in Section 3.3 on page 27. Be cautious;
never drop electrical equipment as this will damage the components.
Lock out/tag out – Lock out and tag out the machine before performing
maintenance or entering the danger zone to adjust this machine.
Moving parts – CLIMAX machines have numerous exposed moving parts
and interfaces that can cause severe impact, pinching, cutting, and other
injuries.
During machine operation:
• Keep hands and tools away from moving parts.
• 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 warning 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.
Always wear hearing protection when operating the machine or working
around it. During testing, the machine produced the following sound lev-
els.1
TABLE 1-1. SOUND LEVELS
Pneumatic Hydraulic
Sound power 87.3dBA 78.9dBA
Operator sound pressure 76dBA 65dBA
Bystander sound pressure 74dBA 68dBA
1. Machine sound testing was conducted in accordance with European Harmonized
Standards EN ISO 3744:2010 and EN 11201:2010.

Page 4 FF6300 Operating Manual
Hazardous environments – Do not operate the machine in environments
where explosive materials, toxic chemicals, or radiation may be present.
Do not expose the machine to rain or wet conditions.
Rotating machinery – Rotating machinery can cause serious injuries. Lock
out all power sources before performing any adjustment, lubrication, or
maintenance.
Secure loose clothing and long hair – Rotating machinery can cause
serious injuries. Do not wear loose fitting clothing or jewelry. Tie back
long hair or wear a hat.
Hoses, pendants, and electrical cables
• Do not abuse the pendant cable as this can damage the cable and pen-
dant.
• Never use the cord for carrying, pulling, or unplugging.
• Remove any and all kinks before straightening the cable.
• Keep cords and hoses away from heat, oil, sharp edges, and moving
parts.
• Plugs must match the outlet. Never modify the plugs in any way. Do
not use an adapter plug with grounded power tools.
• Always examine hoses and cables for damage before use.
Adjustments and maintenance – Stop the machine and lock out all power
sources before performing any adjustment, lubrication, or maintenance.
Controls – The machine controls are designed to withstand the rigors of nor-
mal use. The on/off switches are clearly visible and identifiable. When you
leave the machine, disconnect all power sources to the machine:
• For the pneumatic machine (or portion of the machine), either discon-
nect the air hose or move the lock-out/tag-out valve to the lock posi-
tion.
• For the hydraulic machine, turn off the power at the HPU.