Climax FF7200 User manual

PN: 59129 March 2019 Revision 9
FF7200 Flange Facer Machine
OPERATING MANUAL
This manual is available in electronic format as P/N 59129
Original Instructions
Serial Number Range: 11017900 –15121870

P/N 59129, Rev. 9 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,
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, 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
[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 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: +44 (0) 161-
406-1720
CLIMAX | H&S Tool (European Headquarters)
Am Langen
Graben 8 52353
Düren, Germany
Telephone: [phone]
E-mail: [email protected]
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 FF7200 Operating Manual
CLIMAX WORLDWIDE LOCATIONS

P/N 59129, Rev. 9 Page C
CE

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P/N 59129, Rev. 9 Page E
TABLE OF CONTENTS
Introduction...................................................................................................................................................1
Labeling Guidelines ........................................................................................................................................3
Risk Assessment and Hazard Mitigation .........................................................................................................4
Risk Assessment Checklist ..............................................................................................................................5
Labels ............................................................................................................................................................6
Limited Warranty...........................................................................................................................................7
General Information ......................................................................................................................................8
Standard Components ...................................................................................................................................9
Dimensions and Clearance .............................................................................................................................12
Setup .............................................................................................................................................................13
Surface mount (optional equipment) .............................................................................................................28
Back face attachment setup (optional equipment) .........................................................................................31
OD mount (optional equipment) ....................................................................................................................36
Grinding attachment (optional equipment)....................................................................................................44
Milling attachment (optional equipment) ......................................................................................................46
Operation ......................................................................................................................................................53
Maintenance..................................................................................................................................................60
Storage ..........................................................................................................................................................61
Spare Parts.....................................................................................................................................................62
Specifications.................................................................................................................................................64
Exploded Views and Parts ..............................................................................................................................65
SDS ................................................................................................................................................................97

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P/N 59129, Rev. 9 Page 1
Introduction
About this Manual
CLIMAX machines are highly configurable with many options and accessories. This manual
covers the use and operation of all of those possible options. The machine configuration
purchased by a customer may not contain all of the options and accessories in this manual. If
a specific machine application requires additional options or accessories, please contact
CLIMAX for assistance in obtaining the needed components.
This manual describes the operation and maintenance of your flange facer. The machine is
designed for facing, beveling and grooving operations. All parts meet CLIMAX’s strict quality
standards. For maximum safety and performance, you must read the entire manual before
operating the machine.
Safety Guidelines
The primary safety challenge for most on-site maintenance is that repairs are often done under
difficult conditions.
CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint
effort. As the operator of this machine, you are expected to do your part by closely examining
the job site and following the operating procedures outlined in this manual, your own company
rules, and local regulations.
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 assessment 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 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.
Lifting –Many CLIMAX machine components are very heavy. Whenever possible, lift the
machine or its components using proper hoisting equipment and rigging. Always use
designated lifting points on the machine. Follow all lifting instructions in the setup
procedures of this manual.
Lock out/tag out –Lock out and tag out the machine before doing maintenance.

Page 2 FF7200 Operating Manual
Moving parts –CLIMAX machines have numerous exposed moving parts and interfaces
that can cause severe impact, pinching, cutting, and other injuries. 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.
Sharp edges –Cutting tools and workpieces have sharp edges that can easily cut skin.
Wear protective gloves and exercise caution when handling a cutting tool or workpiece.
Hot surfaces –During operation, motors, some housings, and cutting tools can generate
enough heat to cause severe burns. Pay attention to hot surface labels. Avoid contact
with bare skin until the machine has cooled.
Eye protection is required.
Hearing protection is required.
The maximum temperature data (taken after 35 minutes of operating the machine in a continuous
cut) is 129o F (54o C).

P/N 59129, Rev. 9 Page 3
Labeling Guidelines
The purpose of product safety signs and labels is to increase the level of awareness to possible
dangers.
Safety Alert Symbols indicate DANGER, WARNING or CAUTION. These symbols may be used
in conjunction with other symbols or pictographs. Failure to obey safety warnings can result in
serious injury. Always follow safety precautions to reduce the risk of hazards and serious injury.
DANGER
Indicates a hazardous situation that could be fatal or
cause serious injury.
WARNING
Indicates a potentially hazardous situation that
could be fatal or cause serious injury.
CAUTION
Indicates a potentially hazardous situation that
could result in minor to moderate injury, damage to
the machine or interruption of an important
process.
IMPORTANT
Provides critical information for the completion of a
task. There is no associated hazard to people or the
machine.
TIP
Provides important information regarding the
machine.

Page 4 FF7200 Operating Manual
Risk Assessment and Hazard Mitigation
Machine Tools are specifically designed to perform precise material-removal operations.
Stationary 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 a
complete, self-contained machine. Stationary 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 typically 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 attached to it become one complete machine during the material-removal process.
To achieve the intended results and to promote safety, the operator must understand 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 Portable Machine
Tool and the workpiece as a whole.

P/N 59129, Rev. 9 Page 5
Risk Assessment Checklist
Use these checklists as part of your risk assessment:
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP
Before Set-up

I took note of all the warning labels on the machine (shown on page 6).

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 Setup section on page 13.

I created a lift plan, including identifying the proper rigging, for each of the setup
lifts required during the setup of the support structure and machine.

I located the fall paths involved in lifting and rigging operations. I have taken
precautions to keep workers away from the identified fall path.

I considered how this machine operates and the best placement for the controls,
cabling, and the operator.

I evaluated and mitigated any other potential risks specific to my work area.
TABLE 2. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After Set-up

I checked that the machine is safely installed (according to the Setup section) 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 section with the recommended lubricants on page 60.

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 evaluated and mitigated any other potential risks specific to my work area.

Page 6 FF7200 Operating Manual
Labels
Part Number 29154 –CE Machine Nameplate
Part Number 29152 –Mass Tag displays the
weight of a group of components or the assembly
Part Number 59039 –Designated Lift Point
Part Number 39546 –Chemical Designator
Part Number 35772 –Ball Valve Handle
Part Number 27462 –Warning Label
Part Number 84019 –CLIMAX Logo
Part Number 59037 –Hearing Protection
Required

P/N 59129, Rev. 9 Page 7
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 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.

Page 8 FF7200 Operating Manual
General Information
•Use of large, heavy-duty, construction-grade bearings provides powerful,
rigid performance throughout the entire machine facing range, even
machining over bolt hole patterns.
•Infinitely variable feed rates from 0.002-0.035”/rev (0.051-0.889 mm/rev)
provide operational flexibility and the ability to provide phonographic
finishes with OFF/ON capabilities.
•The tool head may be rotated a full 360˚, providing the ability to create a
variety of chamfers, O-Ring grooves, lens rings and other angular
surfaces as needed.
•Oversized ring gear provides steady rotation for difficult machining
challenges.
•Unique chucking system minimizes parts and greatly simplifies machine
set-up and tear down.
•Chucking system can be removed to allow customers to face mount the
flange facer for applications like machining heat exchanger flanges.
•Turning arm can be infinitely positioned to reduce rotating swing clearance
as needed for close quarter applications.
•Feed box can be mounted to provide either radial or axial feed.
•Features a remote control feed rate adjustment to allow the machine
operator to safely adjust the feed rate without reaching into the rotating
machine. This also allows for feed adjustment while machining.

P/N 59129, Rev. 9 Page 9
Standard Components
Figure 1. Components
Table 3. Components figure identification
Number
Description
1
Lifting eyes
2
Tool arm assembly (30–72" [762–1,829 mm] range)
3
Rotary union
4
Tool arm clamps
5
Drag brake
6
Counterweight assembly
7
Leveling feet
8
Chucking assembly (30–72" [762–1,829 mm] range)
9
Drive assembly

Page 10 FF7200 Operating Manual
Figure 2. Main machine in wood crate
Figure 3. Tool Kit
Number
Description
10
Swiveling tool head
11
Pneumatic feedbox
12
Non-leveling feet
Main Machine Components
1 FF7200 Main Machine with counter weight and turning arm assembly
8 57701 Chuck Leg 2.5 Inch Long
8 57702 Chuck Leg 5.0 Inch Long
8 57703 Chuck Leg 8.0 Inch Long
8 57704 End Cap 4.5 Diameter
4 57637 Leveling Foot with #57556 M30 x 3.5 Jam Nut
4 57899 Non-leveling Foot with #57556 M30 x 3.5 Jam Nut
1 59329 Pneumatic Conditioning Unit w/Quick Coupler #55126
1 58185 Tool Kit Box (see contents below)
1 59245 Hose and Control Valve Assembly (feed unit controller)

P/N 59129, Rev. 9 Page 11
Tool Box Contents
120”50985Tubing 1/4 in OD x .040 Wall DOT 1200 psi Nylon
120”59151 Tubing 1/8 in OD x .023 Wall DOT 1000 psi Nylon
1 59129 Operator Manual FF7200
1 35516 Dead Blow Hammer 1-3/4 Dia. Head
2 65188 WrenchSpanner110mm to 115mm (4-1/2) Dia. .300 Dia. Pin
2 58353 Open End Wrench 55mm x 9-1/2 Long
1 14818 Ratchet Wrench ½ Drive
1 46250 Hex Socket 10mm x ½ Drive
1 46249 Hex Socket 14mm x ½ Drive
1 46252 Hex Socket 17mm x ½ Drive
1 58354 Socket Wrench Extension ½ Drive x 5 Long
1 34866 Air Tool Oil- 4 oz. Bottle
1 33999 Hex Wrench Set- .050- 3/8 Inch Ball End
1 38678 Hex Wrench Set- 1.5- 10mm Ball End
1 63678 Knob Cast Iron
1 29066 Tool Bit HSS ¾ x 5 LH Finish Single SC
1 29067 Tool Bit HSS ¾ x 5 RH Finish Single SC
10 61820 Carbide Insert- Saco WNMP 431-MF1 TM4000
1 39633 Torx Wrench T-15
1 60034 Holder Insert ¾ Sq. Shank RH
1 60033 Holder Insert ¾ Sq. Shank LH
8 45530 Screw M8 x 1.25 x 30mm
4 59085 Setup Finger FF7200

Page 12 FF7200 Operating Manual
Dimensions and Clearance