Climax FLANGE FACER User manual

P/N 35425
May 2019
Revision 2
FF4000
FLANGE FACER
OPERATING MANUAL
SERIAL NUMBER RANGE: 11017900 -
15121870
ORIGINAL INSTRUCTIONS
FF4000 Flange Facer shown

P/N 35425, Rev. 2 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
[e-mail].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-
mail [email protected]m. 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: [e-mail]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
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Headquarters)
Warehouse #5, Plot: 369 272 Um
Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B FF4000 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 35425, Rev. 2 Page C
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 D FF4000 Operating Manual
CE DOCUMENTATION
LACEHOLDER FOR CE DECLARATION OF INCORPORATION

P/N 35425, Rev. 2 Page E
Contents
Safety Guidelines .................................................................................................1
Machine Specific Safety Practices........................................................................2
Labeling Guidelines..............................................................................................3
Introduction...........................................................................................................6
About this manual.................................................................................................7
Receiving Inspection ............................................................................................8
Recommended tools.............................................................................................9
Setup..................................................................................................................10
Operation............................................................................................................17
Disassembly.......................................................................................................21
Maintenance.......................................................................................................22
Storage...............................................................................................................23
Exploded Views and Parts..................................................................................24

Page F FF4000 Operating Manual
This page is intentionally left blank

P/N 35425, Rev. 2 Page 1
Safety Guidelines
The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions.
Climax Portable Machining & Welding Systems 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 scrutinizing the job site and closely following the
operating procedures outlined in this manual, your own company rules, and local regulations. Save all warnings and instructions for
future reference.
WARNING
For maximum safety and performance, read and understand this entire manual and
all other related warnings and safety instructions before using this equipment.
Failure to follow the warnings, instructions and guidelines in this manual could
cause personal injury, fatalities, electric shock, fire and/or property damage.
QUALIFIED PERSONNEL
Before operating this machine, you must receive
training specific to this machine from a qualified
trainer. If you are not familiar with the proper and
safe operation, do not use the machine.
OBEY WARNING LABELS!
Obey all warnings and warning labels. Failure to
follow instructions or heed warnings could result in
injury, or even be fatal. Proper care is your
responsibility. Contact Climax immediately for
replacement of damaged or lost manuals or safety
decals. 1-800-333-8311
INTENDED USE
Only use the machine according to the instructions
in this operating manual. Do not use this machine
for any purpose other than the intended use as
described in this manual. When using the tools,
machine, accessories and/or tool bits, you must
determine the proper working conditions and the
work to be performed.
STAY CLEAR OF MOVING PARTS
Keep clear of the machine during operation. Never
lean toward or reach into the machine to remove
chips or to adjust the machine while it is running.
Keep bystanders away while operating this
machinery.
ROTATINGMACHINERY
Rotating machinery can seriously injure an
operator. Lock out all power sources before you
interact with the machine.
KEEP YOUR WORK AREA CLEAN AND TIDY
Keep all cords and hoses away from moving parts
during operation. Do not clutter the area around the
machine. Keep the work area clean and well lit.
AMBIENT LIGHTING
Do not operate this machine in ambient lighting that
is less than normal intensity.
SECURE LOOSE CLOTHING AND LONG HAIR
Rotating machinery can seriously injure an operator
as well as others close by. Don’t wear loose fitting
clothing or jewelry. Tie back long hair or wear a hat.
HAZARDOUS ENVIRONMENTS
Do not use the machine in a hazardous
environment, such as near explosive chemicals,
flammable liquids, gasses, toxic fumes, or
inappropriate radiation hazards.
HOSES, PENDANT AND ELECTRICAL CABLES
Do not abuse the pendant cable as this can
damage the cable and pedant. 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 or
moving parts. Plugs must match the outlet. Never
modify the plugs in any way. Do not use an adapter
plug with grounded power tools. Do not expose the
machine to rain or wet conditions. Always examine
hoses and cables for damage before use. Be
cautious and never drop electrical equipment, this
will damage the components.
REPETITIVE MOTION
Individuals can be susceptible to disorders of the
hands and arms when exposed to tasks that involve
highly repetitive motions and/or vibration.
STAY ALERT
Stay alert, watch what you are doing and use
common sense when operating machinery. Do not
operate machinery while you are tired or under the
influence of drugs, alcohol or medication

Page 2 FF4000 Operating Manual
Machine Specific Safety Practices
This list includes safety practices applicable to Climax’s Portable Machines.
All aspects of the machine have been designed with safety in mind. Warning signs are affixed to the machine to warn of residual
hazards associated with machine relating to operation, setup, whether or not it is in use.
MACHINE SAFETY FEATURES
Never attempt to defeat or override the safety
features designed into the machine.
SECURING THE MACHINE
Never attempt to run the machine without first
securing it to a stable workpiece.
BODY PROTECTION
Wear safety glasses, earplugs, and safety shoes
while operating the machine.
Gloves are not a form of protection and should not
be worn while operating the machine. Metal chips
and debris created by the machine should be
disposed using a dust pan and broom.
KEEPING CLEAN
Maintain your machine according to the procedures
described in this manual to maximize safety and
machine longevity.
KEEP CLEAR
Keep clear of the machine during operation. Never
lean or reach into the machine to remove chips or
to adjust the machine while it is running. Doing so
can cause serious injury or death.
CONTROLS
Operator controls are located outside the danger
zone of the machine. All controls perform a one-to-
one action.
The machine is not supplied with a power unit and,
therefore, does not have an E-stop.
MACHINE SETUP AND DISASSEMBLY
With a modular design, the machine can be broken
down into components to ease setup.
MACHINE GUARDS
There are no guards used on this machine.
ELECTRICAL EMISSIONS
There are no electrical components used on this
machine.
OPERATOR STATION
Due to the nature of portable machinery, no
designated operator’s station exists.
MOVING PARTS
The operator is not exposed to the cutter head
when the workpiece is being machined.
Keep all cords and hoses from moving parts during
operation. If the cords become tangled in the
machinery the operator could be seriously injured
and the machine extensively damaged.
FLUIDS
Cutting fluids are required for machine operation.
The machine itself does not emit any fluids.
LIFTING
When lifting the machine for setup or disassembly,
a conventional sling-type lift is suggested for
convenience and safety of the operator. Use
designated lifting eyes. Do not lift the machine by
the turning bar.
REPETITIVE MOTION
Individuals can be susceptible to disorders of the
hands and arms when exposed to tasks that involve
highly repetitive motions and/or vibration. To reduce
the likelihood of these disorders, follow these
guidelines:
•Use minimum hand grip force
•Keep wrists straight
•Avoid exposure to continue vibration
•Avoid repeated bending of wrists and hands
•Keep hands and arms warm and dry

P/N 35425, Rev. 2 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.
NOTE
Provides important information regarding the machine.

Page 4 FF4000 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 to be 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.
In contrast, 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 35425, Rev. 2 Page 5
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 and took inventory of all the items required
but not supplied.

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 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 Intervals with 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 evaluated and mitigated any other potential risks specific to my work
area.

Page 6 FF4000 Operating Manual
Introduction
The Model FF4000 is a compact, lightweight, portable flange-facing and pipe
beveling machine notable for its 2-piece “Quick-Lock” ID-mount chuck. Its primary
application is for restoration of flanges from 3” to 19” (76 to 483 mm) diameter.
Secondary operations include beveling, squaring, counter boring and cutting weld-
prep configurations on tube and pipe.
The basic machine configuration includes:
An air motor, pneumatic conditioner and facing head.
Sets of 15 clamp blades (3 blades/set) for bores 3.65" - 12.7" (93 –323 mm)
diameter. (3.0” – 3.65” without a chuck blade)
Tool kit with hexagon wrench set, Operating Manual, dead blow hammer, and
spanner wrench.
Facing bits for roughing and finishing operations.
Heavy-duty plastic containers for storage and shipping.
For beveling operations, the following tool bits are added:
One facing bit, one beveling bit, and one counterbore bit.

P/N 35425, Rev. 2 Page 7
About this manual
This manual describes the most effective setup and operation of your Model FF4000
Flange Facer. All parts meet Climax Portable Machining & Welding Systems’ strict
quality standards. For maximum safety and performance, read the entire manual
before operating this machine.

Page 8 FF4000 Operating Manual
Receiving Inspection
In accordance with normal practice, be sure to inspect the machine for any damage
that may have occurred in shipping. Check parts received against the invoice or
packing slip and promptly notify Climax should there be any discrepancies.

P/N 35425, Rev. 2 Page 9
Recommended tools
Climax includes a general tool kit for use in operating the machine. Additionally, you
may require other items of equipment specific to your job-site and particular setup.
Supplied with the machine:
Dead blow hammer
Spanner wrench
Hex key wrench set
Other tools you could have on hand:
Pliers for pulling chips away from the machine.
Chip brush
Cutting oil
File
Honing stone
Precision instruments
In most cases, this machine can be setup using basic measuring devices such as a
steel rule or tape measure. Should greater precision be required, some or all of the
following may be useful:
Dial or digital calipers
ID calipers
Machinist’s precision level
Micrometers
Dial indicator

Page 10 FF4000 Operating Manual
Setup
CAUTION
Avoid bodily injury from moving machinery. Turn
off and disconnect the air supply before machine
setup.
Tool head installation
Install a tool head (beveling or facing), with the arrow side away from the main body.
Align the bayonet pins in the tool head with the slots on the body. Push and turn to
lock.
Setting clamp blades
Measure the inside diameter of the piece to be machined. This measurement is
important with regard to correct sizing and selection of the clamping blades.
•Install a matched set of clamp blades on the ID clamping chuck; being sure all
blades are secure and properly seated.
•Lightly oil the draw rod and ramps in the chuck.
•Install the chuck on the mandrel. Line up the hexagon in the chuck with the
hexagon in the end of the draw rod. Align the bayonet pins in the chuck with
the slots on the mandrel. Push and turn to lock.
•Use the spanner wrench provided in the tool kit to be sure the pins are seated
correctly. The arrow indicates direction to loosen the chuck.

P/N 35425, Rev. 2 Page 11
Clamp blades are marked with their size. Select the proper set of clamp blades from
the following table:
Clamp blade set selection
Bore diameter inches
(mm)
Part number (set of
3)
3.0 –3.65 (76 –93)
No chuck blade
3.65 - 4.30 (93 - 109)
35525
4.25 - 4.90 (108 - 124)
35526
4.85 - 5.50 (123 - 140)
35527
5.45 - 6.10 (138 - 155)
35528
6.05 - 6.70 (154 - 170)
35529
6.65 - 7.30 (169 - 185)
35530
7.25 - 7.90 (184 - 201)
35531
7.85 - 8.50 (199 - 216)
35532
8.45 - 9.10 (215 - 231)
35533
9.05 - 9.70 (230 - 246)
35534
9.65 - 10.30 (245 - 262)
35535
10.25 - 10.90 (260 - 277)
35536
10.85 - 11.50 (276 - 292)
35537
11.45 - 12.10 (265 - 307)
35538
12.05 - 12.70 (306 - 323)
35539
CAUTION
Dirt or burrs in the bore may prevent the clamp blades from mounting
properly.

Page 12 FF4000 Operating Manual
Setting tool bits
Facing head
•Select and install a suitable tool bit into the tool head.
•Tighten the setscrews.
•For production jobs, set and test the settings on a test work piece.
Beveling head
•Select the tool bit, or combination of bits, and slip them into the tool head.
•Position the tool bits to cut the entire area required.
•Tool bits are installed in a set order to achieve the required bevel
configuration. Inside diameter bits are set first, facing or squaring bits next,
and outside diameter or j-groove bits last.
•With each tool bit correctly in place, tighten the setscrews.
•When a land is required on the work piece, use a facing bit in combination
with the beveling bit. The FF4000 beveling head can plunge cut, but does not
feed in a radial direction. The width of the land is controlled by the position of
the beveling bit or by selecting a bit with a greater or lesser overall height.
•If a specific ID bevel is called for, set and test the ID bit to ensure correct
sizing. Cut the ID portion of the bevel first.
•For production jobs, set and test tool bit settings on a test piece of tube or
pipe.