Climax SHARK FIN DEFENDER User manual

DEFENDER™
SHARK FIN™
CLAMSHELL GUARD HANDS-FREE KIT
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 97475
April 2021
Revision 2

P/N 97475, Rev. 2 Page A
©2021 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]
CLIMAX | 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 Defender Clamshell Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 97475, Rev. 2 Page C
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Page D Defender Clamshell Operating Manual
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new machines
are free from defects in materials and workmanship. This warranty is available to the original purchaser for a
period of 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.

P/N 97475, Rev. 2 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 RISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7.1 Label identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7.2 Label location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 MACHINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 CONNECTING THE PCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.1 Starting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2.2 Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.3 Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2.4 Adjusting the machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 APPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 MAINTENANCE TASKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Check the PCU oil reservoir levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.2 Empty the air filter water trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.3 PCU emergency stop check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.4 PCU drop-out circuit check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 DEFENDER KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.1 AFC Defender kit parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.4.2 BFC Defender kit parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Page ii Defender Clamshell Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
APPENDIX C SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

P/N 97475, Rev. 2 Page iii
LIST OF FIGURES
FIGURE PAGE
1-1 Label locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-1 Operator pendant (P/N 96374) controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 PCU controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-1 Guard and motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-2 Tripper post and fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-3 PCU operator pendant connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-4 Connection to the pneumatic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-1 AFC-14 Defender guard kit exploded view (P/N 97209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A-1 Clamshell fin guard assembly (P/N 96742). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A-2 Operator pendant assembly 1 (P/N 96374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
A-3 Operator pendant assembly 1 (P/N 96374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
A-4 Operator pendant assembly 1 (P/N 96374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A-5 PCU assembly (P/N 97045) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
A-6 PCU manufacturer parts (P/N 96917). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
A-7 4" (102 mm) pneumatic tripper assembly AFC (P/N 5001144). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A-8 7" (178 mm) pneumatic tripper assembly AFC (P/N 5001177). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
A-9 BCF-56 Defender guard kit assembly (P/N 97221). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
A-10 BCF-66 Defender guard kit assembly (P/N 97222). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A-11 BCF-72 Defender guard kit assembly (P/N 97223). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
A-12 BCF-86 Defender guard kit assembly (P/N 97501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
B-1 Pneumatic conditioning unit schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Page iv Defender Clamshell Operating Manual
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P/N 97475, Rev. 2 Page v
LIST OF TABLES
TABLE PAGE
1-1 Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Defender™ labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1-5 Defender label part numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2-1 Operator pendant controls identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 PCU controls identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-1 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-2 Defender kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-3 AFC-8 4" (102 mm) tripper kit (P/N 97176) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-4 AFC-8 Defender guard kit (P/N 97206). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-5 AFC-14 Defender guard kit (P/N 97209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-6 AFC guard assembly kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-7 AFC pneumatic control kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-8 4" (102 mm) tripper pneumatic control kit (P/N 97274) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-9 7" (178 mm) tripper pneumatic control kit (P/N 97275) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-10 BFC pneumatic control kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5-11 4" (102 mm) tripper pneumatic control kit (P/N 98734) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-12 7" (178 mm) tripper pneumatic control kit (P/N 98735) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5-13 7" (178 mm) tripper pneumatic control kit (P/N 98736) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Page vi Defender Clamshell Operating Manual
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P/N 97475, Rev. 2 Page 1
1 INTRODUCTION
IN THIS CHAPTER:
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.7.1 LABEL IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.7.2 LABEL LOCATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the setup, operation, mainte-
nance, storage, shipping, and decommissioning of the Defender™.
TIP:
The first page of each chapter includes a summary of the chapter
contents to help you locate specific information. The appendices
contain supplemental product information to aid in setup, operation, and
maintenance tasks.
Read this entire manual to familiarize yourself with the Defender™ before
attempting to set it up or operate it.
1.2 SAFETY ALERTS
Pay careful attention to the safety alerts printed throughout this manual. Safety
alerts will call your attention to specific hazardous situations that may be encoun-
tered when operating this machine.
Examples of safety alerts used in this manual are defined here1:
DANGER
indicates a hazardous situation which, if not avoided, WILL result in
death or severe injury.
1. For more information on safety alerts, refer to ANSI/NEMA Z535.6-2011, Product
safety Information in Product Manuals, Instructions, and Other Collateral Materials.

Page 2 Defender Clamshell Operating Manual
WARNING
indicates a hazardous situation which, if not avoided, COULD result in
death or severe injury.
CAUTION
indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
indicates a hazardous situation which, if not avoided, could result in
property damage, equipment failure, or undesired work results.
1.3 GENERAL SAFETY PRECAUTIONS
CLIMAX leads the way in promoting the safe use of portable machine tools and
valve testers. Safety is a joint effort. You, the end user, must do your part by being
aware of your work environment and closely following the operating procedures
and safety 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.
Risk assessment – Working with and around this machine poses risks to
your safety. You, the end user, are responsible for conducting a risk assess-
ment of each job site before setting up and operating this machine.
Intended use – Use this machine in accordance with the instructions and
precautions in this manual. Do not use this machine for any purpose other
than its intended use as described in this manual.
Personal protective equipment – Always wear appropriate personal pro-
tective gear when operating this or any other machine tool. Flame-resistant
clothing with long sleeves and legs is recommended when operating the
machine. Hot chips from the workpiece may burn or cut bare skin.
Work area – Keep the work area around the machine clear of clutter. Restrain
cords and hoses connected to the machine. Keep other cords and hoses
away from the work area.
Lifting – Many CLIMAX machine components are very heavy. Whenever
possible, lift the machine or its components using proper hoisting equip-
ment and rigging. Always use designated lifting points on the machine.

P/N 97475, Rev. 2 Page 3
Follow lifting instructions in the setup procedures of this manual.
Lock-out/tag-out – Lock-out and tag-out the machine before performing
maintenance.
Moving parts – CLIMAX machines have numerous exposed moving parts
and interfaces that can cause severe impact, pinching, cutting, and other
injuries. Except for stationary operating controls, avoid contact with mov-
ing parts by hands or tools during machine operation. Remove gloves and
secure hair, clothing, jewelry, and pocket items to prevent them from
becoming entangled in moving parts.
Sharp edges – Cutting tools and workpieces have sharp edges that can eas-
ily cut skin. Wear protective gloves and exercise caution when handling a
cutting tool or workpiece.
Hot surfaces – During operation, motors, pumps, HPUs, and cutting tools
can generate enough heat to cause severe burns. Pay attention to hot sur-
face labels, and avoid contact with bare skin until the machine has cooled.
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS
Eye hazard – This machine produces metal chips during operation. Always
wear eye protection when operating the machine.
Sound level – This machine produces potentially harmful sound levels.
Hearing protection is required when operating this machine or working
around it. During testing, the machine produced the sound levels1listed in
Table 1-1.
Hazardous environments – Do not operate the machine in environments
where potentially explosive materials, toxic chemicals, or radiation may be
present.
Machine mounting – Do not operate the machine unless mounted to a
workpiece in accordance with this manual. If mounting the machine in an over-
head or vertical position, do not remove hoist rigging until the machine is
mounted to the workpiece in accordance with this manual.
1. Machine sound testing was conducted in accordance with European Harmonized
Standards EN ISO 3744:2010 and EN 11201:2010.
TABLE 1-1. SOUND LEVELS
SMotor
Sound power 87.3 dBA
Operator sound pressure 76 dBA
Bystander sound pressure 74 dBA

Page 4 Defender Clamshell Operating Manual
1.5 RISK ASSESSMENT AND HAZARD MITIGATION
Machine Tools are specifically designed to perform precise material-removal oper-
ations.
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 applica-
tions. They typically attach directly to the workpiece itself, or to an adjacent struc-
ture, and achieve their rigidity from the structure to which it is attached. The
design intent is that the Portable Machine Tool and the structure to which it is
attached become one complete machine during the material-removal process.
To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, set-up, and operation practices that are unique
to Portable Machine Tools.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of portable machining applications,
identifying one or more hazards that must be addressed is typical.
When performing the on-site risk assessment, it is important to consider the Porta-
ble Machine Tool and the workpiece as a whole.

P/N 97475, Rev. 2 Page 5
1.6 RISK ASSESSMENT CHECKLIST
The following checklist is not intended to be an all inclusive list of things to watch
out for when setting up and operating this. However, these checklists are typical of
the types of risks the assembler and operator should consider. Use these checklists
as part of your risk assessment:
TABLE 1-2. 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, entan-
glement, 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) and took inventory of all the
items required but not supplied (Section 3).
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 pre-
cautions to keep workers away from the identified fall path.
I considered how this machine operates and identified the best placement for the
controls, cabling, and the operator.
I evaluated and mitigated any other potential risks specific to my work area.
TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After set-up
I checked that the machine is safely installed (according to Section 3) and the
potential fall path is clear. If the machine is installed at an elevated position, I
checked that the machine is safeguarded against falling.
I identified all possible pinch points, such as those caused by rotating parts, and
informed the affected personnel.
I planned for containment of any chips or swarf produced by the machine.
I followed the required maintenance checklist (Section 5.1) with the recommended
lubricants (Section 5.2).
I checked that all affected personnel have the recommended personal protective
equipment, as well as any site-required or regulatory equipment.
I checked that all affected personnel understand and are clear of the danger zone.
I evaluated and mitigated any other potential risks specific to my work area.

Page 6 Defender Clamshell Operating Manual
1.7 LABELS
1.7.1 Label identification
The following warning and identification labels should be on your machine. If any
are defaced or missing, contact CLIMAX immediately for replacements.
TABLE 1-4. DEFENDER™ LABELS
P/N 96876
H&S tool hori-
zontal label
(black back-
ground)
P/N96877,96878
H&S Tool vertical
labels (black
background)
P/N 96879
H&S Tool
Defender label
P/N 96881
H&S Tool label
(white back-
ground)
P/N 97510, 97511, 97512
H&S Tool Clamshell logo
Defender label -- curved to fit guard on all models
See Table 1-5 for part numbers per model
TABLE 1-5. DEFENDER LABEL PART NUMBERS
Part number Description
97064 LABEL DEFENDER CLEAR AFC-4
97065 LABEL DEFENDER CLEAR AFC-6
97052 LABEL DEFENDER CLEAR AFC-8 10 X 1.875
97066 LABEL DEFENDER CLEAR AFC-10
96913 LABEL DEFENDER CLEAR AFC-12 10 X 1.875
97067 LABEL DEFENDER CLEAR AFC-14
96880 LABEL DEFENDER CLEAR AFC-16 19.5 X 2.375

P/N 97475, Rev. 2 Page 7
1.7.2 Label location
The following figures display the location of the labels on each of the components
of the Defender™. For further identification of location placement, refer to the
exploded views in Appendix A.
97068 LABEL DEFENDER CLEAR AFC-18
97069 LABEL DEFENDER CLEAR AFC-20
97053 LABEL DEFENDER CLEAR AFC-24 19.5 X 2.375
97054 LABEL DEFENDER CLEAR AFC-26
97055 LABEL DEFENDER CLEAR AFC-28
97056 LABEL DEFENDER CLEAR AFC-30
97057 LABEL DEFENDER CLEAR AFC-32
97058 LABEL DEFENDER CLEAR AFC-36
97059 LABEL DEFENDER CLEAR AFC-42
97060 LABEL DEFENDER CLEAR BFC-48
97061 LABEL DEFENDER CLEAR BFC-56
97062 LABEL DEFENDER CLEAR BFC-66
97063 LABEL DEFENDER CLEAR BFC-72
97503 LABEL DEFENDER CLEAR BFC-86
TABLE 1-5. DEFENDER LABEL PART NUMBERS
Part number Description

Page 8 Defender Clamshell Operating Manual
FIGURE 1-1. LABEL LOCATIONS
REAR VIEW
SCALE 1 / 4
FRONT VIEW
SCALE 1 / 4
PARTS LIST
DESCRIPTIONP/N:QTYITEM
(NOT SHOWN) SCREW 1/4-20 X 1/2 BHSCS FLANGED SS 18-88896381 LABEL WARNING NOT A LIFT POINT ROUND 1.5"9638442 CLAMSHELL RING GUARD AFC-129657313 CLAMSHELL RING GUARD AFC-129687414 LABEL DEFENDER CLEAR AFC-8 10 X 1.8759705245 LABEL FOR USE WITH H&S PRODUCTS ONLY9769516 LABEL CE 3/4 X 3/49769617
CONFIDENTIAL PROPERTY OF CLIMAX PORTABLE MACHINING & WELDING
CHECKED DATE MFG APPROVED DATE SHEETCAGE CODE
DESCRIPTION:
OFDRAWN DATE
972
DWG NO.
DEFENDER GUARD KIT AFC-8
ENG APPROVED DATE
3
4
7
2
5
2 5
2
6 5 5
NOTES:
1. LABEL LOCATIONS APPROXIMATE AS SHOWN
2. BAG SCREWS AND SHIP LOOSE