Climax FF1000 User manual

Climax FF4000 Flange Facer
P/N 32139
May 2019
Revision 2
FF1000
FLANGE FACER
OPERATING MANUAL
SERIAL NUMBER RANGE:
11017900 - 15121870
ORIGINAL INSTRUCTIONS
FF1000 Flange Facer shown

P/N 32139, Rev. 2 Page 1
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied,
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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.
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CLIMAX documentation, please e-mail
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For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
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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.
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Telephone: [phone]
Fax: [phone]
hstool.com
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Unit 7 Castlehill Industrial Estate Bredbury
Industrial Park Horsfield Way
Stockport SK6 2SU, UK Telephone: +44 (0)
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Page 2 FF1000 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 32139, Rev. 2 Page 3
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 4 FF1000 Operating Manual
CE DOCUMENTATION

P/N 32139, Rev. 2 Page 5
Introduction
The information in this manual is up to date at time of printing. Because Climax is committed to continued
product improvement, the machine you receive may be slightly different than the one described here.
About this manual
WARNING
Moving machine parts can seriously injure untrained
operators. Understand all instructions before operating
this machine.
This manual describes how to use your Model FF1000 Flange Facer (the
ModuLATHE). Every part meets Climax Portable Machining & Welding Systems’
strict quality standards. For maximum safety and performance, read the entire
instruction manual before operating the flange facer.
Typical application of the FF1000 flange facer
The FF1000 Flange Facer (ModuLATHE), featuring a power unit and facing head
attachment, can re-face flanges up to 12" (304.8 mm) in diameter and cut O-ring
grooves. The modular design and setup options allow you to be creative in
solving difficult maintenance problems. Please follow the operating manual and
maintain the integrity of the machine. For your own safety, do not modify this
machine in any way.
Check the machine when you receive it
Inspect the machine for shipping damage. Be sure you received the parts listed
on the invoice. Contact Climax immediately if there are any errors or questions
about this machine.

Page 6 FF1000 Operating Manual
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.

P/N 32139, Rev. 2 Page 7
General Safety Guidelines
The primary challenge for most on-site maintenance is that repairs are often done under difficult
conditions.
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 closely
examining the job site and following the operating procedures outlined in this manual, your own
company rules, and local regulations.
WARNING
For maximum safety and performance, read and understand this
entire manual and all other related safety instructions before using
this equipment. Failure to follow the instructions and guidelines in
this manual could cause personal injury, fatalities and property
damage.
QUALIFIED PERSONNEL
Before operating this machine, you must receive
training specific to this machine from a qualified
trainer. Do not operate the machine If you are
not familiar with the proper and safe operation.
OBEY WARNING LABELS
Obey all 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 manuals or safety decals.
INTENDED USE
Use this machine according to the instructions in
this operating manual. Do not use this machine
for any purpose other than its intended use as
described in this manual.
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.
ELECTRICAL HAZARDS
Electrically ground all machines. Be sure the
electric power source matches the requirements
of the machine and complies with appropriate
electrical codes. Do not operate an electric
machine in damp or explosive conditions. It may
cause an explosion or expose the operator to
electric shock.
ROTATING MACHINERY
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.
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.
HAZARDOUS ENVIRONMENTS
Do not use the machine near explosive
chemicals, toxic fumes, inappropriate radiation
hazards or other hazardous environments.
FLYING CHIPS
Flying metal chips can cut or burn. Do not
remove chips until after the machine has been
locked out, all power sources are off and the
machine has stopped.

Page 8 FF1000 Operating Manual
General safety practices
All aspects of the machine have been designed with safety in mind. Rotating
parts are shielded by machine components or by the workpiece.
PERSONAL PROTECTIVE EQUIPMENT
Eye and hearing protection must be worn
while using the machine. These safety items
do not impose constraints to the safe
operation of the machine.
OPERATING CONDITIONS
Do not operate the machine if it is not
mounted to the workpiece as described in this
manual.
TOOLING
The machine is provided with all the tools for
the setup and operation of the machine.
LIFTING
Most of the machine components are heavy
and must be moved or lifted with approved
rigging and practices. Climax accepts no
responsibility for the selection of lifting
equipment.
Always follow your plant’s procedures for
lifting heavy objects. Do not lift heavy objects
by yourself as serious injury can result.
CUTTING FLUIDS
There are no cutting or cooling fluids used with
this machine.
CONTROLS
The machine controls are designed to
withstand the rigors of normal use and
external factors. The on-off switches are
clearly visible and identifiable. If a compressed
air supply failure occurs, be sure to turn off the
on-off valve before leaving the machine.
DANGER ZONE
The operator and other persons can be
anywhere in the vicinity of the machine. The
operator must ensure there are no other
persons in danger from the machine.
APPROPRIATE LIGHTING
Ensure your work area is well lit.
METAL FRAGMENT HAZARD
The machine produces metallic fragments
during normal operation. You should wear
eye protection and gloves at all times when
working with the machine.
RADIATION HAZARDS
There are no systems or components on this
machine that are capable of producing
hazardous EMC, UV or other radiation
hazards. The machine does not use lasers
nor does it create hazardous materials such
as gasses or dust.
ADJUSTMENTS AND MAINTENANCE
All adjustments, lubrication and
maintenance should be done with the
machine stopped, and locked out from all
power sources. The shut-off valve should be
locked and tagged out before any
maintenance occurs.
WARNING LABELS
Warning labels are already attached to your
machine. Contact Climax immediately if
replacements are required.
MAINTENANCE
Be sure the machine components are free of
debris and properly lubricated prior to use.

P/N 32139, Rev. 2 Page 9
Machine specific Safety Information
Audible noise levels
Pneumatically driven:
A-weighted sound pressure level 89 dBA
A-weighted sound power level 96.5 dBA
Warning labels
The labels shown are attached to your machine. Contact Climax
immediately for replacements if any are defaced or missing.
WARNING

Page 10 FF1000 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 32139, Rev. 2 Page 11
Risk assessment checklist
Use these checklists as part of your on-site risk assessment and include any additional
considerations that may pertain to your specific application.
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP
Before Set-up
I took note of all the warning labels on the machine.
I removed or mitigated all identified risks (such as tripping, cutting, crushing,
entanglement, shearing, or falling objects).
I considered the need for personnel safety guarding and installed any
necessary guards.
I read the machine assembly instructions 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 12 FF1000 Operating Manual
Description
The FF1000 Flange Facer is intended to perform facing operations. Modular
construction allows the machine to perform a variety of operations.
The machine consists of:
Power module:
Drive box assembly
Quill support assembly
Vertical adjustment leadscrew assembly
Air motor assembly
Pneumatic conditioning unit
Tool kit
Flange facing module:
Facing head gearbox assembly
Slide & tool head assembly
Mounting bell assembly
Facing head tool kit
Optional assemblies:
Power feed module
Exploded-view drawings and part lists are at the end of this
manual.

P/N 32139, Rev. 2 Page 13
Setup
Preparation
WARNING
To avoid serious bodily injury, turn off and lock
out the motor before setting up or adjusting the
machine.
1. Mount the power module to the mounting bell.
2. Tighten the mounting screws.
3. Mount the feed cam onto the end of the quill housing.
4. Carefully align the setscrew holes with the slots on the quill
housing.
5. Attach the facing head assembly to the end of the spindle,
using the screws provided.
6. Measure the diameter of the flange.
7. Insert the setup fingers into the mounting bell.
8. Adjust the setup fingers so they will catch on the edge of the
flange and support the machine during setup.
Setup
WARNING
To avoid serious bodily injury from rotating
machinery, turn off and lock out the machine
before setup.
1. Set the machine on the flange. The setup fingers will support
the machine.
2. Center the machine to within .0625 by adjusting the clamping
screws. Because the inside of the mounting bell is machined, it
can be used to determine the center.
3. Completely tighten the clamping screws.

Page 14 FF1000 Operating Manual
To level the machine:
1. Attach the dial indicator to the tool carrier
WARNING
To avoid serious bodily injury from rotating
machinery, use the manual rotation tool to level
the machine.
2. Remove the motor from the drive box.
3. Insert the manual rotation tool into the drive box.
4. Swing the dial indicator by turning the rotation tool with a
3/4" box-end wrench (in power module tool kit).
5. Adjust the leveling setscrews in the base of the quill
housing until the dial indicator indicates a level surface.
6. Tighten the clamping screws.
To accurately center the machine:
1. Slightly loosen the level clamping screws.
2. With the indicator on a diameter, adjust the centering
screw in the centering/leveling plate until centered.
3. Verify the adjustment and correct if needed.
2. Remove the setup fingers and indicator.

P/N 32139, Rev. 2 Page 15
Tool setup
1. Loosen the quill support clamping screws.
2. Turn the vertical adjustment leadscrew counterclockwise to
raise the tool bit carrier.
NOTE
Be careful not to raise the facing head too high.
The feed cam will be forced off and you will
have to set the machine up again.
3. Insert the tool bit into the tool carrier.
4. Position the tool bit for clockwise rotation (when looking down
from the top of the power head).
Air power connection
WARNING
Rotating machinery can seriously injure the
operator. Securely mount the machine to the
work piece before connecting the air supply
line.
Motor connection
If the air motor is to be mounted to the drive box:
1. Insert the drive key into the air motor output shaft keyway.
2. Align the air motor output shaft with the worm carrier shaft
inside the drive box.
3. Insert the air motor shaft into the worm carrier shaft until the
motor flange fits snugly against the drive box.
4. Tighten the motor mounting screws. Climax strongly
recommends using the air filter and lubricator supplied with the
machine. The lubricator should be set to deliver oil air at a rate
of 2-4 drops per minute.
CAUTION
To avoid air motor damage and increase air
motor performance, use the filter and lubricator
provided.

Page 16 FF1000 Operating Manual
Starting and stopping U.S. style machines
The U.S. style flange facer is equipped with needle valves and
lockout valves.
NOTE
Use non-restrictive fittings for air connections.
To start the machine:
1. Push the lever (on the lockout valve) until the word CLOSED
and the lockout can be seen from the bottom of the valve. Be
sure the lever is pushed all the way in.
2. Turn the needle valve clockwise all the way. You will not see
any colored bands when the valve is completely closed.
3. Connect the pneumatic conditioning unit and air supply line.
4. Press the lever (on the lockout valve) until the word OPEN can
be seen from the top of the valve. Be sure the lever is pushed
all the way in.
5. Slowly turn the needle valve counterclockwise until the
machine is rotating at the desired speed. The more colored
bands you see, the faster the machine rotation.
WARNING
In case of emergency, push the lockout valve
lever closed.
To stop the machine:
1. Turn the air supply off all the way.
2. Push the lockout valve lever until the word CLOSED and the
lockout can be seen from the bottom of the valve. Be sure the
lever is pushed all the way in.
3. Lock out the machine.
4. Disconnect the air supply line.

P/N 32139, Rev. 2 Page 17
Starting and stopping CE compliant machines
NOTE
Use non-restrictive fittings for air connections.
To start the machine:
1. Be sure the emergency valve assembly is connected to the air
motor.
2. Turn the air supply valve OFF all the way.
3. Connect the pneumatic conditioning unit and air supply line to
the valve assembly.
4. Pull the spring plunger out to let air into the valve assembly.
5. Slowly turn the air supply valve ON until the machine is
rotating at the desired speed.
WARNING
In case of emergency, push the spring plunger
closed.
To stop the machine:
1. Push the spring plunger to close the valve assembly.
2. Close the air supply valve all the way.
3. Lock out the machine.
4. Disconnect the air supply line.

Page 18 FF1000 Operating Manual
Setting the feed rate
Set the feed rate before machining. The feed rate is adjustable
from 0 to .035" (0 to 0.88 mm) per revolution. Turn the feed rate
shaft counterclockwise to increase the feed rate or clockwise to
decrease the feed rate. The machined rings on the shank of the
feed rate shaft show the relative speed at which the machine will
feed.
Setting the feed direction
Before machining, set the feed direction. The three positions are:
NEUTRAL - tool bit will not travel
OUT - tool bit will travel out from the center of the work piece
IN - tool bit will travel in toward the center of the work piece.
To set the feed direction:
1. Turn off and lock out the machine.
2. Place a crank on the dial carrier shaft.
3. While holding the carrier shaft with the crank, loosen the feed
direction knob with a screwdriver (in the power module tool
kit).
4. To ensure full movement to the desired position, jog the crank
as you move the feed direction knob.
5. Tighten the feed direction knob with a screwdriver.