Climax VM1350 User manual

VM1350-
1500-1600
Gate Valve Grinding and Lapping Machine
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 89800
May 2017
Revision 2

P/N 89800, Rev. 2 Page A
©2017 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
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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: [phone]
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 VM1350-1500-1600 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 89800, Rev. 2 Page C
CE DOCUMENTATION

Page D VM1350-1500-1600 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 89800, 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
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 SELECTING AND PREPARING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.1 Selecting tools for planet wheels DN 80–DN 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.2 Preparing tools for DN 80–DN 600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2.3 Selecting solid grinding discs for DN 40–DN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 MOUNTING THE TILTING ADAPTER ON THE VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3.1 Mounting the tilting adapter on valves with flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3.2 Collar band mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3.3 Mounting the bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.4 Mounting the drive shaft with ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.5 Adaptating the planet wheel dia. 100 or dia. 135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.6 Adaptating the planet wheel dia. 220 mm or bigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.7 Adaptating the solid grinding discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 LOCATING AND ALIGNMENT OF MACHINE IN TILTING ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.1 PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2 ELECTRIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 PNEUMATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 CHANGE OF ABRASIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.5 CHANGE OF DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.1 Change of mounted drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.2 Mounting of new drive motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Page ii VM1350-1500-1600 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5.2 APPROVED LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3 LUBRICATING THE MACHINE MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.3.1 Pneumatic drive motor gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.2 Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3.3 Ball joint coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 LUBRICATING THE PNEUMATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3 DECOMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

P/N 89800, Rev. 2 Page iii
LIST OF FIGURES
FIGURE PAGE
2-1 Valve machine with pneumatic drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1 Machine case (here VM 1350; including some options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-2 Accessory case (here VM 1350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-3 Machine case (here VM 1500; including some options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-4 Accessory case (here VM 1500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-5 Tool components for planet grinding wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-6 Planet grinding wheel, completely assembled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-7 Solid grinding disc components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-8 Tilting adapter with base plate and standard clamping elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-9 Connecting clamping pads to base plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3-10 Mounting of base plate to flange by means of forged steel clamps. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-11 optional extended clamping pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3-12 Tilting adapter and base plate mounted to valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-13 Components for collar band mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3-14 Adjustment of collar band mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-15 Positioning of collar band into fastening system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-16 Locating the collar band and mounting plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-17 Fastening of the collar band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-18 Installed collar band mounting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-19 Tilting adapter on collar band mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3-20 Unlocking the collar band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-21 Mounting the bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-22 Mounting of drive shaft with ball joint Type 15 G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3-23 Adaptation of planet wheel dia. 100 mm or dia. 135 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-24 Mounting of ball joint coupling to machine spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-25 Adaptation of planet wheel to ball joint coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-26 Adaptation of solid grinding disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3-27 Locating the machine arm into the tilting adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3-28 Machine arm in clamped position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3-29 Centering the machine arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4-1 Appliance of grinding pressure at star knob of tilting adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4-2 Grinding pressure in relation to the torque applied at the star knob of the tilting adapter . . . . . . . . . . . 35
4-3 Electric drive motor controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4-4 Maintenance unit with operating buttons for pneumatic drive (optional) . . . . . . . . . . . . . . . . . . . . . . . . 37
4-5 Change of mounted drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4-6 Disconnection of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
A-1 Gate valve grinding and lapping machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
A-2 440-10S-N01-00 basic machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
A-3 240-11S-N01-00 electric drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
A-4 240-13S-N01-00 pneumatic drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
A-5 240-15S-N01-00 electric drive 115 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
A-6 440-20S-N01-00 upper gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A-7 440-21S-N01-00 upper gear (additional parts for T = 1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
A-8 440-32S-N01-00 machine arm with submerging depth T=600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Page iv VM1350-1500-1600 Operating Manual
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
A-9 440-33S-N01-00 machine arm with submerging depth T=800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
A-10 440-34S-N01-00 swing check spindle extension 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A-11 440-35S-N01-00 machine arm with submerging depth T=1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
A-12 440-36S-N01-00 swing check spindle extension 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
A-13 440-37S-N01-00 machine arm general parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
A-14 440-40S-N01-00 ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A-15 440-41S-N01-00 ball joint type 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
A-16 170-30S-N01-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
A-17 440-42S-N01-00 ball joint type 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
A-18 170-10S-N01-00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
A-19 Mounting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
A-20 440-51S-N01-00 tilting adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
A-21 440-52S-N01-00 Mounting for valve bodies with flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
A-22 440-53S-N01-00 Mounting for valve bodies without flanges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
A-23 440-55S-N01-00 Swing check adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
A-24 440-57S-N01-00 Tilting Adapter (additional parts for T = 1000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
A-25 240-71S-N01-00 Planet Wheels DN 80 ... DN 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
A-26 240-73S-N01-00 Planet Wheels DN 400 ... DN 500 (VM 1500/1600 only). . . . . . . . . . . . . . . . . . . . . 81
A-27 110-20S-N01-02 Planet Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
A-28 440-72S-N01-00 Solid Grinding Discs DN 40 ... DN 65 (VM 1350 only) . . . . . . . . . . . . . . . . . . . . . . 83

P/N 89800, 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
2-1 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1 Diameters for seats and grinding discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-2 Approved lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5-3 Troubleshooting for possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Page vi VM1350-1500-1600 Operating Manual
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P/N 89800, 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
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the setup, operation, mainte-
nance, storage, shipping, and decommissioning of the VM1350-1500-1600.
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 VM1350-1500-1600
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.
WARNING
indicates a hazardous situation which, if not avoided, COULD
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 VM1350-1500-1600 Operating Manual
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.
Follow lifting instructions in the setup procedures of this manual.
Lock-out/tag-out – Lock-out and tag-out the machine before performing
maintenance.

P/N 89800, Rev. 2 Page 3
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
overhead 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 >85 dBA
Operator sound pressure >85 dBA
Bystander sound pressure >85 dBA

Page 4 VM1350-1500-1600 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 89800, 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 Portable Machine Tool. However, these
checklists are typical of the types of risks the assembler and operator should con-
sider. 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 3.3).
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 VM1350-1500-1600 Operating Manual
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P/N 89800, Rev. 2 Page 7
2 OVERVIEW
IN THIS CHAPTER:
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2.2 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
2.1 FEATURES AND COMPONENTS
The Gate Valve Grinding and Lapping Machine, Models VM1350-1500-1600 (in
the following called Gate Valve Grinder or machine) are specifically designed for
grinding and lapping of gate valve seats. The VM 1350 for Gate Valves size DN 40
– DN 350, the VM 1500 for size DN 80 DN 500 and the VM 1600 for size DN 80
DN 600. The models with an additional “…S” written behind the model number
are designed for grinding only. They don’t include the lapping equipment.
Options are also described. The basic machine includes an electric or a pneumatic
drive system. Optionally, the machine can be delivered with electric and pneumatic
drive system. However, both drive systems are described in this operating manual.
Also the grinding tools are described from DN 40 – DN 600, but the different mod-
els don’t include all sizes of tools.
The lapping is also described, however the “…S” models (grinding only) don’t
include the lapping equipment.
DANGER
The Gate Valve Grinder should only used as prescribed. If the
Gate Valve Grinder is not used accordingly, safe operation is not
guaranteed.
Any danger to people and all damage to the Gate Valve Grinder
resulting from misuse will be the customer’s responsibility.
Any modifications of the Gate Valve Grinder made by the
customer will be at their own responsibility. This applies
especially to any changes that do not comply with the safety
requirements of the Gate Valve Grinder.

Page 8 VM1350-1500-1600 Operating Manual
The Gate Valve Grinder is driven by
an electric or a pneumatic motor,
which is mounted to the upper gear
housing. Both drives are adapted to
the machine by means of a drive
flange with clamping screw. Depend-
ing on the application, the Gate
Valve Grinder can be delivered with
an electric and pneumatic drive unit.
The machine arm connects the gear
drive with the machine spindle.
During operation, the machine spin-
dle is driven by a chain drive system.
The tools are adapted to the machine spindle by means of a drive shaft with ball
joint and a self-aligning coupling. This ensures that the tools are automatically
aligned during machine operation.
Planet grinding and lapping wheels (in the following called planet grinding
wheels) are used as tools.
The planet grinding wheels consist of:
• a ball joint coupling for self-alignment of planet wheels
• a planet wheel
• planet arms with integrated spindle bearing system
• grinding or lapping discs to put onto planet arms
• abrasives for grinding (for lapping operation, a lapping paste is used
instead of abrasives)
Each planet grinding wheel covers a wide working range. To adjust the wheel to
the machining diameter, the planet arms can be moved into the planet wheel
guides. The planet arms are clamped with one screw quick clamping system.
TABLE 2-1. COMPONENTS
Item Description
1 Drive Motor
2 Gear
3 Machine arm
4 Drive shaft with ball joint
5Tools (grinding and lapping
tools)
6 Tilting adapter
FIGURE 2-1. VALVE MACHINE WITH PNEUMATIC DRIVE
MOTOR