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-
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
[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