Climax FF3000 User manual

P/N 35426
May 2019
Revision 3
FF3000
FLANGE FACER
OPERATING MANUAL
MACHINE SERIAL RANGE: 11017900-
ORIGINAL INSTRUCTIONS

P/N 35426, Rev. 3 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied,
transmitted, disseminated, downloaded, or stored in any storage medium, without the express
prior written consent of CLIMAX. CLIMAX hereby grants permission to download a single copy
of this manual and of any revision hereto onto an electronic storage medium to be viewed and to
print one copy of this manual or any revision hereto, pro- vided that such electronic or printed
copy of this manual or revision must contain the complete text of this copyright notice and
provided further that any unauthorized commercial distribution of this manual or any revision
hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[e-mail].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]m. For quick and accurate service, please provide your representative with the
following:
•Your name
•Shipping address
•Telephone number
•Machine model
•Serial number (if applicable)
•Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street Newberg, Oregon
97132 USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate Bredbury
Industrial Park Horsfield Way
Stockport SK6 2SU, UK Telephone: +44 (0)
161-406-1720
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8 52353 Düren,
Germany
Telephone: [phone]
E-mail: [e-mail]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
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 FF3000 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 35426, Rev. 3 Page C
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new
machines are free from defects in materials and workmanship. This warranty is available to the
original purchaser for a period of one year after delivery. If the original purchaser finds any defect in
materials or workmanship within the warranty period, the original purchaser should contact its factory
representative and return the entire machine, shipping prepaid, to the factory. CLIMAX will, at its
option, either repair or replace the defective machine at no charge and will return the machine with
shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor
has been performed properly. This warranty is available to the customer purchasing parts or labor for
a period of 90 days after delivery of the part or repaired machine or 180 days on used machines and
components. If the customer purchasing parts or labor finds any defect in materials or workmanship
within the warranty period, the purchaser should contact its factory representative and return the part
or repaired machine, shipping pre- paid, to the factory. CLIMAX will, at its option, either repair or
replace the defective part and/ or correct any defect in the labor performed, both at no charge, and
return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
•Damage after the date of shipment not caused by defects in materials or workmanship
•Damage caused by improper or inadequate machine maintenance
•Damage caused by unauthorized machine modification or repair
•Damage caused by machine abuse
•Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability
and fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms
control and limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX
cannot guarantee that the information contained in this manual is correct for applications other than
the application described in this manual. Product specifications are subject to change without notice.

Page D FF3000 Operating Manual
CE DOCUMENTATION

P/N 35426, Rev. 3 Page E
Table of Contents
Contents
CE..................................................................................................................................................1
Safety Guidelines...........................................................................................................................2
Machine Specific Safety.................................................................................................................3
Labeling Guidelines .......................................................................................................................4
Risk assessment and hazard mitigation....................................................................................5
Risk assessment checklist.........................................................................................................6
Machine Lock-Out.....................................................................................................................7
Introduction....................................................................................................................................8
About this manual......................................................................................................................9
Check the machine when you receive it....................................................................................9
Recommended tools .................................................................................................................9
Basic hand tools...................................................................................................................... 9
Precision instruments............................................................................................................ 10
Machine Setup...............................................................................................................................11
Assemble and install tool head................................................................................................11
Selecting and setting clamp blades.........................................................................................11
Selecting and setting tool bits..................................................................................................12
Facing head.......................................................................................................................... 12
Beveling head....................................................................................................................... 12
Mount the machine in the work piece......................................................................................13
Power connection....................................................................................................................14
Starting and stopping the machine..........................................................................................15
Starting the machine............................................................................................................. 15
Stopping the machine........................................................................................................... 15
Feeding the machine ............................................................................................................ 15
Operation.......................................................................................................................................16
Pre-start checks ......................................................................................................................16
Facing .....................................................................................................................................16
Facing feed direction............................................................................................................. 17
Facing feed rate.................................................................................................................... 17
Beveling...................................................................................................................................18
Disassembly...................................................................................................................................20
Maintenance ..................................................................................................................................21
Recommended lubricants........................................................................................................21
Air motor and pneumatic conditioning unit...............................................................................21
Troubleshooting.............................................................................................................................23
Exploded View Drawings and Parts Lists.......................................................................................24

Page F FF3000 Operating Manual
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P/N 35426, Rev. 3 Page 1
CE
Recommended air pressure: 90 psi (DO NOT EXCEED 120 psi)
Noise level: 89 dB(A) –Hearing protection required
Sound Power Level: 88.8 dB(A) (Pneumatic)
Operator Sound Pressure Level: 86.0 dB(A) (Pneumatic)
Bystander Sound Pressure Level: 83.4 dB(A) (Pneumatic) P/N 59035
Labels on the Machine
Weight = Approx. 100 Kg
P/N 29152
P/N 34734
P/N 29154
P/N 55547

Page 2 FF3000 Operating Manual
Safety Guidelines
The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions.
CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. As the operator of this
machine, you are expected to do your part by scrutinizing the job site and closely following the operating procedures
outlined in this manual, your own company rules, and local regulations. Save all warnings and instructions for future
reference.
WARNING
For maximum safety and performance, read and understand this entire manual and all
other related warnings and safety instructions before using this equipment. Failure to
follow the warnings, instructions and guidelines in this manual could cause personal
injury, fatalities, electric shock, fire and/or property damage.
QUALIFIED PERSONNEL!
Before operating this machine, you must receive training
specific to this machine from a qualified trainer. If you are not
familiar with the proper and safe operation, do not use the
machine.
OBEY WARNING LABELS!
Obey all warnings and warning labels. Failure to follow
instructions or heed warnings could result in injury, or even
be fatal. Proper care is your responsibility. Contact CLIMAX
immediately for replacement of damaged or lost manuals or
safety decals.
INTENDED USE
Only use the machine according to the instructions in this
operating manual. Do not use this machine for any purpose
other than the intended use as described in this manual.
When using the tools, machine, accessories and/or tool bits,
you must determine the proper working conditions and the
work to be performed.
STAY CLEAR OF MOVING PARTS!
Keep clear of the machine during operation. Never lean
toward or reach into the machine to remove chips or to
adjust the machine while it is running. Keep bystanders
away while operating this machinery.
ROTATINGMACHINERY
Rotating machinery can seriously injure an operator. Lock
out all power sources before you interact with the machine.
KEEP YOUR WORK AREA CLEAN AND TIDY!
Keep all cords and hoses away from moving parts during
operation. Do not clutter the area around the machine. Keep
the work area clean and well lit.
AMBIENT LIGHTING
Do not operate this machine in ambient lighting that is less
than normal intensity.
SECURE LOOSE CLOTHING AND LONG HAIR!
Rotating machinery can seriously injure an operator as well
as others close by. Don’t wear loose fitting clothing or
jewelry. Tie back long hair or wear a hat.
HAZARDOUS ENVIRONMENTS
Do not use the machine in a hazardous environment, such
as near explosive chemicals, flammable liquids, gasses,
toxic fumes, or inappropriate radiation hazards.
HOSES, PENDANT AND ELECTRICAL CABLES
Do not abuse the pendant cable as this can damage the
cable and pedant. Never use the cord for carrying, pulling or
unplugging. Remove any and all kinks before straightening
the cable. Keep cords and hoses away from heat, oil, sharp
edges or moving parts. Plugs must match the outlet. Never
modify the plugs in any way. Do not use an adapter plug with
grounded power tools. Do not expose the machine to rain or
wet conditions. Always examine hoses and cables for
damage before use. Be cautious and never drop electrical
equipment, this will damage the components.
REPETITIVE MOTION
Individuals can be susceptible to disorders of the hands and
arms when exposed to tasks that involve highly repetitive
motions and/or vibration.
STAY ALERT
Stay alert, watch what you are doing and use common
sense when operating machinery. Do not operate machinery
while you are tired or under the influence of drugs, alcohol or
medication

P/N 35426, Rev. 3 Page 3
Machine Specific Safety
All aspects of the machine have been designed with safety in mind. Rotating parts are not always shielded by machine components or
by the workpiece. Do not force the machine.
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 work-
piece as described in this manual.
TOOLING
The machine is provided with all the tools for the setup and
operation of the machine. Remove all adjustment tools before
starting 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 TOOLS AND FLUIDS
There are no cutting or cooling fluids supplied with this
machine. Keep cutting tools sharp and clean.
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 hydraulic power supply failure
occurs, be sure to turn off the supply 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.
METAL FRAGMENT HAZARD
The machine produces metallic fragments during normal
operation. You should wear eye protection at all times when
working with the machine. Only remove fragments with a brush
after the machine has stopped completely.
HAZARDOUS ENVIRONMENTS
Do not use the machine in a hazardous environment, such as
near explosive chemicals, toxic fumes, or a radiation hazard.
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 valves should be locked and tagged out
before performing any maintenance. Do not operate the
machine if moving parts are misaligned, binding or broken. If
the machine or parts are damaged, have the machine repaired
before use.
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. Have your machine serviced
by a qualified repair person using only identical replacement
parts
NOISE LEVEL
89 dB(A) –Hearing Protection is required
STORED ENERGY
Hydraulic fluids could still be under pressure! Make sure the
HPU is shut off and locked out properly.
MSDS
Material Data Safety Sheets are included in the maintenance
manual.
UNINTENTIONAL STARTING
Prevent unintentional starting. The machine must be properly
locked out and/or shut down before maintenance.

Page 4 FF3000 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.
TIP
Provides important information regarding the machine.

P/N 35426, Rev. 3 Page 5
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.

Page 6 FF3000 Operating Manual
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.

P/N 35426, Rev. 3 Page 7
Machine Lock-Out
Air shutoff in the operating position (UP)
To lockout the machine, Push down
on the lockout and insert locks into the
openings at the bottom of the air
shutoff on the air intake side of the
pneumatic conditioning unit.
Recommended air pressure: 90 psi (DO NOT EXCEED 120 psi)

Page 8 FF3000 Operating Manual
Introduction
The Model FF3000 is a right-angled machining tool designed for facing flanges from
1.85 to 12.0 inches diameter (47 to 304.80 mm). Also, for beveling, squaring, counter
boring, and cutting welding prep configurations on tube and pipe.
An internal, expanding clamping chuck grips inside diameters from 1.50 to 6.75 inches
(38.10 to 171.45 mm) with interchangeable jaw sets.
The basic facing package includes:
Machine with air motor, pneumatic conditioner, and facing head
12 sets of clamp blades (3 blades/set) for bores 1.5" to 6.75" diameter (38.10 to
171.45 mm)
Tool kit with hex wrench set, Operating Manual, and dead blow hammer
Two facing bits, one roughing and one finishing
One heavy duty storage and shipping container
The basic beveling package includes:
FF3000 machine with air motor, pneumatic conditioner, and beveling head
12 sets of clamp blades (3 blades/set) for bores 1.5" to 6.75" diameter
Tool kit with hex wrench set, operators manual, and dead blow hammer
One facing bit, beveling bit, and counter bore bit
Heavy duty plastic container for storage and shipping
Observe the instructions in this Operating Manual and preserve the integrity of the
machine by not modifying it in any manner.

P/N 35426, Rev. 3 Page 9
About this manual
WARNING
Working machinery can cause serious injury.
Understand all instructions before operating this
machine.
This manual describes how to use your Model FF3000 flange
facing/pipe beveling machine. All parts meet CLIMAX’s strict
quality standards. For maximum safety and performance, read the
entire instruction manual before operating the machine.
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 regarding this machine.
Recommended tools
Below is a list of tools that you should have on hand before you
start using this machine. Although CLIMAX includes a general tool
kit for basic operation, you will need to bring to the job all other
tools necessary for your specific application and setup.
CLIMAX portable machines are designed to get your repair jobs
done safely, quickly, and accurately. Preparation prior to setup
can be as important as the actual machining operation. Know your
application and what you will need to do it safely, quickly, and
accurately.
Basic hand tools
Supplied with the machine:
Dead blow hammer
Hex key wrench set
Suggested:
Pliers for pulling chips away from the machine
Chip brush
Cutting oil
File
Honing stone

Page 10 FF3000 Operating Manual
Precision instruments
In most cases, these machines can be setup using basic
measuring devices such as a steel rule or tape measure. In cases
where precision machining and alignment is required, these
additional items may be useful:
Dial/digital slide calipers
ID spring and/or dial calipers
Precision level
Micrometers
Dial indicator

P/N 35426, Rev. 3 Page 11
Machine Setup
WARNING
Avoid bodily injury from working machinery. Turn off
and disconnect the air supply hose before machine
setup.
Assemble and install tool head
Make sure the ramps in the clamping chuck are fully retracted
before sliding a tool head over them. Install a tool head (beveling
or facing), with the arrow-side facing away from the main body.
Align the bayonet pins in the facing head with the slots on the
body. Push and turn to lock. A good whack with a dead blow
hammer in the opposite direction of the arrow on the tool head
ensures proper seating of the tool head.
Selecting and setting clamp blades
1. Measure the inside diameter of the piece to be machined. This
measurement is important for correct sizing and selection of
the clamping blades.
2. No clamp blades are used for ID’s between 1.5” and 1.94”.
3. Clamp blades are marked with their size. Select the proper set
of clamp blades from the following table:
Clamp blade set selection
Bore diameter ID (mm)
Part number (set of 3)
1.5 –1.94 (38 –49)
NONE
1.94 - 2.35 (48 - 60)
35702
2.30 - 2.76 (58 - 70)
35703
2.71 - 3.17 (69 - 81)
35704
3.12 - 3.58 (79 - 91)
35705
3.53 - 3.99 (90 - 101)
35706
3.94 - 4.40 (100 - 112)
35707
4.35 - 4.81 (110 - 122)
35708
4.76 - 5.22 (121 - 133)
35709
5.17 - 5.63 (131 - 143)
35710
5.58 - 6.04 (142 - 152)
35711
5.99 - 6.45 (152 - 164)
35712
6.40 - 6.81 (163 - 173)
35713
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Page 12 FF3000 Operating Manual
TIP
Dirt, burrs, and grease inside the work piece may
prevent the clamp blades from mounting properly.
4. Install the correct clamp blade set on the ID clamping chuck
ramps, being sure all blades are the same size and are secure
and properly seated.
5. Lightly oil the draw rod and ramps in the chuck.
Selecting and setting tool bits
Facing head
1. Select the correct bit and slip it into the tool head. Secure it by
tightening the setscrews.
2. For production jobs, set and test the settings on a test flange.
Beveling head
1. Select the bit or combination of bits the job requires and slip
them into the tool head. Be sure to place bits in a position
where they will cut the entire area required.
2. Depending upon the required bevel configuration, bits must be
installed in a set order. Boring bits first, facing or squaring bits
next, and O.D. or j-groove bits last.
3. With each bit in position, tighten the setscrews securely.
4. When a land is required on the work piece, use a facing bit in
combination with the beveling bit. The FF3000 beveling head
can plunge cut, but does not feed in a radial direction.
The width of the land can be controlled by adjusting the
position of the beveling bit or by using a bit with a greater or
lesser overall height.
5. When a specific ID bevel is required, set and test the ID bit to
ensure correct sizing. Cut the ID portion of the bevel first.
6. For production jobs, set and verify the bit settings on a test
piece of tube or pipe.