Climax KM4000 User manual

P/N 16328
June 2019
Revision 7
KM4000
KEY MILL MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE
BEGINNING WITH 14001731
ORIGINAL INSTRUCTIONS
KM4000 Key Mill Machine

P/N: 16328, Rev. 7 Page i
TABLE OF CONTENTS
GENERAL SAFETY...................................................................................................................................................................II 
SAFETY PRACTICES..............................................................................................................................................................III 
LABELING GUIDELINES.........................................................................................................................................................IV 
CE DATA..................................................................................................................................................................................VII 
WARNINGLABELS.........................................................................................................................................................................1 
WARRANTY...............................................................................................................................................................................3 
INTRODUCTION........................................................................................................................................................................3 
SETUP.......................................................................................................................................................................................10 
OPERATION.............................................................................................................................................................................15 
MAINTENANCE........................................................................................................................................................................20 
STORAGE.................................................................................................................................................................................23 
SPARE PARTS.........................................................................................................................................................................24 
SPECIFICATIONS....................................................................................................................................................................25 
EXPLODED VIEWS AND PARTS............................................................................................................................................26 
MSDS..........................................................................................................................................................................................65 

Page ii KM4000 Operating Manual
General Safety
The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions.
Climax 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 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. 1-800-333-8311
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.
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
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.
Measured vibration emission value a 4.5 m/s2
Vibration uncertainty value K 2.1 m/s2
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
medical.

P/N: 16328, Rev. 7 Page iii
Safety Practices
All aspects of the machine have been designed with safety in mind. Rotating parts are not always shielded by
machine components or by the work-piece. 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
workpiece 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.
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
96 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.
LOCK OUT/TAG OUT
Prevent unintentional starting. Follow your company’s
procedures before performing maintenance on the
machine.
SHARP EDGES
Cutting tools have sharp edges. Keep hands away
from the cutting tool during operation. Always wear
protective gloves when handling the cutting tool.

Page iv KM4000 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: 16328, Rev. 7 Page v
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 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.

Page vi KM4000 Operating Manual
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 1-1. 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.


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 1-2. 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 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 with the recommended lubricants.


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.

P/N: 16328, Rev. 7 Page vii
CE Data
Hearing protection is required
The Declared Sound Power Level is: L
WA
= 88.8 dBA
The Declared Operator Sound Pressure Level is: L
pA
= 89.4 dBA
The Declared Bystander Sound Pressure Level is: L
pA
= 84.5 dBA

Page viii KM4000 Operating Manual

P/N: 16328, Rev. 7 Page 1
Warning Labels
The following warning labels should be on your machine. If any are defaced or missing, contact Climax immediately for
replacements. Machine labels are listed in Table 1. Machine label locations are shown in Figure 1.
Table 1. KM4000 labels
P/N 59037 P/N 78748
P/N 59039 P/N 78824
P/N 78741 P/N 79575
P/N 59044 P/N 79385

Page 2 KM4000 Operating Manual
Figure 1 - KM4000 label locations

P/N: 16328, Rev. 7 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 KM4000 Operating Manual
Introduction
The Model KM4000 Portable Key Mill is designed to cut extra wide keyways, stress relief pockets, motor mount
slots, and more. Built for rugged duty, the machine features permanently lubricated reduction gears so the
machine can be operated at any angle. Anti-friction bearings are used throughout. The dovetail ways are
machined to offer smooth movement in both the longitudinal and side travel directions. The universal type motor
and triple gear reduction produce plenty of torque for most operations. An electronic speed control offers
precision control of spindle speeds. The two-inch side travel allows cutting wide pockets or slots with a single
end mill. The Model KM4000 Key Mill will mount on shafts up to 24 inches(609 mm) in diameter (with optional
extra chain) and may be used anywhere along the shaft. With the optional shim kit the machine can be used on
shafts as small as 4 inches (100 mm) in diameter.
 Compact, rugged, portable milling machine for on-site keyway and other milling jobs.
 Mounts on shafts from 4 to 24 inches (101 to 610 mm) in diameter.
 Cuts new keyways up to 3.25 inches (83 mm) wide and 7.88 inches (200 mm) long in one setup (cut
dimensions include the width of the end mill).
 Contoured base is self-aligning with the shaft.
 Triple gear reduction with permanently sealed lubrication.
 Zeroing type adjusting dial for controlling cutter depth.
About this Manual
This Operating Manual provides instructions for the effective use and care of the Model KM4000 Key
Mill. Read this entire manual before attempting to setup and operate this precision machine tool.
Figure 2 - KM4000 Side Shift Key Mill
Electric moto
r
Vertical adjustment
Gear box
Spindle
and quill
Top slide
Feed lever
Cross slide
Base
Small clamp
Hand cran
k
Lifting eyes

P/N: 16328, Rev. 7 Page 5
Electric Power
The electric version of the KM4000 has a 1 hp (.75 kW), 1750-rpm motor rated at either 115 volt or
230 volt. Check the serial number plate on the motor to find the voltage. The motor operates on either
50 or 60 cycle AC or on DC current.
Spindle speed can be controlled by an in-line speed control. The no-load spindle speed is fully
adjustable from 350 to 675 rpm.
CAUTION
Do not use the variable speed control with DC
power, as it will damage the unit. The control
switch set to FULL when using DC power will
bypass the electric circuit.
Figure 3 - KM4000 Electrical schematic

Page 6 KM4000 Operating Manual
Pneumatic Power
The pneumatic version of the KM4000 has a 2 hp (1.49 kW) air motor. Spindle free speed is
continuously variable up to 900 rpm and is adjusted by opening or closing the needle valve. The
motor requires 105 ft3/min (1m3/min) of air at 80 psi.
The air filter and lubricator supplied with the machine must be used or the machine warranty is void.
The lubricator should be set to deliver oil at a rate of 20-30 drops per minute at full throttle.
Figure 4 - KM4000 Pneumatic Power Schematic Diagram
Maximum working pressure 90 psi (6.2 Bar)
Working temperature range 27F – 150F (-3C to 65C)
Flow rate 48 SCFM (1.36 m^3/min.)
Maximum allowable motor speed 1100 RPM
CAUTION
Motor must be operated with sufficient load to
prevent speed from exceeding maximum
allowable speed.
Adjust the speed by turning the needle valve.

P/N: 16328, Rev. 7 Page 7
Figure 5 - Air valves
CAUTION
Avoid damaging the air motor and voiding your
warranty by routing incoming air through the
filter and lubricator.
For machines with air motors, if the machine
stops moving unexpectedly, lock out the
pneumatic safety valve located at the filter
lubricator assembly before performing any
troubleshooting.
CAUTION
Using air that is not filtered and lubricated can
damage the air motor. Avoid damage by routing
incoming air through the air filter and lubricator.
Hydraulic Power
A wide variety of hydraulic power options are available. Please contact your Climax sales
representative for details.
The table below lists operating specifications of the hydraulically powered version of the KM4000
using standard mineral-based hydraulic oil.
Maximum working pressure 2050 psi (140 Bar)
Working temperature range -3C to 68C
Flow rate 21 L/min
Down to
close
Up to
open
Faste
r
Slowe
r
A
i
r
in
Ai
r
out
Needle valve

Page 8 KM4000 Operating Manual
CAUTION
A hydraulically powered KM4000 operating with
flame retardant, water/glycol-based hydraulic
fluid has operating specifications different from
those listed below. Consult the hydraulic fluid
manufacturer data for operating specifications.
The Hydraulic Power Unit (HPU) is an electrically-driven piston pump with horizontally mounted high-
torque motor. Separate documentation detailing the HPU is available with the HPU.
CAUTION
To avoid damaging the power unit pump,
connect the hydraulic motor to the power unit
before turning it on.
The KM4000 hydraulic power schematic drawing is shown in Figure 6.
Figure 6 - KM4000 Hydraulic Power Schematic Diagram
The end mill turning direction on a hydraulically powered KM4000 depends on hydraulic line connections. Refer to 7.

P/N: 16328, Rev. 7 Page 9
Figure 7 - KM4000 Hydraulic Power Schematic Diagram

Page 10 KM4000 Operating Manual
Setup
WARNING
When moving the machine and setting it up on the
workpiece, support the machine by its lifting eyes with
proper rigging. Failure to do so could allow the machine
to shift or slip suddenly or fall, resulting in death or
severe crushing or pinching injury.
Pre-start Checks
 Make sure end mills are sharp and free from nicks.
 Lubricate all gibs.
 Check that moving parts move freely.
 Clean chips away from threaded parts.
Electrical Checks
1. Check electrical parts for damage. Repair or replace any damaged parts.
2. Turn the power to OFF before plugging in the unit.
3. Plug the machine into a properly grounded outlet.
WARNING
The electric motor is not rated to run motor in a damp or
explosive environment. Keep liquids away from the motor.
4. When operating spindle with an in-line speed control, connect spindle power unit to speed
controller. Make sure speed control on/off switch is set to OFF.
WARNING
To avoid serious bodily injury from moving machinery,
turn speed control power switch OFF before connecting
the power source.
5. Connect speed controller to the power source. Set spindle motor on/off switch to ON. Apply
power by switching speed controller ON.
CAUTION
Do NOT use on/off switch on spindle motor when speed
control is connected. Controller damage may result and
void all warranties.