Climax PM4200 User manual

P/N 66757 July 2020 Revision 6
PM4200
PORTABLE MILLING MACHIINE
OPERATING MANUAL

P/N 66757, Rev. 6 Page A
©2020 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
[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]-
1720
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]
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Warehouse #5, Plot: 369
272 Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B PM4200 Operating Manual
CLIMAX WORLDWIDE LOCATIONS

P/N 66757, Rev. 6 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 PM4200 Operating Manual
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P/N 66757, Rev. 6 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1INTRODUCTION.....................................................................................................................1
1.1 LIMITED WARRANTY ...........................................................................................................................1
1.2 HOW TO USE THIS MANUAL.................................................................................................................2
1.3 SAFETY PRECAUTIONS.......................................................................................................................3
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS..........................................................................................5
1.5 RISK ASSESSMENT AND HAZARD MITIGATION.......................................................................................5
1.6 RISK ASSESSMENT CHECKLIST ...........................................................................................................6
1.7 ITEMS REQUIRED BUT NOT SUPPLIED ..................................................................................................7
1.8 LABELS IDENTIFICATION .....................................................................................................................7
1.9 LABELS PLACEMENT.........................................................................................................................10
2OVERVIEW...........................................................................................................................15
2.1 GENERAL DESCRIPTION....................................................................................................................15
2.2 APPLICATIONS .................................................................................................................................15
2.3 PM4200 FEATURES AND OPTIONS....................................................................................................15
2.4 DETAILED DESCRIPTIONS .................................................................................................................16
2.4.1 Main bed saddle.......................................................................................................................16
2.4.2 Tool attachment methods.........................................................................................................16
2.4.3 HSK vertical slide assembly.....................................................................................................18
2.4.4 Manual feed assemblies ..........................................................................................................18
2.4.5 Electric feed with local control..................................................................................................18
2.4.6 Hydraulic motor (optional equipment) ......................................................................................19
2.4.7 Hydraulic power unit (optional equipment)...............................................................................19
2.5 COMPONENTS .................................................................................................................................19
2.6 SPECIFICATIONS..............................................................................................................................20
2.6.1 Operating temperatures...........................................................................................................20
2.6.2 Machine performance ranges ..................................................................................................20
2.6.3 Tooling recommendations........................................................................................................21
2.6.4 Pneumatic pressure and flow...................................................................................................21
2.6.5Hydraulic pressure...................................................................................................................21
2.6.6 Electric voltage.........................................................................................................................21
2.7 WEIGHTS AND DIMENSIONS ..............................................................................................................22
3MACHINE SETUP AND OPERATION..................................................................................27
3.1 RECEIPT AND INSPECTION................................................................................................................27
3.2 PRE-SETUP CHECK ..........................................................................................................................27
3.3 MACHINE SETUP ..............................................................................................................................27
3.3.1 Lifting and rigging.....................................................................................................................27
3.3.2 Bed installment.........................................................................................................................31
3.3.3 Bed leveling..............................................................................................................................31
3.3.4 Gib adjustment.........................................................................................................................32

TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
Page ii PM4200 Operating Manual
3.3.5 Saddle orientation....................................................................................................................33
3.4 CHECKING CUTTER ROTATION (HYDRAULIC SPINDLE VERSION)...........................................................33
3.5 INSERTING TOOLS IN TOOL HOLDERS ................................................................................................34
3.6 REMOVING TOOLING FROM TOOL HOLDERS.......................................................................................34
3.7 MOUNTING THE MILLING CUTTER OPTION ..........................................................................................35
3.7.1 Weldon spindle tool setup........................................................................................................35
3.7.2 Switching and installing tools (HSK spindle)............................................................................36
3.8 TRAMMING THE MILLING SPINDLE (OPTIONAL EQUIPMENT) .................................................................37
3.9 POSITIONING THE MILLING HEAD.......................................................................................................38
3.10 POWER CONNECTION.......................................................................................................................38
3.10.1 Hydraulic power connection.....................................................................................................38
3.10.2 Electrical power........................................................................................................................39
3.10.3 Pneumatic power .....................................................................................................................40
4OPERATION .........................................................................................................................41
4.1 PRE-START CHECKS.........................................................................................................................41
4.2 FEED OPERATION.............................................................................................................................42
4.2.1 Main bed hand wheel...............................................................................................................42
4.2.2 Ram saddle hand wheel ..........................................................................................................42
4.2.3 Ram milling head hand wheel..................................................................................................42
4.2.4 WeldonTraverse end mill feed.................................................................................................43
4.2.5 Weldon vertical end mill feed...................................................................................................43
4.2.6 Manual feed –electric feed hand wheel ..................................................................................43
4.2.7 Electric feed .............................................................................................................................44
4.2.8 Pneumatic feed........................................................................................................................44
4.3 ELECTRIC MACHINE OPERATION .......................................................................................................45
4.4 PNEUMATIC MACHINE OPERATION.....................................................................................................46
4.5 HYDRAULIC MACHINE OPERATION.....................................................................................................47
4.6 DISASSEMBLY..................................................................................................................................47
5MAINTENANCE ....................................................................................................................49
5.1 PART MAINTENANCE ........................................................................................................................49
5.1.1 Main bed ..................................................................................................................................49
5.1.2 Top slide ..................................................................................................................................50
5.1.3 Gearbox and spindle/quill ........................................................................................................50
5.1.4 Vertical adjustment leadscrew .................................................................................................50
5.1.5 Saddle......................................................................................................................................50
5.1.6 Electric power ..........................................................................................................................50
5.1.7 Air power..................................................................................................................................51
5.1.8 Hydraulic power .......................................................................................................................51
5.1.9 Hydraulic motor........................................................................................................................51
5.1.10 Hydraulic filter and fluid............................................................................................................51

TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
P/N 66757, Rev. 6 Page iii
5.1.11 Electric feed assembly .............................................................................................................51
5.1.12 Pneumatic feed assembly........................................................................................................52
5.2 APPROVED LUBRICANTS...................................................................................................................52
5.3 TROUBLESHOOTING.........................................................................................................................53
5.3.1 The machine isn’t feeding or traveling, or does so slowly........................................................53
5.3.2 The spindle isn’t turning...........................................................................................................53
5.3.3 The machine is cutting poorly ..................................................................................................54
5.3.4 The machine isn’t cutting flat or evenly ....................................................................................54
5.4 REPAIRS..........................................................................................................................................54
5.5 SPECIFICATIONS..............................................................................................................................54
5.5.1 Hydraulic specifications............................................................................................................54
5.5.2 Electrical controller specifications............................................................................................55
6STORAGE.............................................................................................................................57
6.1 SHORT-TERM STORAGE....................................................................................................................57
6.2 LONG-TERM STORAGE......................................................................................................................57
6.3 SHIPPING.........................................................................................................................................57
6.4 DECOMMISIONING............................................................................................................................58
APPENDIX A SPARE PARTS....................................................................................................59
APPENDIX B EXPLODED VIEWS.............................................................................................61
APPENDIX C MSDS.................................................................................................................114

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P/N 66757, Rev. 6 Page v
LIST OF FIGURES
FIGURE PAGE
FIGURE 1LABEL LOCATION ON WELDON HSK MOTOR .....................................................................................10
FIGURE 2LABEL LOCATION ON WELDON SPINDLE............................................................................................10
FIGURE 3ELECTRIC HSK FEED LABEL LOCATIONS ..........................................................................................10
FIGURE 4HYDRAULIC MOTOR LABEL LOCATIONS.............................................................................................10
FIGURE 5BLANK POST LABEL LOCATIONS .......................................................................................................11
FIGURE 6PNEUMATIC FEED DRIVE LABEL LOCATIONS......................................................................................11
FIGURE 7HOIST BAR AND BED LABEL LOCATIONS............................................................................................11
FIGURE 8FEED DRIVE LABEL LOCATION..........................................................................................................11
FIGURE 9RAM LABEL LOCATIONS...................................................................................................................12
FIGURE 10 PNEUMATIC CONNECTION LABEL LOCATIONS..................................................................................12
FIGURE 11 PNEUMATIC CONNECTION LABEL LOCATIONS (BACK SIDE)...............................................................12
FIGURE 12 WELDON MILL LABEL LOCATIONS ...................................................................................................12
FIGURE 13 PNEUMATIC SPINDLE MOTOR LABEL LOCATIONS .............................................................................13
FIGURE 14 WELDON SPINDLE 230V CONTROLLER SIDE LABEL LOCATIONS.......................................................13
FIGURE 15 WELDON SPINDLE 230V CONTROLLER TOP LABEL LOCATIONS ........................................................13
FIGURE 16 HSK SPINDLE 120V/230V CONTROLLER RIGHT SIDE LABEL LOCATIONS ..........................................13
FIGURE 17 120V/230V CONTROLLER LEFT SIDE LABEL LOCATIONS..................................................................14
FIGURE 18 ELECTRICAL CORD LABEL LOCATIONS (FRONT)...............................................................................14
FIGURE 19 ELECTRICAL CORD LABEL LOCATIONS (BACK).................................................................................14
FIGURE 20 SADDLE ON BED ASSEMBLY...........................................................................................................16
FIGURE 21 EXTENDED RAM............................................................................................................................16
FIGURE 22 SLIDE WITH AN INTEGRAL WELDON SPINDLE ..................................................................................17
FIGURE 23 BLANK TOOL POST ........................................................................................................................17
FIGURE 24 HSK VERTICAL SLIDE ASSEMBLY ...................................................................................................18
FIGURE 25 ELECTRIC FEED DRIVE ..................................................................................................................18
FIGURE 26 HYDRAULIC MOTOR.......................................................................................................................19
FIGURE 27 PM4200 WITH HSK RAM AND ELECTRIC FEED.................................................................................19
FIGURE 28 DIMENSIONS FOR HSK SPINDLE (INCHES AND MILLIMETERS) ..........................................................23
FIGURE 29 DIMENSIONS FOR WELDON SPINDLE (INCHES AND MILLIMETERS)....................................................24
FIGURE 30 DIMENSIONS OF BLANK TOOL POST (INCHES AND MILLIMETERS)......................................................25
FIGURE 31 LIFTING POINT LABEL 59039..........................................................................................................28
FIGURE 32 HOIST RING BAR INSTALLMENT ......................................................................................................28
FIGURE 33 FLAT-HORIZONTAL LIFTING.............................................................................................................29
FIGURE 34 VERTICAL-HORIZONTAL LIFTING......................................................................................................29
FIGURE 35 VERTICAL-VERTICAL LIFTING .........................................................................................................30
FIGURE 36 LIFT POINTS ON HOIST RING BAR....................................................................................................30
FIGURE 37 MOUNTING SCREW HOLE SPACING.................................................................................................31
FIGURE 38 LEVEL BED ON WORKPIECE............................................................................................................31
FIGURE 39 LEVELING SCREW .........................................................................................................................32
FIGURE 40 GIB SCREWS.................................................................................................................................32
FIGURE 41 SADDLE SECURING SCREWS..........................................................................................................33
FIGURE 42 GIB SCREWS ATTACHING SADDLE TO BASE.....................................................................................33
FIGURE 43 ELECTRIC MOTOR LOCK ................................................................................................................34
FIGURE 44. LOWER QUILL CLAMPING SCREW LOCATION ...................................................................................34

LIST OF FIGURES (CONTINUED)
Page vi PM4200 Operating Manual
FIGURE 45 WELDON QUILL CLAMPING SCREWS...............................................................................................36
FIGURE 46 REMOVING TOOLING USING ALLEN WRENCH...................................................................................36
FIGURE 47 DEEP NOTCH IN ONE SIDE OF TOOL HEAD.......................................................................................37
FIGURE 48 HSK END MILL COLLET INSTALLATION............................................................................................37
FIGURE 49 DIAL INDICATOR ATTACHED TO MILLING HEAD.................................................................................37
FIGURE 50 MILLING HEAD LEVELING DATUMS..................................................................................................38
FIGURE 51 HANDWHEEL REMOVAL DURING POWER FEED MACHINING OPERATION.............................................41
FIGURE 52 MANUAL HAND FEED DIRECTION ....................................................................................................42
FIGURE 53 TRAVERSE END MILL FEED ............................................................................................................43
FIGURE 54 VERTICAL END MILL FEED..............................................................................................................43
FIGURE 55 ELECTRIC HAND FEED DIRECTION..................................................................................................44
FIGURE 56 PNEUMATIC FEED DRIVE................................................................................................................45
FIGURE 57 CRITICAL FLAT SURFACES.............................................................................................................49
FIGURE 58 HYDRAULIC MOTOR SPECIFICATIONS .............................................................................................55
FIGURE 59 SHIPPING CONTAINER FOR PM4200..............................................................................................58

P/N 66757, Rev. 6 Page vii
LIST OF TABLES
TABLE PAGE
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP ...................................................................................6
TABLE 2. RISK ASSESSMENT CHECKLIST AFTER SET-UP......................................................................................6
TABLE 3WARNING LABELS...............................................................................................................................7
TABLE 4HPU OIL TEMPERATURE RANGES.......................................................................................................20
TABLE 5MACHINE PERFORMANCE RANGES.....................................................................................................20
TABLE 6TOOLING RECOMMENDATIONS FOR HSK 40A....................................................................................21
TABLE 7MAXIMUM FLOWS ..............................................................................................................................21
TABLE 8ELECTRIC OPERATING PARAMETERS ..................................................................................................21
TABLE 9MACHINE WEIGHTS...........................................................................................................................22
TABLE 10 OVERALL DIMENSIONS ....................................................................................................................22
TABLE 11 MOUNTING SCREW HOLE SPECIFICATIONS .......................................................................................31
TABLE 12 MAINTENANCE INTERVALS ..............................................................................................................49
TABLE 13 APPROVED LUBRICANTS .................................................................................................................52
TABLE 14 CONTROLLER PART NUMBERS.........................................................................................................55
TABLE 15 ALL PM4200 MODEL OPTIONS SPARE PARTS...................................................................................59
TABLE 16 PM4200 MODEL ELECTRIC MOTOR OPTION SPARE PARTS (120V &230V) ........................................59
TABLE 17 PM4200 MODEL PNEUMATIC OPTION SPARE PARTS .........................................................................59

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P/N 66757, Rev. 6 Page 1
1 INTRODUCTION
1.1 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 prepaid, 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 2 PM4200 Operating Manual
1.2 How to use this manual
Alerts
Pay careful attention to the alerts appearing in this manual. Alert types are defined in the following examples.
DANGER
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, WILL result in injury or loss of life.
WARNING
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, COULD result in injury or loss of life.
CAUTION
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, could result in minor or moderate injury.
NOTICE
concerns a condition, procedure, or practice worthy of special
attention.
TIP:
A tip provides additional information that can aid in completion of a
task.

P/N 66757, Rev. 6 Page 3
1.3 Safety precautions
Climax Portable Machining and Welding Systems leads the way in promoting the safe use of portable machine tools.
Safety is a joint effort. You, the machine operator, 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.
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 (PPE) –Always wear the appropriate personal protective gear when
operating this or any other machine tool. Eye and ear protection are required when operating or working
around the machine. Flame-resistant clothing with long sleeves and legs is recommended when operating the
machine, as hot flying chips from the workpiece may burn or cut bare skin.
Work area –Keep the work area around the machine clear of clutter. Keep all cords and hoses away from the
work area when operating the machine.
Moving parts –Except for operating controls, avoid contact with moving parts by hands or tools during
machine operation. Secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled
in moving parts.
Obey warning labels –Obey all warning labels. Failure to follow instructions or heed warnings could result
in injury, or even be fatal. Proper care is your responsibility. Contact Climax immediately for replacement
manuals or safety decals.
Intended use –Use this machine according to the instructions in this operating manual. Do not use this
machine for any purpose other than its intended use as described in this manual.
Stay clear of moving parts –Keep clear of the machine during operation. Never lean toward or reach
into the machine to remove chips or to adjust the machine while it is running.
Rotating machinery –Rotating machinery can seriously injure an operator. Lock out all power sources
before you interact with the machine.
Keep your work area clean and tidy –Keep all cords and hoses away from moving parts during
operation. Do not clutter the area around the machine.
Hazardous environments –Do not use the machine in a hazardous environment, such as a potentially
explosive atmosphere, toxic fumes, or a radiation hazard.
Flying chips –Flying metal chips can cut or burn. Do not remove chips until after the machine has been
locked out, all power sources are off and the machine has stopped.
Operating conditions –Do not operate the machine if it is not mounted to the workpiece as described in
this manual.

Page 4 PM4200 Operating 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. Do not operate machine outside of recommended temperature ranges for fluids.
Temperature ranges of fluids are available on the MSDS sheets for each type.
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 must
wear eye protection at all times when working with the machine. Only remove fragments with a brush after the
machine has stopped completely. Do not reach into the machine during operation.
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.
Stored energy –Hydraulic fluids could still be under pressure. Make sure the HPU is shut off and locked out
properly.

P/N 66757, Rev. 6 Page 5
1.4 Machine-specific safety precautions
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 following sound levels
1
:
•Declared Sound Power Level: LWA = 98.3 dBA
•Declared Operator Power Level: LpA = 93.6 dBA
•Declared Bystander Power Level: LpA = 95.2 dBA
1.5 Risk assessment and hazard mitigation
Machine Tools are specifically designed to perform precise material-removal operations.
Stationery 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.
Stationery Machine Tools achieve the rigidity needed to accomplish material-removal operations from the structure
that is an integral part of the machine tool.
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.
1
Machine sound testing was conducted in accordance with European Harmonized Standards EN ISO 3744:2010 and EN
11201:2010

Page 6 PM4200 Operating Manual
1.6 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.