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]
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 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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