Model FF6000 Flange Facer Operating Manual

Transcription

1 Model FF6000 Flange Facer Operating Manual January 2007 Bringing the solution to you. Contents General Safety Guidelines 3 Safety Practices Specific to Flange Facers 4 Warning labels 5 Labeling Guidelines in this Manual 7 Limited Warranty 9 Introduction 10 Features 11 Machine Description 12 Receiving your Machine 15 Setup 16 Operation 26 Optional assemblies 35 Maintenance 39 Storage 41 Spare parts 43 Machine Dimensions 44 Exploded Views and Parts Lists 46 Corporate Headquarters Climax Portable Machine Tools, Inc East Second Street Newberg, Oregon, USA World Wide Telephone USA Toll Free: Fax: Climax Model FF6000 shown with the removable single plane chuck Copyright 2007 Climax Portable Machine Tools, Inc. European Headquarters Climax GmbH Willi - Bleicher - Strasse Düren, Germany Telephone: (+49) (0) Fax: (+49) (0) info.de@cpmt.com Request an electronic copy of this manual, which is part number I. Send your comments or suggestions about this manual to: documentation@cpmt.com.

2 Copyright 2005 Climax Portable Machine Tools, Inc. Page 2

3 General Safety Guidelines The primary challenge for most on-site maintenance is that repairs must be done under grueling conditions. Risks expected in a regular maintenance shop are intensified when an active job-site presents extra hazards. CLIMAX Portable Machine Tools Inc., 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. DANGER For maximum safety and performance, read and understand this entire manual and all other safety instructions before using this equipment. Failure to follow the instructions and guidelines in this manual could result in property damage and personal injury. 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 until you have received training specific to this machine. OBEY WARNING LABELS! Obey all warning labels. Failure to follow instructions or heed warnings could result in injury or death. 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. DRUGS, ALCOHOL Do not operate this machine while tired or under the influence of alcohol or other drugs. KEEP YOUR WORK AREA TIDY! Keep all cords and hoses away from moving parts during operation. Do not clutter the area around your machine. LOOSE CLOTHING AND HAIR When working with rotating machinery, don t wear loose fitting clothing or jewelry. LONG HAIR Long hair is extremely dangerous around machinery. Always keep long hair completely covered. HAZARDOUS ENVIRONMENTS Do not use the machine in a hazardous environment, such as near explosive chemicals, toxic fumes, or inappropriate radiation hazard. ROTATING MACHINERY Rotating machinery can seriously injure an operator. Before you intervening with the machine, push the E-stop button to disable the all machine motion. FLYING CHIPS Flying chips can cut or burn operators and bystanders. After the machine has stopped and been locked out, remove chips with a brush. Copyright 2005 Climax Portable Machine Tools, Inc. Page 3

4 Safety Practices Specific to Flange Facers This list includes safety practices applicable to Climax Model FF6000 Flange Facer. All aspects of the machine have been designed with safety in mind. Warning signs are affixed to the machine to warn of residual hazards associated with machine relating to operation, setup, whether or not it is in use. SAFETY RULES Always follow company and OSHA safety rules. MACHINE SAFETY FEATURES Never attempt to defeat or override the safety features designed into the machine. SECURING THE MACHINE Never attempt to run the machine without first securing it to a stable workpiece. BODY PROTECTION Wear safety glasses, earplugs, and safety shoes while operating the machine. KEEPING CLEAN Keep your equipment clean and in good condition for maximum operator protection and machine longevity. Keep turning bar and tool slide free from debris. AUDIBLE NOISE LEVELS Pneumatically Driven: A-weighted sound pressure level approx. 80 dba KEEP CLEAR Keep clear of the machine during operation. Never lean or reach into the machine to remove chips or to adjust the machine while it is running. Doing so can cause serious personal injury or fatality. MACHINE GUARDS Always keep guards in place while operating the machine. DISCONNECT AIR SUPPLY When setting up or servicing the machine, disconnect the air supply line. Failure to do so could result in the machine accidentally being turned on, which can seriously injure you or another operator. MOVING PARTS Keep all cords and hoses from moving parts during operation. If the cords become tangled in the machinery the operator could be seriously injured and the machine extensively damaged. Quick disconnects enable the operator to quickly shut off the air supply. CLOSE AIR CONTROL VALVES Close air control valves before connecting the supply line to the machine. If the air control valve is open, the machine may suddenly start, seriously injuring the operator. LIFTING When lifting the machine for setup or disassembly, a conventional sling-type lift is suggested for convenience and safety of the operator. Wrap the sling around the body of the machine. DO NOT LIFT THE MACHINE BY THE TURNING BAR. LIGHTING Do not operate the Climax FF6000 in poor lighting conditions. Copyright 2005 Climax Portable Machine Tools, Inc. Page 4

5 Warning labels The following warning labels are attached to your machine upon delivery. If any labels are defaced or missing, contact Climax immediately for replacements. Copyright 2005 Climax Portable Machine Tools, Inc. Page 5

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7 Labeling Guidelines in this Manual When you read this manual, notice that different strategies are used to call your attention to certain pieces of information. In order of how critical the information is to your machine, these items are marked as follows: DANGER Indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury, or serious damage to the machine. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, damage to the machine or interruption of an important process. IMPORTANT Provides critical information for the completion of a task. Do not disregard an Important note. However, there is no associated hazard to people or machine. NOTE Provides important information to remember regarding the machine. Page 7

8 Figure 1 - Stay well clear of defined areas while the machine is running. Page 8

9 Limited Warranty 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. For quick and accurate service, please provide your factory representative with your name, shipping address and telephone number, the machine model, serial number, and date of purchase. 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; or 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. Be sure to review the terms and conditions of sale which appear on the reverse side of your invoice. Those provisions control and limit your rights with respect to the goods purchased from Climax. Page 9

10 Introduction The Climax Model FF6000 enables you to repair flanges on-site and in-line. The FF6000 Flange Facer can be used in a wide variety of flange facing applications. The modular design and versatile setup allow you to be creative in solving difficult flange facing problems. Flange facing jobs can be done quickly with the Model FF6000. An experienced operator can usually mount the machine in the flange bore, align it, and start cutting in 30 minutes. About this manual This manual describes the efficient use of the Climax Model FF6000 Portable Flange Facer. Every part meets Climax's strict quality standards. For maximum safety and performance, read the entire instruction manual before operating this machine. Information in this manual is up-to-date at the time of going to print. However, with the Climax commitment to ongoing product improvement, the machine you receive may differ slightly from the one described herein. Page 10

11 Features Key Features Solid 8-jaw chuck provides rigid clamping in the bore. 76 mm (3 ) diameter turning bar ensures a rigid tool platform, even at maximum extension. Heavy duty spindle bearings for smooth, chatter free machining. Versatile Sealed lubrication allows inverted operation. Tool head swivels 45 degrees in either direction to cut angles, groves, chamfers, RTJs, and weld preps. Down-feed available to turn flange edges, and dress inside flange/pipe joints. Optional oversize chuck and bar assembly for flanges up to 60 in diameter. Grinding head available for fine finishes. Other modifications available for special applications. Effective Gear reduction provides 798 N m (550 ft lbs) of torque at the cutter to remove metal fast. Radial feed is mm ( ) per revolution, infinitely variable, reversible, rack & pinion system. Down feed rates from mm ( ) per revolution are provided by the down-feed actuator system. Tool holder accepts 13mm or 1/2 square tool bits. Page 11

12 Machine Description The Model FF6000 is an ID-(Inside Diameter) mounted portable flange facer. Its compact design makes it an ideal on-site maintenance tool. The machine fits into bores with IDs from 14" to 34" (356 to 863 mm) and can face flanges from 14" out to 42" (356 to 1066 mm) diameter. With the optional large chuck and bar assembly, the range is extended for facing flanges up to 60" (1524 mm) diameter. The FF6000 Flange Facer consists of: Mechanical radial feed Mechanical tool down feed (not shown) Chuck, jaws, and jacking bolts (double plane chuck shown in Figure 2) Turning bar and counterweight bar Air motor and rotary union Tool head with 45 o swivel and tool holder Pneumatic conditioning unit (not shown) Tool kit (not shown) Chuck Selection The FF6000 has three available chucks: Double plane chuck Extended range double plane chuck Removable single plane chuck The double plane chuck requires more depth for the ID bore mounting. It does provide a more rigid base for the flange facer. It requires that the machine and the chuck are installed as a unit. 14 to 34 (355 to 865 mm). The double plane extended chuck allows the id bore to be increased to from 31.5 to 60 (800 mm 1525 mm) The removable single plane chuck allows the chuck to be installed independently of the flange facer. Requires only 3.5 (89 mm) of id bore depth. Range is 14 to 34 (355 to 865 mm). Page 12

13 Machine Images Model FF6000 with double plane chuck Model FF6000 with removable single plane chuck Model FF6000 with Double Plane Chuck Figure 2 Double plane chuck callout Page 13

14 Model FF6000 with Removable Single Plane Chuck Air Motor Rotary Union Radial Feed Shaft Tool Holder Tool Holder Feed Shaft Feed Cam Counterweight Tool Head Setup Finger (only 1 shown) Chuck Center Plate Plate Adaptor Leg Extension Turning Bar Adjustable Foot for Leveling Non Adjustable Foot Leg Extensions Figure 3 Removable Single plane chuck callout Page 14

15 Receiving your Machine 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 about this machine. Page 15

16 Setup Setup of the Climax FF6000 Flange Facer consists of the following steps: Chuck setup Setting machine into the work piece Centering the Machine Leveling the machine to the work piece Tool bit setup Depending on the chuck you re going to use, use the following procedures to set up each step. Assembling the Double Plane Chuck To assemble the double plane chuck 1. Mount the chuck core to the flange facer if it s not already connected. 2. Manually rotate the machine at least one full turn to be sure the machine moves freely and does not interfere with other objects. Remove interfering objects if necessary. 3. Measure the work piece bore diameter. 4. Select and sort the double plane chuck components required based on the section Double Plane Chuck Components on page Loosely mount the jaw clamping plates and plate screws onto both the upper and lower chuck arms. IMPORTANT To properly center the machine, you must use the same length jaws and the same number of jaw spacers in the chuck. 6. Thread the clamp rest or adjusting bolt into the end of the appropriate chuck jaw. 7. Insert the jaws into the chuck arms. 8. Screw in the jacking bolts until they are smaller than the work piece ID. 9. Set-up finger placement options: a) For bore diameters less than 18" (457 mm), mount the setup fingers directly to the side of the chuck with the two socket head cap screws provided. b) For bore diameters larger than 18" (457 mm), mount the setup fingers on the chuck jaws. 10. Slide the fingers as close to the end of the jaw as possible, and lock them down with the setup finger set screw. Page 16

17 11. Slide the counterweight bar into the main body. The pin and cap screw located at the ends of the bar, keep the bar from sliding out of the main body during operation. CAUTION To prevent the counterweight bar from sliding out of the machine during operation, the roll pin end of the bar must be on the tool head side of the main body. 12. On top of the main body, directly above and in line with the counterweight bar hole, there are two deep holes with setscrews in the bottom. Use the long T-handle hex wrench to firmly lock the setscrews against the bar. The bar set screw on the tool head side of the main body can be accessed through the hole in the safety guard. 13. Push the counterweight onto the bar. CAUTION Prevent the counterweight from slipping off the counterweight bar by tightening the screws against the flat on the bar. A falling counterweight can damage the machine or personal injury. 14. Secure the counterweight with the three square-headed screws. The safety flat on the counterweight bar assures good contact between the screws and the bar. 15. Install the counterweight retaining screw into the bar at the counterweight end. Page 17

18 Double Plane Chuck Components Use the following table to select the components required to fit your work piece bore diameter. Lifting the Machine into the Work Piece To lift the machine into the work piece 1. Use the lifting eyes, or wrap a strap around the body of the machine. DO NOT LIFT THE MACHINE BY THE TURNING BAR. 2. Be sure the chuck jaws are locked solidly in the bore. The jaws need to be smaller than the ID of the work piece. 3. Ensure that the setup fingers are securely mounted. Bore diameter range inch (mm) ( ) 1, 5, ( ) 1, 5, 10 Items required ( ) 1, 8, 5, ( ) 1, 8, 8, 5, ( ) 1, 6, ( ) 1, 6, 8, ( ) 1, 6, 8, 8, ( ) 1, 7, ( ) 1, 7, 8, ( ) 1, 7, 8, 8, ( ) 2, 3, 5, ( ) 2, 3, 5, ( ) 2, 3, 5, 8, 8, ( ) 2, 3, 6, ( ) 2, 3, 6, 8, ( ) 2, 3, 4, 5, ( ) 2, 3, 4, 5, 8, ( ) 2, 3, 4, 5, 8, 8, ( ) 2, 3, 4, 6, ( ) 2, 3, 4, 6, 8, ( ) 2, 3, 4, 6, 8, 8, ( ) 2, 3, 4, 7, ( ) 2, 3, 4, 7, 8, ( ) 2, 3, 4, 7, 8, 8, 10 Page 18

19 4. Using the hoist, lift the flange facer into the work piece bore.the machine should slide easily into the bore and rest on the setup fingers. WARNING Swinging or falling machinery can seriously injure the operator. Keep clear of the hoist and machine during setup. 5. Roughly, level the machine by adjusting the setscrews in the setup fingers. Centering the Machine to the Work Piece To center the machine to the work piece 1. Mount a magnetic-base dial indicator to the tool head. The tip of the dial indicator should be touching any machined surface that can be referenced to the center of the bore, or the center of the feature to be machined. 2. Manually rotate the turning bar and tool head around the work piece. Screw the upper jaws in or out to center the machine. At this stage, USE ONLY THE UPPER JAWS. 3. Tighten the jaws and their lock nuts. Leveling the Machine to the work piece DANGER Falling machinery can seriously injure the operator. Be sure the machine is secure inside the work piece before releasing the hoist. To level the machine to the work piece 1. Mount a dial indicator to the tool head. The tip of the dial indicator should be against the face of the flange. 2. Manually rotate the tool head around the work piece. 3. Screw the lower jaws in or out to level the machine USING ONLY THE LOWER JAWS. 4. Remove the setup fingers. 5. Tighten the jaws and lock nuts securely. 6. Remove the hoist. CAUTION Be sure to remove the lower lifting eyebolt before using the machine. Otherwise, as the machine rotates, this lifting eyebolt will hit the set-up fingers causing damage or injury. Be sure all hoist and rigging is clear of the machine before you use the machine. Hoist and rigging can get entangled and cause damage and injury. Page 19

20 Assembly of the Removable Single Plane Chuck Figure 4 Single plane chuck callout To setup the removable single plane chuck 1. Measure the work piece bore diameter. 2. Select the chuck jaws and jaw spacers that will fit the bore. Refer to section Single Plane Chuck Components to pick the appropriate ID arrangement. Page 20

21 Single Plane Chuck Components Use the following table as a guide when setting up your single plane chuck to fit the ID of your work piece. ID Diameter Center Pl Position Parts 13.5 to (343 to 425 mm) Extension Leg: Not applicable Adjustable foot: Part Optional Brace Foot: Not applicable Center Plate: Part to 20 (343 to 508 mm) Extension Leg: Not applicable Adjustable foot: Part Optional Brace Foot: Not applicable Center Plate: Part to 23.5 (508 to 597 mm) Extension Leg: (3.3 ) Adjustable foot: Part Optional Brace Foot: Not applicable Center Plate: Part to 26 (508 to 660 mm) Extension Leg: (3.3 ) Adjustable foot: Part Optional Brace Foot: Part (5.3 ) Center Plate: Part Page 21

22 ID Diameter Center Pl Position Parts 24 to 27.5 (609 to 699 mm) Extension Leg: Part (5.3 ) Adjustable foot: Part Optional Brace Foot: Part (3.3 ) Center Plate: Part to 30.5 (609 to 775 mm) Extension Leg: Part (5.3 ) Adjustable foot: Part Optional Brace Foot: Part (7 ) Center Plate: Part to (775 to 870 mm) Extension Leg: (7 ) Adjustable foot: Part Optional Brace Foot: Parts (3.3 ) and (5.3 ) Center Plate: Part To go from to 35 inches (870 to 889 mm), add a (part number 42022) 3/8 inch thick spacer between the leg extension (39859) and the chuck center plate. Page 22

23 Assembling the Removable Single Plane Chuck To assemble the removable single plane chuck 1. Assemble the chuck with the parts in step 2. Make sure the OD (Outer Diameter) of the chuck is slightly less than the ID of the work piece. 2. Install the setup fingers on each adjustable foot. 3. On the adjustable feet, make sure the serrated face is flush with the body of the adjustable foot. See figure Figure 5 Setting the serrated face. The top of the serrated face must be flush with the body of the top of the adjustable foot adjustable foot serrated face Figure 5 Setting the serrated face 4. Make sure the length of each leg including the adjustable feet is equal in length to the other legs. 5. Using a crane or hoist, place the chuck into the work piece. CAUTION Use a hoist or crane to lift the machine. At its heaviest, the single plane chuck is 80 lbs (36 kg). Always follow the manufacturer s operating instructions for using the crane or hoist. 6. Turn each jacking screw an equal amount until the feet make contact with the mounting surface. Centering the Single-Plane Chuck To center the single plane chuck 1. Use the centering attachment and a dial indicator to align one pair of legs. 2. Align the opposing legs. 3. Re-verify that the initial legs you centered are still centered. Page 23

24 Leveling the Single-Plane Chuck To level the single plane chuck 1. Make sure the chuck is tightly secured to the work piece before following the next step. 2. Remove the setup fingers. 3. Using a dial indicator, level one set of legs. 4. Level the other set of legs. 5. Re-verify the initial legs are still centered. Re-center if necessary. Lifting the Machine onto the Chuck To lift the machine into the chuck 1. Use the lifting eyes, or wrap a strap around the body of the machine. DO NOT LIFT THE MACHINE BY THE TURNING BAR. 2. Using the hoist, lift the flange facer onto the chuck. IMPORTANT If centering and levelling are critical then mount an indicator on the tuning bar and use the adjustments on the single plane chuck to fine tune the measurements. Page 24

25 Tool Bit Set-up IMPORTANT Climax recommends that you use high-speed steel tool bits. To set up the tool bit 1. Select a pre-ground tool bit from the tool kit, or grind your own 1/2" square (12 mm) tool bit. See Figure 3: Tool bit geometry for correct rake and clearance angles. Figure 6 - Tool bit geometry 2. Insert the tool bit into the tool holder. The machine rotates clockwise as seen from the top. Be sure the cutting edge of the tool bit faces the correct direction for cutting. CAUTION To avoid air motor damage and to increase air motor performance, route the incoming air through the air filter and lubricator provided. Page 25

26 Operation Setting motor speed The FF6000 Flange Facer has a 1.45 hp (1.08 kw) air motor. Set the motor speed by adjusting the air control valve. Fill the lubricator oil cup with air oil before using the machine. The air filter and lubricator supplied with the machine must be used or the machine warranty is void. The lubricator should oil the air at a rate of 2-4 drops per minute Starting and stopping the machine The FF6000 Flange Facer is equipped with an air control valve, shown below. The air control valve regulates the rotation speed of the Model FF6000. Figure 7 Air control valve for the Model FF6600 IMPORTANT Be sure to use non-restrictive fittings to make air connections. WARNING Rotating machinery can cause serious injury. Be sure to secure the machine to the work piece before connecting the air supply line. To start the machine: 1. Shut the air control valve completely. 2. Connect the air supply line at the quick disconnect. 3. Open the air control valve until the machine is turning at the desired speed. 4. To stop the machine: 5. Close the air control valve all the way clockwise. 6. Disconnect the air supply line at the quick disconnect. Page 26

27 Manually Feeding the Machine Figure 8 To manually feed the machine 7. Turn off the machine and disconnect the air line. 8. Place a crank handle on the radial feed shaft. When using the feed engagement crank, be sure the pins are not engaging the slots in the feed box (which would engage the automatic feed). 9. Turn the crank handle clockwise to feed the tool head outward away from the main body. Turn the crank handle counterclockwise to feed the tool head in toward the main body. Page 27

28 Automatic Radial Feed The feed box is stamped FEED IN on one side, and FEED OUT on the other side. To feed the cutting tool in toward the main body, mount the box so the words FEED IN are up. To feed the cutting tool out away from the main body, mount the box so the words FEED OUT are facing up. IMPORTANT An extended roll pin on the feed box aligns with a clearance hole in the feed box lid. The feature prevents the serious damage that would occur should the feed box be used with the cam follower on the wrong side of the cam. To mount the mechanical feed box onto the adapter plate: 1. Remove the two screws holding the feed box and safety guard to the main body. Figure 9 To mount the mechanical feed box 2. The feed box has an extended pin through the roller bearing. This is for the automatic down feed feature and must be repositioned whenever you turn the feed box over. Remove the small snap ring and put the pin through the other side of the ratchet arm. IMPORTANT When changing feed direction by reversing the feed box, you must also turn over the pin so the extension does not interfere with the main body. 3. Realign the safety guard and the feed box. Only two holes in the guard will be in line. 4. Remount the guard and feed box using the two mounting screws. 5. Place the crank handle on the feed box. Push down until the pins engage with the slots in the feed box. Automatic radial feed is infinitely variable from.003" to.032" (.08 to.81 mm) per revolution. The feed ratchet is activated as the feed box rotates around the cam. Increase feed speed, by turning the finger screw counter-clockwise (out). Page 28

29 To adjust the radial feed 1. Close the air control valve and disconnect the air supply. 2. Turn the finger screw counterclockwise to set an increased feed. Turn the finger screw clockwise to decrease feed rate. 3. Be sure the air control valve is completely closed before reconnecting the air line. Figure 10 To adjust the radial feed Page 29

30 Tool Down Feed WARNING Rotating machinery can cause serious injury. Turn off the air control valve firmly before connecting the air supply. Manual tool down feed To manually set the tool depth: 1. Turn off the air control valve and disconnect the air supply. 2. Place a crank handle on the vertical feed shaft. 3. Turn clockwise to lower the tool bit; counterclockwise to raise the tool bit. Automatic tool down feed Automatic tool down feed requires the mechanical tool down feed assembly and the radial feed box. The feed box is stamped FEED IN and FEED OUT. To feed the tool down, FEED OUT should be up. To set up the flange facer for automatic tool down feed: 1. Mount the feed box and safety guard onto the adapter plate. The radial feed box must be mounted with "FEED OUT" on top. See Automatic radial feed on how to mount the box. Figure 11 Automatic tool down feed 2. Select the desired feed rod. Put the feed assembly together as shown above. 3. Place the engagement crank on the down feed ratchet. 4. Engage the automatic tool down feed by pushing the engagement feed crank until the engagement pins seat in the slots in the down feed ratchet arm. Automatic tool down feed is infinitely variable from.003" to.010" (.08 to.25 mm) per revolution. Page 30

31 5. Turn the finger screw on the radial feed box counterclockwise (out) to increase feed speed. Turn the finger screw on the radial feed box clockwise (in) to decrease feed speed. Flat Facing To flat face CAUTION Protect yourself from flying chips and machine noise by wearing eye and ear protection while operating the machine. 1. Close the air control valve all the way clockwise. 2. Crank the radial feed shaft clockwise to retract the turning bar until the tool bit is inside the minimum diameter to be faced. 3. Tighten the turning bar tension screws. The screws should be snug, but not restrict bar movement. 4. Crank the tool head feed shaft to lower the tool bit to the desired cutting depth. 5. Tighten the tool holder swivel screws, shown below. Figure 12 Swivel screws 6. Press the crank handle down to engage the automatic feed. WARNING Rotating machinery can cause serious injury. Be sure guards are in place before operating the machine. 7. Connect the air supply line. 8. Slowly open the air control valve counterclockwise until the machine is turning at the desired speed. CAUTION In case of an emergency, close the air control valve and disconnect the air supply at the quick disconnect. 9. Allow the flange facer to completely machine the work piece 10. After facing, close the air valve all the way clockwise. Page 31

32 11. Disconnect the air supply line at the quick disconnect. 12. Repeat Steps #1 through #9 as necessary. 13. After the flange is completely re-faced, disconnect the air supply. To remove the machine from the work piece, see Disassembly. Cutting Angles, Groove, and Chamfers The tool head swivels up to 45 o in either direction, enabling the flange facer to cut angles and chamfers. You must attach the tool down feed assembly to cut angles, grooves, and chamfers. See Tool down feed for instructions on setting up the down feed system. Figure 13 To cut angles, grooves and chamfers 1. Grind a 1/2" (12 mm) tool bit with enough relief to face the desired angle or chamfer. WARNING Rotating machinery can cause serious injury. Turn off the air control valve firmly before connecting the air supply. 2. Insert the tool bit into the holder in the swivel tool head. The Flange Facer rotates clockwise. Be sure the cutting edge of the tool bit faces into the cut. Tighten the tool set screws. 3. Loosen the two socket-head cap screws holding the tool swivel in place. 4. Rotate the swivel until the tool bit is at the desired cutting angle. Retighten the socket-head cap screws. 5. Using the crank handle, manually feed the tool downward until the tool bit is just above the work piece. Page 32

33 Figure 14 Angle Cuts 6. Engage the automatic radial and tool down feeds by pushing the engagement feed crank until the engagement pins seat in the slots in the down feed ratchet arm. 7. Close the air control valve all the way clockwise. WARNING Rotating machinery can cause serious injury. Turn off the air control valve firmly before connecting the air supply. 8. Connect the air supply line at the quick disconnect. CAUTION To guard yourself from flying chips and machine noise, wear eye and ear protection while machining. 9. Open the air control valve until the machine is turning at the desired speed. 10. Make a trial cut. 11. Close the air control valve to stop the machine. 12. Disconnect the air supply line. 13. Check that the tool is cutting at the desired angle. 14. If required, adjust the tool head or machine, reconnect the air supply line, and finish cutting. Page 33

34 Disassembly WARNING Rotating machinery can cause serious injury. Turn off and disconnect the air supply before disassembling the machine. To disassemble the machine 1. Close the air control valve to stop the machine. 2. Disconnect the air supply at the quick disconnect. 3. Reattach the setup fingers to the chuck or four upper jaws. 4. Use the lifting eyes, or wrap a strap around the main body of the machine. DO NOT LIFT THE MACHINE BY THE TURNING BAR. Take out all slack in the chain/strap so the machine will not slip when the jaws are loosened. WARNING Falling machinery can seriously injure the operator. Be sure the hoist is securely wrapped around the machine before loosening the chuck jaws. 5. Back out the jaw jacking bolts until the machine is loose inside the work piece. 6. Remove the machine from the work piece. Page 34

35 Optional assemblies Back Facing Attachment For machining the back face of flange surfaces a back facing attachment is offered as an optional accessory. This application is common when machining gasket surfaces of tube sheets on heat exchangers. TURNING BAR POSITION FOR 4"-6" ( mm) FLANGE THICKNESS ATTACH TURNING BAR DEPENDING ON FLANGE THICKNESS POSITION SHOWN FOR 2"-4" (50-100mm) TURNING BAR POSITION FOR <2" (<50mm) FLANGE THICKNESS TURNING BAR BACKFACING ATTACHMENT REORIENT TOOL HOLDER AS SHOWN RELOCATE TOOL HEAD TO END OF BACKFACING ATTACHMENT Figure 15 Angle Cuts To back face machine up to 45 (1145 mm)diameter, it is necessary to use the large bore turning bar assembly. Page 35

36 To setup the back facing attachment 1. Remove the tool holder from the end of the turning bar 2. Attach the back facing attachment to the turning bar with the screws and key supplied 3. Attach the tool holder to the end of the back facing attachment so that the down feed adjustment is facing away from the flange. 4. Reorient the tool holder so that the tool can be correctly inserted for clockwise rotation (when viewed from the top of the machine). BACK FACING ATTACHMENT MAX 6 (152) MIN 1 (25) Figure 16 Back facing dimension requirements Page 36

37 Side Cut Tool Holder (PN 42010) To machine shallow angle chamfers (< 45 degrees from the flange face), a side cut tool holder is offered: Figure 17 Side cut tool holder This tool holder is simply used in place of the standard FF6000 tool holder. It can also be useful for deep counter bores. Page 37

38 Large chuck and turning arm assembles Using the large diameter chuck assembly, the machine can fit bores with diameters from 32" to 60" (813 to 1524 mm) in diameter. The large bore turning bar assembly enables the flange facer to machine flanges up to 60" (1524 mm) in diameter. The chuck assembly must be purchased to fit bore diameters greater than 33.5" (850 mm). Figure 18 Large chuck and turning arm assembly (Operation is the same as the standard machine.) Grinding attachment Climax offers a grinding attachment as an optional accessory for those applications demanding greater precision and finer surface finish. The air powered grinding assembly mounts to the end of the turning bar. It includes pneumatic couplers, clamps, grinding wheel, and complete instructions. For more information, contact your Climax factory representative. Figure 19 Grinding attachment Page 38

39 Maintenance Recommended lubricants Lubricant Brand Where used Gear grease UNOBA EP #2 Gearbox gears, thrust bearings Light oil WD-40 Unpainted surfaces Cutting oil UNOCAL KOOLKUT Tool bits, work piece Lubricating oil Almo 525 Lubricator oil cup Feed assembly maintenance Lightly oil the assembly every time it is used. Chuck assembly maintenance The chuck/spindle unit needs no maintenance. Lightly lubricate the jaws with light oil before every use. Main body assembly maintenance The main body is sealed and lubricated for the life of the machine. Grease the bull gear every 100 hours by removing the counterweight bar and inserting grease into the hole with a flexible-hose grease gun. Gearbox assembly maintenance Every 100 hours, remove the gearbox assembly from the main body and generously grease all parts. Gearbox parts need not be disassembled for servicing. Turning bar assembly maintenance Lightly oil the turning bar every time the flange facer is used. Page 39

40 Air motor assembly and pneumatic condition unit To extend the useful life of the air motor: 1. Route the air supply through a lubricator and air filter. 2. Use nonrestrictive air lines and fittings. Check the air system periodically to be sure the air pressure is 90 psi (620 kpa). 3. Adjust the air motor speed by slowly turning the air control valve. CAUTION Do not control motor speed by adjusting air line pressure. Damage to the motor can result. 4. Fill the lubricator oil cup with air oil before using the machine. Use high-quality oil with rust inhibitors and emulsifiers such as Almo 525. The lubricator should oil the air at a rate of 2-4 drops of oil per minute. 5. Drain the air filter before and after using the machine. CAUTION Using air that is not filtered and lubricated can damage the motor. When operating the machine, route the incoming air through the air filter and lubricator. Tool holder maintenance Lightly oil the tool holder each time the flange facer is used. Periodically remove the tool holder and grease the worm gear. Page 40

41 Storage Figure 20 Climax Model FF6000 Properly stored in its crate Proper storage of the flange facer will prevent undue deterioration or damage. Before storing the machine, clean it with solvent to remove grease, metal chips, and moisture. Spray the machine with corrosion protective and store it as shown (Figure 5) in the container provided. Place desiccant bags or vapor wrap around the machine to absorb moisture. To replace a container, order Climax Part No Page 41

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43 Spare parts Parts listed below include items most frequently replaced (due to wear, loss, or damage). To avoid unscheduled down time you may want to stock any or all of the parts listed. Part No. Description Qty Where used /4" short arm hex wrench /8" short arm hex wrench /32" short arm hex wrench /16" short arm hex wrench /4" end wrench Crank handle /2 Sq X 3.5" HSS pre-ground tool bit /2 Sq X 4" HSS pre-ground tool bit /32" short arm hex wrench /8" short arm hex wrench /2" short arm hex wrench Feed box crank handle /16" x 6" T-handle hex wrench /2" end wrench /8" utility end wrench 1 Tool Kit Screw 5/16-18 X 1/4" SSSCP Screw 3/8-16 x 2-1/4" SHCS 2 Swivel & tool head assembly Screw 1/2-13 X 1-3/4" SQHSS Screw 1/2-13 X 3/4" BHSCS 2 Main body assembly Screw 1/4-20 x 1-3/4" BHSCS 2 Radial feed assembly Screw 1/2-13 X 3" SHCS Screw 1/2-13 X 1-1/2" SSSCP Jaw cover plate Setup finger 4 Chuck assembly Page 43

44 Machine Dimensions Figure 21 Side View Dimensions Page 44

45 Figure 22 Overhead View Dimensions Page 45

46 Exploded Views and Parts Lists The following diagrams and parts lists are for your reference purposes only. The machine Limited Warranty is void if the machine has been tampered with by anyone who has not been authorized in writing by Climax Portable Machine Tools Inc. to perform service on the machine BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 US STYLE BALLOON NO. PART DESCRIPTION BRG CONE ID X WIDE BRG CUP OD X.8125 WIDE SEAL ID X OD X PLUG SOFT SHALLOW 2-1/4 DIA SCREW 1/2-13 X 3/4 SSSCP BODY MAIN MECHANICAL FEED FF SCREW 3/8-16 X 1 SSSHDPNI GEAR MAIN BRG BALL ID X OD X RING O 3/32 X 7-1/2 ID X 7-11/16 OD NUT BRG SCREW 3/8-16 X 3/8 SSSBT UNION ROTARY RING SNAP 2 OD RING O 3/32 X 2 ID X 2-3/16 OD HOSE ASSY 801 1/2 X 1/2 NPTMS ENDS X 12 IN FTG ELBOW 1/2 NPTM X 1/2 NPTF STREET 90 DEG SHAFT VERTICAL FEED ASSY RING SNAP ID (40 mm) SHAFT PINION KEY 3/16 SQ X.75 SQ BOTH ENDS GEAR WORM MODIFIED HOUSING BRG BRG BALL.6693 ID X OD X RING SNAP 2-5/8 ID COUNTERWEIGHT WEIGHT BAR COUNTERWEIGHT SCREW 1/2-13 X 1-3/4 SQHSS SCREW 1/2-13 X 3/4 BHSCS WASHER THRUST.750 ID X OD X BRG THRUST.750 ID X OD X BRG NEEDLE 3/4 ID X 1 OD X.750 OPEN GEAR JACK SHAFT JACK Page 46

47 The following diagrams and parts lists are for your reference purposes only. The machine Limited Warranty is void if the machine has been tampered with by anyone who has not been authorized in writing by Climax Portable Machine Tools Inc. to perform service on the machine BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 US STYLE BALLOON NO. PART DESCRIPTION SCREW 1/4-20 X 3/4 SSSCP BALL NYLON 3/16 DIA BALL NYLON 7/16 DIA BALL NYLON 1/4 DIA SPINDLE 4 BOLT FF KEY 1/2 SQ X 1.81 RADIUS ONE END NOT-SHOWN EYE LIFTING 5/8 MODIFIED FTG NIPPLE 1/2 NPTM BLACK PIPE PIN ROLL 1/4 DIA X PLATE SERIAL NUMBER SEE DWG PLUG KNOCK OUT 1-1/2 IN. Page 47

48 29471 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 CE STYLE BALLOON No. PART DESCRIPTION BRG CONE ID X WIDE BRG CUP OD X.8125 WIDE SEAL ID X OD X PLUG SOFT SHALLOW 2-1/4 DIA SCREW 1/2-13 X 3/4 SSSCP BODY MAIN MECHANICAL FEED FF SCREW 3/8-16 X 1 SSSHDPNI GEAR MAIN BRG BALL ID X OD X RING O 3/32 X 7-1/2 ID X 7-11/16 OD NUT BRG SCREW 3/8-16 X 3/8 SSSBT UNION ROTARY RING SNAP 2 OD RING O 3/32 X 2 ID X 2-3/16 OD HOSE ASSY 801 1/2 X 1/2 NPTMS ENDS X 12 IN FTG ELBOW 1/2 NPTM X 1/2 NPTF STREET 90 DEG SHAFT VERTICAL FEED ASSY RING SNAP ID (40 mm) SHAFT PINION KEY 3/16 SQ X.75 SQ BOTH ENDS GEAR WORM MODIFIED HOUSING BRG BRG BALL.6693 ID X OD X RING SNAP 2-5/8 ID COUNTERWEIGHT WEIGHT BAR COUNTERWEIGHT SCREW 1/2-13 X 1-3/4 SQHSS SCREW 1/2-13 X 3/4 BHSCS WASHER THRUST.750 ID X OD X BRG THRUST.750 ID X OD X BRG NEEDLE 3/4 ID X 1 OD X.750 OPEN GEAR JACK SHAFT JACK SCREW 1/4-20 X 3/4 SSSCP BALL NYLON 3/16 DIA Page 48

49 29471 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 CE STYLE BALLOON No. PART DESCRIPTION BALL NYLON 7/16 DIA BALL NYLON 1/4 DIA SPINDLE 4 BOLT FF KEY 1/2 SQ X 1.81 RADIUS ONE END PLATE MASS SEE DWG PLATE SERIAL NUMBER CE MARK SEE DWG NOT SHOWN EYE LIFTING 5/8 MODIFIED FTG NIPPLE 1/2 NPTM BLACK PIPE PIN ROLL 1/4 DIA X PLUG KNOCK OUT 1-1/2 IN. Page 49

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51 16416 CHUCK ASSEMBLY 14" TO 34" DIA FF6000 BALLOON No. PART DESCRIPTION CHUCK FF6000 STANDARD 1 PIECE PLUG - CHUCK BOTTOM PLATE JAW COVER SCREW 1/2-13 X 1-1/4 HHCS FINGER SETUP SCREW 1/2-13 X 1-1/2 SSSCP SPACER JAW 1 IN JAW 4-1/ JAW 7-1/ JAW 10-1/ NUT 3/4-10 JAM BOLT JACKING RING SNAP 11/16 WIRE RING PAD THRUST CLAMP RESTS MODIFICATION SCREW 5/8-11 X 7 SHCS SCREW 1/2-13 X 3 SHCS Page 51

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53 14333 BAR TURNING ASSEMBLY 25.5 STANDARD FF6000 BALLOON No. PART DESCRIPTION BAR TURNING STANDARD MODEL FF RACK TURNING BAR FF SCREW X 3/8 FHSCS KEY 1/2 X 3/4 X RADIUS BOTH ENDS Page 53

54 18302 FEED MECHANICAL RADIAL ASSEMBLY FF6000 BALLOON No. PART DESCRIPTION RING SNAP 1 OD PLATE ADAPTER SCREW 5/16-18 X 3/4 FHSCS BOX FEED FINGER SCREW KNURLED HEAD MODIFIED WASHER THRUST ID X OD X BRG ROLLER CLUTCH 1 ID X 1-5/16 OD X RATCHET FEED BRG CAM FOLLOWER.750 OD X.500 WIDE OPEN PIN CAM ROLLER SPRING EXT.36 OD X.045 WIRE X 1.00 LOOP END GUARD CHIP RING SNAP 7/32 ID E-RING CARRIER FEED RATCHET LID BOX SCREW 1/4-20 X 1-3/4 BHSCS CAM FEED SCREW 3/8-16 X 1/2 SHCS SCREW X 1/2 FHSCS SCREW 6-32 X 3/8 BHSCS SCREW 1/4-20 X 1 BHSCS SPRING COMP.60 OD X.063 WIRE X 1.75 LONG GUARD SAFETY FF6000 MECH. FEED SCREW 5/8-11 X 1-3/4 SSSCP NUT 5/8-11 X 1-3/4 COUPLING PIN COTTER Page 54

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56 18304 FEED MECHANICAL DOWN ASSEMBLY FF6000 BALLOON No. PART DESCRIPTION BRG ROD END SPHERICAL.250 ID SCREW 1/4-20 X 3/8 SSSHDP COUPLING DOWN FEED SET DOWN FEED ROD FF WASHER THRUST.375 ID X.812 OD X PIVOT RING SNAP 3/8 OD RING SNAP 1 OD WASHER THRUST ID X OD X RATCHET DOWN FEED BRG ROLLER CLUTCH 1 ID X 1-5/16 OD X LUG DRIVE Page 56

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58 35303 TOOL HEAD ASSY FF6000 BALLOON No PART DESCRIPTION HEAD TOOL KEY 1/2 SQ X 2.37 SQ BOTH ENDS SCREW 3/8-16 X 3-1/2 SHCS HOLDER TOOL FF SWIVEL TOOL HOLDER SCREW 3/8-16 X 2-1/4 SHCS SCREW 5/16-18 X 1/4 SSSCP NUT TEE SLOT CIRCULAR SCREW 5/16-18 X 3/8 SSS BRASS TIPPED SHAFT PINION BRG NEEDLE 5/16 ID X 1/2 OD X.562 CLOSED BRG NEEDLE 1/2 ID X 11/16 OD X.500 OPEN KEY WOODRUFF 3/32 X 1/ GEAR WORM ASSY COVER WORM GEAR SCREW X 3/8 FHSCS WASHER THRUST.250 ID X.687 OD X BRG THRUST.250 ID X.687 OD X BRG NEEDLE 1/4 ID X 7/16 OD X.438 CLOSED SHAFT WORM ASSY NUT THRUST BRG NEEDLE 1/4 ID X 7/16 OD X.438 OPEN ADAPTER FEED SHAFT SCREW X 3/16 SSSCP WASHER BELLEVILLE 1/4 ID X 1/2 OD X.022 THK WASHER 3/8 FLTW SAE Page 58

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60 14106 POWER UNIT ASSEMBLY AIR INGERSOLL BALLOON No. PART DESCRIPTION MOTOR AIR MODIFIED INGERSOLL 120 RPM FF SCREW 5/16-18 X 3/4 BHSCS GEAR DRIVE SCREW 5/16-18 X 5/16 SSSCP KEY 3/16 SQ X 1.50 SQ BOTH ENDS Page 60

61 29473 PNEUMATIC CONTROL ASSEMBLY FF6000 BALLOON No. PART DESCRIPTION PNEUMATIC CONDITIONING UNIT 1/2 IN. Page 61

62 14970 CHUCK ASSEMBLY DIA FF6000 BALLOON No. PART DESCRIPTION CHUCK CORE DIA FF SPACER LEG 5 IN SCREW 5/8-11 X 7 SHCS SCREW 1/2-13 X 1-1/4 SHCS ARM CHUCK Page 62

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64 15004 BAR TURNING ASSEMBLY LARGE BORE FF6000 BALLOON No. PART DESCRIPTION BAR TURNING 35.5 LARGE BORE FF RACK TURNING BAR FF SCREW X 3/8 FHSCS KEY 1/2 X 3/4 X RADIUS BOTH ENDS BAR COUNTERWEIGHT LARGE BORE FF6000 Page 64

65 14648 TOOL KIT MODEL FF6000 PART DESCRIPTION BIT TOOL 1/2 BRAZED CARBIDE BLANK BIT TOOL 1/2 HSS X 4 IN. LONG PRE-GROUND CRANK FEED BOX ENGAGEMENT HANDLE CRANK WRENCH END 1-1/8 UTILITY WRENCH END 1/ WRENCH END 3/ WRENCH HEX 1/2 SHORT ARM WRENCH HEX 1/4 SHORT ARM WRENCH HEX 1/8 SHORT ARM WRENCH HEX 3/16 X 6 T-HANDLE WRENCH HEX 3/32 SHORT ARM WRENCH HEX 3/8 SHORT ARM WRENCH HEX 5/16 SHORT ARM WRENCH HEX 5/32 SHORT ARM Page 65