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Climax FF5000 Operating Manual

Flange facer machine
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FF5000
FLANGE FACER MACHINE
OPERATING MANUAL
P/N 36668
December 2015
Revision 4

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  • Page 1 FF5000 FLANGE FACER MACHINE OPERATING MANUAL P/N 36668 December 2015 Revision 4...
  • Page 3 For comments or questions about this manual or other Climax documentation, please e- mail documentation@cpmt.com. For comments or questions about Climax products or services, please call Climax or e- mail info@cpmt.com. For quick and accurate service, please provide your factory representative with the following: ...
  • Page 4 CLIMAX WORLDWIDE LOCATIONS Page B FF5000 Operating Manual...
  • Page 5 P/N 36668, Rev. 4 Page C...
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  • Page 7: Table Of Contents

    1.6 N OISE LEVEL 1.7 L ABELS OVERVIEW ........................... 7 2.1 A ....................... 7 BOUT THIS MANUAL 2.2 A FF5000 ....................... 7 BOUT THE 2.3 FF5000 ......................8 SPECIFICATIONS 2.4 P ............8 NEUMATIC MOTOR OPTION PERFORMANCE SPECIFICATIONS SETUP ............................11 3.1 R...
  • Page 8 7.1 S ......................31 HORT TERM STORAGE 7.2 L ......................31 TERM STORAGE 7.3 S HIPPING APPENDIX A SPARE PARTS ....................33 APPENDIX B EXPLODED VIEWS AND PARTS ..............35 APPENDIX A MSDS ......................... 51 Page F FF5000 Operating Manual...
  • Page 9 LIST OF FIGURES 1. C FF5000 .......................7 IGURE LIMAX MODEL PORTABLE FLANGE FACER 2. P/N 59246 P .........................9 IGURE NEUMATIC SCHEMATIC 3. C ............................... 12 IGURE HUCKS AND JAWS 4. M ..........................12 IGURE OUNTING INTERFACE PLATE 5. L ............................13...
  • Page 10 ISK ASSESSMENT CHECKLIST BEFORE SET ........................4 ABLE RISK ASSESSMENT CHECKLIST AFTER SET 3. R ..........................29 ABLE ECOMMENDED LUBRICANTS 4. S ..............................33 ABLE PARE PARTS LIST 5. T – P/N 29116 ............................35 ABLE OOL KIT Page H FF5000 Operating Manual...

  • Page 11: Introduction

    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 12: How To Use This Manual

    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. Page 2 FF5000 Operating Manual...

  • Page 13: Safety Precautions

    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...

  • Page 14: Items Required But Not Supplied

     I have evaluated and mitigated any other potential risks specific to my work area. Items required but not supplied There are no items required but not supplied with the FF5000 machine. Noise level Sound power level is 80.3 dB(A) Operator Sound Pressure Level is 86.2 dB(A)

  • Page 15: Labels

    Labels The following labels should be on yhour machine. If any are defaced or missing, contact Climax immediately for replacements. P/N 35772 P/N 59044 Plus or minus direction Lable safety warning indicator read manual P/N 81008 P/N 80510 label safety...
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  • Page 17: Overview

    ID's from 5.0" to 14.0" (127.0 to 355.6 mm). With the optional larger chuck, the mounting range is increased to 24” (610 mm) and I.D. flanges from 5" to 24" (127 to 610 mm) can be machined. Call Climax if you have special requirements outside of this range.

  • Page 18: Ff5000 Specifications

    170 ft-lb (230 Nm) at maximum rated power (assumes .85 efficiency each gearbox) Air requirements 60 scfm (1700 SLPM) at 90 psi Air motor torque: 8.25 ft-lbs (11.25 Nm) at maximum power 13.75 ft-lbs (18.75 Nm) stall Page 8 FF5000 Operating Manual...

  • Page 19: Figure 2. P/N 59246 Pneumatic Schematic

    2. P/N 59246 P IGURE NEUMATIC SCHEMATIC NOTICE Contact Climax right away if there are any errors or questions about this equipment. P/N 36668, Rev. 4 Page 9...
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  • Page 21: Setup

    SETUP Receipt and inspection Your Climax product was inspected and tested prior to shipment, and packaged for normal shipment conditions. Climax does not guarantee the condition of your machine upon delivery. When you receive your Climax product, perform the following receipt checks.

  • Page 22: Mounting The Interface Plate

    4. Using the knob, attach the alignment assembly onto the chuck. Do not tighten the knob. 4. M IGURE OUNTING INTERFACE PLATE Page 12 FF5000 Operating Manual...

  • Page 23: Leveling The Machine

    Leveling the machine 1. Select the setup fingers that will span the flange bore and support the chuck. (Be sure both setup fingers are the same length.) 2. Place the setup fingers between the interface plate and the setup arm swivel, then hand tighten the spindle knob.

  • Page 24: Tool Head Setup And Adjustment

    6. P IGURE RECISION LEVEING AND CENTERING THE MACHINE Tool head setup and adjustment The FF5000 traverses on a fixed turning bar. Please note that the turning bar can be adjusted to reduce swing radial clearance. Page 14 FF5000 Operating Manual...

  • Page 25: Adjusting The Tool Head

    Do the following proceedure to roughly adjust the turning bar and tool head. 1. Loosen the eight screws below the handle in the main body. 2. Slide the turning bar to the desired position. 3. Retighten the screws. The tool head adjusts to enable cutting at many different angles. The tool holder swivel rotates 90º...
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  • Page 27: Operation

    Close the valve to the pneumatic motor before conecting the air hose. The Model FF5000 Flange Facer has a premium quality 1.07 hp (.800 W) air motor. The air motor will rotate the machine at approximately 20-rpm free speed. Adjust the motor speed by opening or closing the air control valve.

  • Page 28: Preparing The Machine For Start-Up

    4.1.2 Stopping the machine 1. Close the air control valve by turning the handle counterclockwise until it stops. 2. Disconnect the air supply line at the quick disconnect. IGURE PNEUMATIC AIR CONTROL VALVE SHUT OFF Page 18 FF5000 Operating Manual...

  • Page 29: Setting Vertical And Radial Tool Feed

    Setting vertical and radial tool feed Tool feed is set using the feed selector lever, the direction selector, and spring plunger on the tool head. 8. S IGURE ETTING TOOL FEED Jog the feed Do the follwing proceedure to manually jog the feed: 1.

  • Page 30: Figure 9. Cap Screw Locations

    4. Turn the crank so the tool holder slide moves. Tighten the three set screws evenly to the 10. S IGURE ET SCREW LOCATIONS point that the drag can be felt at the crank. Tighten the set screw jam nuts. Page 20 FF5000 Operating Manual...

  • Page 31: To Set The Feed

    4.2.2 To set the feed 1. Close the air control valve by turning the valve clockwise until it stops. 2. Pull up the spring plunger (see Figure 8). 3. Move the feed select lever to either VERTICAL or RADIAL while turning the crank handle attached to the side of the main body.

  • Page 32: Setting Tool Feed Speed And Direction

    The feed adjust arm can be placed anywhere along the speed path, including between the increments. Operate the machine as described in "Facing." WARNING To protect yourself from flying chips and machine noise, wear eye and ear protection while operating the machine. Page 22 FF5000 Operating Manual...

  • Page 33: To Set The Feed Speed/Direction When Flat Facing

    4.3.2 To set the feed speed/direction when flat facing 1. Turn the air control valve clockwise until it is completely closed. 2. Be sure the pneumatic conditioning unit is correctly connected and set up. 3. Connect the supply air line. WARNING The motor can operate unexpectedly when the air hose is connected.

  • Page 34: Cutting Angles, Grooves And Chamfers

    4.4.1 To adjust the tool head 1. Grind a 1/2" (12 mm) square tool bit. Climax recommends high-speed steel tool bits. 2. The tool bit clamp can be turned to provide tool clearance without having to grind a relief.
  • Page 35 14. Move the feed speed arm to the desired feed rate setting. 15. Open the air control valve until the machine is rotating at the desired rpm. 16. Allow the flange facer to completely machine the work piece. WARNING Rotating machinery can cause serious injury. Turn off the air control valve and disconnect the air line before removing chips.
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  • Page 37: Disassembly

    DISASSEMBLY Post-operation checks 1. Check for damage. 2. Clean thoroughly. 3. Repair any damage/replace parts as necessary. To disassemble the machine 1. Close the air control valve and disconnect the air line. 2. Unscrew the spindle bolt and remove the machine. 3.
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  • Page 39: Maintenance

    Main body assembly The main body is sealed and lubricated for life. If problems with the main body occur contact Climax immediately. Tool head assembly Apply a light layer of oil to the turning bar and the tool holder slide and tool holder swivel dovetails each time the flange facer is used.

  • Page 40: Air Motor And Pneumatic Assembly Maintenance

    Air motor and pneumatic assembly maintenance To extend the life of the air motor do the following. 1. Route the air supply through the lubricator and air filter. CAUTION Using air that is not filtered or lubricated can damage the motor. When operating the machine, route the incoming air through the air filter and lubricator.

  • Page 41: Storage

    2. Store the FF5000 in its shipping container. 3. Store the shipping container in an environment out of direct sunlight with temperature < 70ºF and humidity < 50%. Shipping The FF5000 can be shipped in its original shipping box. P/N 36668, Rev. 4 Page 31...
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  • Page 43: Appendix Aspare Parts

    APPENDIX A SPARE PARTS The spare parts list below includes items most frequently required due to wear, loss, or damage. To minimize downtime, these items should be stocked. 4. S ABLE PARE PARTS LIST PART No. DESCRIPTION WHERE USED 27797 Jaw 5"...
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  • Page 45: Appendix Bexploded Views And Parts

    The following diagrams and parts lists are for reference purposes only. The machine Limited Warranty is void if the machine has been altered by anyone who has not been authorized in writing by Climax Portable Machining & Welding Systems to service the machine.
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  • Page 61: Appendix Amsds

    APPENDIX A MSDS The following MSDSs are found on the pages listed. MSDS Page Polytac EP ......................52 Jet-Lube Anti-Seize Compound ................59 LPS 1 ........................61 LPS 2 ........................70 Koolkut Spectrum ....................78 Unax AW ......................84 P/N 36668, Rev. 4 Page 51...
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