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Climax FF7200 Operating Manual

Flange facer machine
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FF7200 Flange Facer Machine
OPERATING MANUAL
This manual is available in electronic format as P/N 59129
Original Instructions
Serial Number Range: 11017900 – 15121870
PN: 59129
March 2019
Revision 9

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Summary of Contents for Climax FF7200

  • Page 1 FF7200 Flange Facer Machine OPERATING MANUAL This manual is available in electronic format as P/N 59129 Original Instructions Serial Number Range: 11017900 – 15121870 PN: 59129 March 2019 Revision 9...
  • Page 3 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...
  • Page 4 CLIMAX WORLDWIDE LOCATIONS Page B FF7200 Operating Manual...
  • Page 5 P/N 59129, Rev. 9 Page C...
  • Page 6 This page left intentionally blank Page D FF7200 Operating Manual...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction ..............................1 Labeling Guidelines ............................3 Risk Assessment and Hazard Mitigation ......................4 Risk Assessment Checklist ..........................5 Labels ................................6 Limited Warranty ............................7 General Information ............................8 Standard Components ........................... 9 Dimensions and Clearance ..........................12 Setup ................................
  • Page 8 This page left intentionally blank Page F FF7200 Operating Manual...

  • Page 9: Introduction

    The primary safety challenge for most on-site maintenance is that repairs are often done under difficult conditions. CLIMAX 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 closely examining the job site and following the operating procedures outlined in this manual, your own company rules, and local regulations.
  • Page 10 Moving parts – CLIMAX machines have numerous exposed moving parts and interfaces that can cause severe impact, pinching, cutting, and other injuries. 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.

  • Page 11: Labeling Guidelines

    Labeling Guidelines The purpose of product safety signs and labels is to increase the level of awareness to possible dangers. Safety Alert Symbols indicate DANGER, WARNING or CAUTION. These symbols may be used in conjunction with other symbols or pictographs. Failure to obey safety warnings can result in serious injury.

  • Page 12: Risk Assessment And Hazard Mitigation

    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. Page 4 FF7200 Operating Manual...

  • Page 13: Risk Assessment Checklist

    Risk Assessment Checklist Use these checklists as part of your risk assessment: 1. R ABLE ISK ASSESSMENT CHECKLIST BEFORE SET Before Set-up  I took note of all the warning labels on the machine (shown on page 6). I removed or mitigated all identified risks (such as tripping, cutting, crushing, ...

  • Page 14: Labels

    Part Number 59039 – Designated Lift Point Part Number 39546 – Chemical Designator Part Number 35772 – Ball Valve Handle Part Number 27462 – Warning Label Part Number 59037 – Hearing Protection Part Number 84019 – CLIMAX Logo Required Page 6 FF7200 Operating Manual...

  • Page 15: Limited Warranty

    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.

  • Page 16: General Information

    • Feed box can be mounted to provide either radial or axial feed. • Features a remote control feed rate adjustment to allow the machine operator to safely adjust the feed rate without reaching into the rotating machine. This also allows for feed adjustment while machining. Page 8 FF7200 Operating Manual...

  • Page 17: Standard Components

    Standard Components Figure 1. Components Table 3. Components figure identification Number Description Lifting eyes Tool arm assembly (30–72" [762–1,829 mm] range) Rotary union Tool arm clamps Drag brake Counterweight assembly Leveling feet Chucking assembly (30–72" [762–1,829 mm] range) Drive assembly P/N 59129, Rev.
  • Page 18 Figure 2. Main machine in wood crate Figure 3. Tool Kit Main Machine Components 1 FF7200 Main Machine with counter weight and turning arm assembly 8 57701 Chuck Leg 2.5 Inch Long 8 57702 Chuck Leg 5.0 Inch Long 8 57703 Chuck Leg 8.0 Inch Long 8 57704 End Cap 4.5 Diameter...
  • Page 19 50985Tubing 1/4 in OD x .040 Wall DOT 1200 psi Nylon 120” 59151 Tubing 1/8 in OD x .023 Wall DOT 1000 psi Nylon 1 59129 Operator Manual FF7200 1 35516 Dead Blow Hammer 1-3/4 Dia. Head 2 65188 WrenchSpanner110mm to 115mm (4-1/2) Dia. .300 Dia. Pin 2 58353 Open End Wrench 55mm x 9-1/2 Long 1 14818 Ratchet Wrench ½...

  • Page 20: Dimensions And Clearance

    Dimensions and Clearance Page 12 FF7200 Operating Manual...

  • Page 21: Setup

    Contact CLIMAX immediately to report damaged or missing components. Preparing the Machine for Use Pre-setup Check The FF7200 can be set up and mounted in many ways. Before setting up the flange facer, check the following: 1. The machine assemblies are positioned correctly.
  • Page 22 Lifting and rigging DANGER The FF7200 is very heavy when fully assembled. Use caution and follow all site rigging procedures such as a lift plan and never allowing anyone under the load. Falling or uncontrolled swinging of machinery can cause serious injury or death.
  • Page 23 • Follow all proper lifting procedures and secure the machine properly before lifting. • Only use slings, straps or chains that are rated for the weight of the equipment. DANGER Do not lift the assembled machine by the lifting eyes or hoist rings on the counterweight or the machining arm.
  • Page 24 • If not possible, contact CLIMAX to determine a custom solution. To avoid the risk of a falling machine, secure the machine by tack-welding safety blocks over the upper jaws or by using clamps bolted to the underside of the leveling feet (safety blocks and clamps not included with the machine).
  • Page 25 Eight-Step Installation Instructions The FF6200 is shown in the above illustration. P/N 59129, Rev. 9 Page 17...
  • Page 26 Overview of FF7200 flange facer setup Inspect and perform necessary maintenance on the machine before mounting on a workpiece. The following steps are an overview of the processes involved with setting up the FF7200 in the ID mounting configuration. Do the following to mount the machine to the workpiece: 1.
  • Page 27 WARNING Only use individual slings for each hoist rings and be sure that they are of appropriate and equal length, and rated for the machine weight, and sling angle. 8. Lift the machine slowly and carefully. If it is out of balance, lower the machine to the ground.
  • Page 28 Do not disable the safety stop pin. The safety stop pin is intended to prevent unwanted shifting of the machining arm, which could result in serious injury or death. Page 20 FF7200 Operating Manual...
  • Page 29 CAUTION After adjusting the machining arm, make sure that the counterweight is set to the corresponding bolt location increment. For precise machining and to avoid damage to the machine, the counterweight and machining arm should always be equally spaced from the center of the machine. Figure 8.
  • Page 30 Positioning the counterweight IMPORTANT The counterweight must be installed when the machine is used in a vertical machining application. CLIMAX recommends that you always use the counterweight as it improves the performance of the machine and produces a flatter surface.
  • Page 31 CAUTION For precise machining and to avoid damage to the machine, the counterweight and machining arm should always be equally spaced from the center of the machine. The location numbers should be the same. Chuck mounting See the Installation Hazards section on page 15 for a full list of installation hazards. The machine ships with the main body mounted to the chuck.
  • Page 32 16. Make sure that the machine is secure in the fixture. 17. Remove the setup fingers. CAUTION Use only the small wrench on the jam nuts. Do not use excess force by using a larger wrench, which could damage the machine. Page 24 FF7200 Operating Manual...
  • Page 33 Feed system The feed system includes a flow control at the 3-way control valve that is set at the factory at 5 scfm. IMPORTANT CLIMAX recommends that you do not adjust this valve. Figure 14. Flow control P/N 59129, Rev. 9...
  • Page 34 In neutral, the tool may be manually fed in either direction. Hoses connected to the feedbox should have approximately 12” of extra length coiled inside the arm to allow the arm to move and still keep the hoses clear of snag hazards. Page 26 FF7200 Operating Manual...
  • Page 35 To disconnect feed hoses, press down on the collar around the hose and pull the hose out. Single point turning with the milling arm option Use the supplied ratchet box wrench to operate the feedbox in this configuration, P/N 48854 3/8” / 7/16”.

  • Page 36: Surface Mount (Optional Equipment)

    Surface mount (optional equipment) The surface mount kit provides the ability to use the FF7200 in situations where the regular inside diameter mount cannot be used. The surface mount kit may be used in backfacing applications or where there is a need to machine up to or past the outside dimension and there is no way to mount the FF7200.
  • Page 37 Do the following procedure to assemble the machine for surface mounted facing. 1. Remove the chuck from the bottom of the FF7200, as seen in Figure 15. 2. Attach the plate extensions to the bottom plate, as seen in Figure 16 3.
  • Page 38 1. Center the machine using a tape measure to get a rough centering. 2. Use the set screws to make the final adjustments. 3. Level the machine using the eight leveling set screws. Figure 19. Location of leveling and centering set screws Page 30 FF7200 Operating Manual...

  • Page 39: Back Face Attachment Setup (Optional Equipment)

    Back face attachment setup (optional equipment) The back face attachment consists of the back face attachment and screws to mount the attachment to the turning arm. Figure 20. Backfacing attachment CAUTION Always use the counterweight arm with the back face attachment.
  • Page 40 Table 6. Backfacing attachment on flange figure identification Number Description Lift point Figure 22 Backfacing attachment on flange Hole pattern for adjusting the position for different flange thicknesses Machine Four attachment screws Flange Tool head Page 32 FF7200 Operating Manual...
  • Page 41 Tool head assembly Do the following to assemble the tool head for back facing: 1. Attach the tooling head to the back face attachment using the M20 socket head cap screw and flat washer used to attach the tool head to the radial arm (see Figure 23).
  • Page 42 Page 34 FF7200 Operating Manual...
  • Page 43 P/N 59129, Rev. 9 Page 35...

  • Page 44: Od Mount (Optional Equipment)

    OD mount (optional equipment) Figure 25. FF7200 OD Mount Preparation If the machine is not setup for OD machining, then the main body or chuck of the flange facer must be rotated upside down in order to use the OD mount.
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  • Page 47 Table 7. Recommended OD mounting setup Mounting Machining 10" (254 5" (127 2.5" (63.5 Diameter* Diameters mm) leg mm) leg mm) leg Arm bolt position 30–45" 58" (1,473 mm) (762-1,143 mm) Leg in 3 30–50" 63" (1,600 mm) (762-1,270 mm) Leg in 2 30–55"...
  • Page 48 Figure 27. Detail of leg pieces 6. Unscrew 2 chuck screws on either side of one leg and install a block spacer with new screws. Repeat for the other three legs. Page 40 FF7200 Operating Manual...
  • Page 49 7. Install the top plates as shown. 8. Install lifting eyes in holes on top plate. Figure 28. Block Riser and Leg Assembly 9. Weld on tack weld plates to quadrants of the fixture on the underside. (1.5x5x10 minimum dimensions) 10.
  • Page 50 Do not remove support rigging until machine is completely secured by all fixed and adjustable legs. 13. Install the proper vertical supports shown in Figure 29. 14. Leave leveling and centering fasteners loose for later setup steps. Figure 29. Fixture and vertical assembly Page 42 FF7200 Operating Manual...
  • Page 51 Refer to Figure 30 while doing the following: 1. Lift the assembly using the lifting eyes. 2. Carefully lower the machine in between the vertical supports. 3. Position the machine onto workpiece. Use the jack screw legs while positioning. 4. Adjust to approximate center and align the verticals radial to the machine using the leveling and centering fasteners and tighten.

  • Page 52: Grinding Attachment (Optional Equipment)

    Grinding attachment (optional equipment) Page 44 FF7200 Operating Manual...
  • Page 53 Grinding attachment setup 1. Set up the ID machine in the flange. 2. Install the grinding head to the arm. 3. Screws mount the grinder to the face of the tool head. 4. Attach hoses to the grinding attachment and rotary union. See the Airline Connection section. 5.

  • Page 54: Milling Attachment (Optional Equipment)

    Milling attachment (optional equipment) Page 46 FF7200 Operating Manual...
  • Page 55 If you have the standard flange facer, you must replace that turning arm with the milling turning arm and counterweight (for vertical applications), arm assembly with the milling arm assembly, and standard drive with the milling drive. P/N 59129, Rev. 9 Page 47...
  • Page 56 Do the following to adjust the milling head and spindle: 1. Loosen the lock. 2. Adjust milling head Figure 32. Milling head components (P/N 72277) spindle. 3. Use the DRO to position the milling head. 4. Tighten the lock before machining. Page 48 FF7200 Operating Manual...
  • Page 57 Table 8. Milling head figure identification Number Description Precision ball screw down feed Z axis DRO #50 taper spindle Do the following to tram the spindle to the table: 1. Install and secure an appropriate indicator into the mounting hole. 2.
  • Page 58 With the standard spindle, the angle is limited to ± 0.17 degrees. If a greater angle is needed, a swivel head adapter will be needed. For further information, contact CLIMAX. Optional swivel head P/N 63250 is an optional swivel head for use with the milling head.
  • Page 59 CAUTION Be aware of all personnel near the machine when operating. 7. Turn on the spindle and verify the rotation direction of the cutter. If it is rotating the incorrect direction, do the following: a. Turn off the spindle. b. Press the E-Stop button. c.
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  • Page 61: Operation

    Operation Do not operate this machine without adequate training to understand fully the safe setup, operation, and maintenance procedures. WARNING To avoid serious personal injury, keep clear of moving machinery during operation. Pre-start checks WARNING Rotating machinery can cause serious injuries. Turn off and lock out the machine before making the pre-start checks.
  • Page 62 1,508 1,206 1,008 The colors shown are defined in Table 10. Table 10. Operating range color definitions SFPM Definition <150 Do not operate 150-250 Safe to operate 250-500 Optimal operating range >500 Safe to operate Page 54 FF7200 Operating Manual...
  • Page 63 Pneumatic conditioning unit WARNING For machines with air motors, if the machine stops moving unexpectedly, lock out the pneumatic safety valve located at the filter lubricator assembly before performing any troubleshooting. This section explains the pneumatic conditioning unit (PCU) controls and machining instructions. There are different pneumatic configurations depending on machine type.
  • Page 64 Figure 33. PCU components Table 11. PCU components figure identification Number Description Connections (Conn A [Shop Air] and Conn B) Pneumatic conditioning unit Feed on/off valve Feed rate adjustment Rotary union Feed trip Feed box Page 56 FF7200 Operating Manual...
  • Page 65 Machining Do the following: 1. Connect the energy sources. 2. Push the S button on the PCU. TART 3. Use the speed adjustment valve to turn on the drive motor. 4. Turn the feed rate adjustment dial to the minimum feed or to the desired setting, if known. 5.
  • Page 66 Adjusting the machine when the cut is completed CAUTION The cutting tools can get hot during machining. Wear gloves or other protective personal protective equipment and be careful of hot surfaces to avoid burns. Page 58 FF7200 Operating Manual...
  • Page 67 When the cut is completed, stop the feed and the machine and do the following: 1. Make sure that all power sources to the machine drive are isolated and locked out. 2. Adjust the machine direction, depth of cut, or tool position as needed. 3.

  • Page 68: Maintenance

    Lightly oil the lead screws periodically to ensure smooth travel. NOTE Do not grease the ball screws. Milling Head Gearbox Change the gearbox grease after the first 10 hours of use, then every 50 hours of use. Page 60 FF7200 Operating Manual...

  • Page 69: Storage

    Storage Proper storage of the machine will extend its usefulness and prevent undue damage. Before storing, clean the machine with solvent to remove grease, metal chips, and moisture. Prevent corrosion by spraying with LPS for short-term storage and Cosmoline for long-term storage. P/N 59129, Rev.

  • Page 70: Spare Parts

    DESCRIPTION FF7200 ROTARY TABLE 58128 CLAMP ARM ASSY SAFETY STOP 57815 CLAMP ARM LARGE FF7200 43001 HOIST SWIVEL RING M12 40697 SCREW M12 X 1.75 X 30MM FF7200 ARM SYSTEM...
  • Page 71 57701 LEG CHUCK TUBE 4.5 OD X 2.5 57702 LEG CHUCK TUBE 4.5 OD X 5 57703 LEG CHUCK TUBE 4.5 OD X 10 FF7200 DRIVE SYSTEM 42494 SCREW M8 X 1.25 X 25MM SHCS 59340 REGULATOR PRECISION 1-60 59635 AIR CONTROL ASSY FOR 60887 MOTOR AIR 3.5HP REVERSIBLE...

  • Page 72: Specifications

    Specifications Page 64 FF7200 Operating Manual...

  • Page 73: Exploded Views And Parts

    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 to perform service on the machine. Tool Kit P/N 58185...
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  • Page 105: Sds

    10W30 weight motor oil ......................98 Koolkut ............................ 107 LPS1 ............................113 LPS2 ............................121 PolyTac EP 2 .......................... 130 P/N 59129, Rev. 9 Page 97...
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