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Climax FF1200 Operating Manual

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FF1200
P/N 95936
July 2019
Revision 0
COMPACT FLANGE FACER
OPERATING MANUAL
FF3600
FF1200
FF2400
FF3600
ORIGINAL INSTRUCTIONS
FF2400

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Summary of Contents for Climax FF1200

  • Page 1 FF1200 FF2400 FF3600 COMPACT FLANGE FACER OPERATING MANUAL ORIGINAL INSTRUCTIONS FF2400 FF1200 FF3600 P/N 95936 July 2019 Revision 0...
  • 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 hereto, pro-...
  • Page 4 CLIMAX GLOBAL LOCATIONS Page B FF1200-FF2400-FF3600 Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 95936, Rev. 0 Page C...
  • Page 6 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 7: Table Of Contents

    ACHINE ASSEMBLY 3.3.1 FF1200: Determining the chucking range - - - - - - - - - - - - - - - - - - - - - - - - - 28 3.3.2 FF2400: Determining the chucking range - - - - - - - - - - - - - - - - - - - - - - - - - 29 3.3.3...
  • Page 8 SDS ............109 Page 2 FF1200-FF2400-FF3600 Operating Manual...
  • Page 9 3-17 Level the RDU (FF3600 shown) ........... . . 39 3-18 5/16" rods for manually rotating the RDU bearing (FF1200 shown) ......39 3-19 Center the RDU (FF3600 shown) .
  • Page 10 3-25 Motor installed (FF1200 shown) ........... . . 43 3-26 Turn the axial feed drive shaft to adjust tool height (FF1200 shown) ......45 3-27 Axial gib lock screw (FF1200 shown) .
  • Page 11 A-21 FF1200 chucking foot assembly (P/N 78911) ........
  • Page 12 This page intentionally left blank Page 4 FF1200-FF2400-FF3600 Operating Manual...
  • Page 13 2-1 FF1200-FF2400-FF3600 component identification ........
  • Page 14 This page intentionally left blank Page 2 FF1200-FF2400-FF3600 Operating Manual...

  • Page 15: Introduction

    The first page of each chapter includes a summary of the chapter contents to help you locate specific information. The appendices contain supplemental product information to aid in setup, operation, and maintenance tasks. Read this entire manual to familiarize yourself with the FF1200-FF2400-FF3600 before attempting to set it up or operate it. AFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual.

  • Page 16: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. You, the end user, must do your part by being aware of your work environment and closely following the operating procedures and safety pre- cautions contained in this manual, as well as your employer’s safety guidelines.

  • Page 17: Machine - Specific Safety Precautions

    Machine-specific safety precautions injuries. Except for stationary operating controls, avoid contact with mov- ing parts by hands or tools during machine operation. Remove gloves and secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts. Sharp edges –...

  • Page 18: 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 Porta- ble Machine Tool and the workpiece as a whole. Page 4 FF1200-FF2400-FF3600 Operating Manual...

  • Page 19: Risk Assessment Checklist

    Risk assessment checklist ISK ASSESSMENT CHECKLIST The following checklist is not intended to be an all inclusive list of things to watch out for when setting up and operating this Portable Machine Tool. However these checklists are typical of the types of risks the assembler and operator should be considering.

  • Page 20: Labels

    Labels ABELS Label identification The following warning labels should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements.  1-4. L ABLE ABELS P/N 46902 Warning P/N 29152 label: hot Mass plate surface P/N 59035...
  • Page 21 Labels 1-4. L ABLE ABELS P/N 70226 CLIMAX logo P/N 80569 Air direction and pressure label P/N 80682 Serial, year, model, mass plate CE Plate P/N 84645 High temperature warning; read manual P/N 84856 Warning label: tether machine before use P/N 95936, Rev.
  • Page 22 Labels Label location The following figures display the location of the labels on each of the components of the FF1200-FF2400-FF3600. For further identification of location placement refer to the exploded views in Appendix A. 1-2. FF1200 IGURE RADIAL SLIDE ASSEMBLY LABEL LOCA 1-1.
  • Page 23 Labels 1-5. RDU 1-6. P IGURE SIDE LABEL LOCATIONS IGURE NEUMATIC MOTOR LABEL LOCATIONS Label P/N: 84645, 84856, 59039 Label P/N: 59037, 80569 P/N 95936, Rev. 0 Page 9...
  • Page 24 Labels This page left intentionally blank Page 10 FF1200-FF2400-FF3600 Operating Manual...

  • Page 25: Overview

    - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22 PECIFICATIONS EATURES AND COMPONENTS The FF1200-FF2400-FF3600 is a portable, air-powered, belt-driven, single-point flange facing machine for use on workpieces with the outside diameters listed in Table 2-1.
  • Page 26 CHUCK FOOT (depending on the ASSEMBLY machine model) for more 2-3. FF3600 IGURE PRINCIPAL COMPONENTS mounting dimensional constraints. 2-1. FF1200-FF2400-FF3600 ABLE COMPONENT IDENTIFICATION Number Component Pneumatic motor Slide assembly Rotational drive unit Chuck foot assembly Page 12 FF1200-FF2400-FF3600 Operating Manual...

  • Page 27: Controls

    Controls ONTROLS The FF1200-FF2400-FF3600 controls are all located on the machine (Figure 2-4, Figure 2-5) or on the pneumatic conditioning unit (PCU) (Figure 2-6). WARNING Always stop the machine and lock-out/tag-out the PCU before making adjustments to controls or components on areas of the machine in motion during machine operation.
  • Page 28 VALVE FILTER RESERVOIR 2-6. PCU IGURE CONTROLS AND FEATURES 2-2. PCU ABLE CONTROL IDENTIFICATION Number Component Air supply lock-out Regulator Start button Emergency stop button Oil drip rate dial Speed adjustment valve Oil reservoir Filter Page 14 FF1200-FF2400-FF3600 Operating Manual...

  • Page 29: Items Required But Not Supplied

    Items required but not supplied TEMS REQUIRED BUT NOT SUPPLIED • Torque wrench • Dial indicator • Wood blocks IMENSIONS Machine and operating dimensions are shown in Figure 2-9 and Figure 2-12 on the subsequent pages. P/N 95936, Rev. 0 Page 15...
  • Page 30 18.0 [457 mm] MIN. WHEN CHUCKED TO MIN. FLANGE 29.8 [757 mm] MAX. WHEN 11.2 [285 mm] 8.6 [218 mm] CHUCKED TO MAX. FLANGE 16.9 [429 mm] 8.0 [203 mm] 5.7 [144 mm] 2-7. FF1200 IGURE MACHINE DIMENSIONS Page 16 FF1200-FF2400-FF3600 Operating Manual...
  • Page 31 Dimensions 31.0 [786 mm] 18.3 [465 mm] 15.5 [393 mm] 34.5 [876 mm] MIN. WHEN CHUCKED TO MIN. FLANGE 52.2 [1326 mm] MAX. WHEN CHUCKED TO MAX. FLANGE 8.7 [222 mm] 18.6 [473 mm] 6.5 [165 mm] 2-8. FF2400 IGURE MACHINE DIMENSIONS P/N 95936, Rev.
  • Page 32 46.5 [1181 mm] MIN. WHEN CHUCKED TO MIN. FLANGE 25.1 [637 mm] 22.3 [565 mm] 64.2 [1631 mm] MAX. WHEN CHUCKED TO MAX. FLANGE 8.7 [222 mm] 19.0 [482 mm] 6.8 [172 mm] 2-9. FF3600 IGURE MACHINE DIMENSIONS Page 18 FF1200-FF2400-FF3600 Operating Manual...
  • Page 33 29.8 [757 mm] WHEN 11.2 [285 mm] 8.6 [218 mm] CHUCKED TO MAX. FLANGE 18.0 [457 mm] WHEN CHUCKED TO MIN. FLANGE 9.9 [252 mm] 8.0 [203 mm] 5.8 [147 mm] 2-10. FF1200 IGURE MACHINE DIMENSIONS P/N 95936, Rev. 0 Page 19...
  • Page 34 29.8 [757 mm] WHEN 11.2 [285 mm] 8.6 [218 mm] CHUCKED TO MAX. FLANGE 18.0 [457 mm] WHEN CHUCKED TO MIN. FLANGE 9.9 [252 mm] 8.0 [203 mm] 5.8 [147 mm] 2-11. FF2400 IGURE MACHINE DIMENSIONS Page 20 FF1200-FF2400-FF3600 Operating Manual...
  • Page 35 Dimensions 31.0 [786 mm] 18.3 [465 mm] 15.5 [393 mm] 34.5 [876 mm] MIN. WHEN CHUCKED TO MIN. FLANGE 52.2 [1326 mm] MAX. WHEN CHUCKED TO MAX. FLANGE 8.7 [222 mm] 10.6 [270 mm] 6.4 [163 mm] 2-12. FF3600 IGURE RIGHT ANGLE PNEUMATIC MOTOR MACHINE DIMENSIONS P/N 95936, Rev.

  • Page 36: Specifications

    Rotational Drive Unit P/N 79752 85 lbs (38.5 kg) Radial Axial Slide P/N 79192 (9.89 kg) 21.8 lbs 1.07 hp Straight Air Motor P/N 80570 6.64 lbs (3.01 kg) Total 143 lbs (64.9 kg) 2-13. FF1200 IGURE ASSEMBLIES Page 22 FF1200-FF2400-FF3600 Operating Manual...
  • Page 37 Specifications 2-4. FF2400 ABLE COMPONENT MASS Sub-assembly number Component Mass Chuck Foot P/N 78979 20.2 lbs (9.16 kg Rotational Drive Unit P/N 79903 204 lbs (92.7 kg) 2.2 hp Straight Air Motor P/N 80632 8.84 lbs (4.01 kg) Radial Axial Slide P/N 80683 49.2 lbs (22.3 kg) Total 343 lbs (156 kg)
  • Page 38 Chuck Foot P/N 78979 20.2 lbs (9.16 kg) 2.2 hp Straight Air Motor P/N 80632 8.84 lbs (4.01 kg) Radial Axial Slide P/N 80702 68.2 lbs (30.9 kg) Total 666 lbs (302 kg) 2-15. FF3600 IGURE ASSEMBLIES Page 24 FF1200-FF2400-FF3600 Operating Manual...

  • Page 39: Setup

    ILT THE RADIAL SLIDE ECEIPT 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 40 Lifting and rigging DANGER The FF1200-FF2400-FF3600 can weigh up between 143–-666 lbs (65– 302 kg) when fully assembled (see Table 2-3 through Table 2-5 on page 24). To prevent serious injury to yourself and others, always follow the operating procedures outlined in this manual, your own company rules, and local regulations for heavy lifting.
  • Page 41 Lift the machine slowly, making sure that no components will be crushed or bent if the machine is lifted in the vertical orientation. If the rigging causes the FF1200-FF2400-FF3600 to swing or become unstable, lower it and adjust the rigging.

  • Page 42: Machine Assembly

    Machine assembly ACHINE ASSEMBLY 3.3.1 FF1200: Determining the chucking range Do the following to set the chuck- ing range and attach the chucking feet to the machine body: 1. Measure the workpiece out- side diameter. 2. If the workpiece diameter is CHUCKING FOOT smaller than 12.5"...

  • Page 43: Ff2400: Determining The Chucking Range

    Machine assembly 3.3.2 FF2400: Determining the chucking range Do the following to set the chuck- ing range and attach the chucking feet to the machine body: 1. Measure the workpiece out- side diameter. CHUCKING FOOT ADJUSTMENT 2. If the workpiece diameter is SCREW smaller than 24.5"...

  • Page 44: Ff3600: Determining The Chucking Range

    3-4. FF3600 (P/N 80088) ABLE CHUCKING RANGE CHART RANGE inch 22.0 23.6 25.2 26.8 28.4 30.0 31.6 inch 20.0 21.6 23.2 24.8 26.4 28.0 29.6 RANGE inch 33.2 34.8 36.4 38.0 inch 31.2 32.8 34.4 36.0 Page 30 FF1200-FF2400-FF3600 Operating Manual...

  • Page 45: Attaching The Chucking Feet

    36 ft-lbs (49 Nm). 4. Turn the jam nut away from the chucking foot body. 5. Turn the chucking foot set- 3-7. RDU (FF1200 IGURE INVERTED SHOWN screw to retract the chuck- ing foot all the way open.

  • Page 46: Mount The Chuck To The Workpiece

    3-13, Figure 3-14, Figure 3-15, and Figure 3-16 for example tether arrange- ments for horizontal, vertical, and upside-down mounting. WARNING Failure to properly mount and tether the machine may allow the machine to rotate or fall. Page 32 FF1200-FF2400-FF3600 Operating Manual...
  • Page 47 80371 EXAMPLE WORKPIECE NOTE: TETHER, ANCHOR POINT, PROVIDED BY CUSTOMER TETHER LENGTH MUST LIMIT ANY FALL TO NO MORE THAN 6 INCHES (152mm) HOIST RING 80371 AVAILABLE FROM CLIMAX 3-11. V IGURE ERTICAL EXAMPLE WITH TETHER 3-5. V ABLE ERTICAL TETHER IDENTIFICATION...
  • Page 48 ERTICAL EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component Example restraint arrangement for use in vertical machining applications Example workpiece Restrain by means of additional back side setup fingers P/N 78916 & screws 78924 Detail A Page 34 FF1200-FF2400-FF3600 Operating Manual...
  • Page 49 (E.G. CHAIN, CABLE, STRAP) RATED FOR 5000 LBS (22.2KN) NOTE: TETHER, ANCHOR POINT, PROVIDED BY CUSTOMER TETHER LENGTH MUST LIMIT ANY FALL TO NO MORE THAN 6 INCHES (152mm) HOIST RING 80371 AVAILABLE FROM CLIMAX 3-13. U IGURE PSIDE DOWN EXAMPLE WITH TETHER 3-7.
  • Page 50 3-8. U ABLE PSIDE DOWN EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component Example restraint arrangement for use in upside down machining applica- tions Example workpiece Restrain by means of back side setup fingers Detail A Page 36 FF1200-FF2400-FF3600 Operating Manual...
  • Page 51 RATED FOR 5000 LBS (22.2KN) EXAMPLE WORKPIECE NOTE: TETHER, ANCHOR POINT, PROVIDED BY CUSTOMER TETHER LENGTH MUST LIMIT ANY FALL TO NO MORE THAN 6 INCHES (152mm) HOIST RING 80371 AVAILABLE FROM CLIMAX 3-15. H IGURE ORIZONTAL EXAMPLE WITH TETHER 3-9. H ABLE...
  • Page 52 ORIZONTAL EXAMPLE WITH SETUP FINGERS 3-10. H ABLE ORIZONTAL EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component Example restraint arrangement for use in horizontal machining applications Example workpiece Restraint by means of setup fingers Detail A Page 38 FF1200-FF2400-FF3600 Operating Manual...

  • Page 53: Level The Rdu

    (Figure 3-17). IGURE EVEL THE SHOWN 4. Alternate the centering pro- cedure (Section 3.3.5.2) and this procedure until the desired alignment is achieved. 3-18. 5/16" IGURE RODS FOR MANUALLY ROTATING THE (FF1200 BEARING SHOWN P/N 95936, Rev. 0 Page 39...

  • Page 54: Rdu Centering

    For the FF2400 or FF3600, a minimum torque of 60 ft-lbs (27 Nm). CAUTION Do not tighten the chucking foot setscrews beyond 40 ft-lbs (18 Nm) for the FF1200, or 100 ft-lbs (45 Nm) for the FF2400 or FF3600. Exceeding the maximum torque value may cause damage to the machine or workpiece.

  • Page 55: Install The Slide Assembly

    (Fig- 3-20. A IGURE LIGN THE SLIDE BODY OVER THE CAM SLOT ure 3-20). (FF1200 SHOWN 4. With the feed body cam aligned over the cam slot, place the slide body onto the RDU bearing (Figure 3-21).

  • Page 56: Install Or Replace The Cutting Tool

    3.3.7 Install or replace the cutting tool NOTICE The FF1200-FF2400-FF3600 is designed to drag the cutting tool around the workpiece surface. The RDU and slide assembly rotate only in the counterclockwise direction. Keep these characteristics in mind when installing a new tool in the machine.

  • Page 57: Install The Motor

    Install the motor Do the following to install the motor: 1. Align the motor key with the motor coupling keyway (Figure 3-24). 3-24. A (FF1200 IGURE LIGN THE AIR MOTOR SHOWN 2. Mate the motor to the drive assembly (Figure 3-25).

  • Page 58: Set Up The Pcu

    3. Connect the PCU to an air supply with the following specifications, depending on the machine: • For the FF1200, connect to an air supply with minimum 90 psi (6.21 bar) at 55 cfm (1.6 m /min). For the right angle air motor, the PCU should be set to 75 cfm (2.2 m...

  • Page 59: Set The Tool Cutting Depth

    (Figure 3-26). 3-26. T IGURE URN THE AXIAL FEED DRIVE SHAFT TO ADJUST Shift the feed box to axial (FF1200 TOOL HEIGHT SHOWN feed and use the manual feed knob to adjust tool depth. 5. Finger tighten the axial gib lock screw (Figure 3-27).

  • Page 60: Loosen The Swivel Lock Setscrews

    29) until you feel the inter- nal pins give way. 3-28. L IGURE OOSEN THE SWIVEL LOCK SETSCREWS 3. Loosen both swivel release setscrews about two turns. 3-29. T IGURE IGHTEN THE SWIVEL RELEASE SETSCREWS Page 46 FF1200-FF2400-FF3600 Operating Manual...

  • Page 61: Tilt The Radial Slide

    Nm). 6. Hand tighten both swivel release setscrews to prevent the setscrews from vibrat- ing out during operation. 3-30. S (FF1200 IGURE WIVEL THE TOOL HEAD SHOWN 3.4.3 Tilt the radial slide The radial slide can be tilted to enable machining of tapered flanges.

  • Page 62: Support The Radial Slide (Ff1200 Shown)

    B (in) feed in/up 1 (IN): RADIAL FEED CLUTCH POSITION Clutch position legend 2 (OUT): AXIAL FEED LEGEND Feed axis shift 3-33. F (FF1200 IGURE EED CONTROLS SHOWN 1 (in): radial feed 2 (out): axial feed Page 48 FF1200-FF2400-FF3600 Operating Manual...

  • Page 63: Remove The Plug Screw (Ff1200 Shown)

    7. With a 4 mm hex key, remove the plug setscrew from the top of the slide body (Figure 3-34). 3-34. R (FF1200 IGURE EMOVE THE PLUG SCREW SHOWN 8. Position a depth gauge with a flat contact head to mea-...

  • Page 64: Loosen The Radial Slide Screws (Ff1200 Shown)

    Table 3- 12 on page 51 (for the 3-36. L (FF1200 IGURE OOSEN THE RADIAL SLIDE SCREWS FF1200) or Table 3-13 on SHOWN page 52 (for the FF2400 or FF3600). 13. With a 4-mm hex key, slowly turn the tilt adjust...
  • Page 65 Machine configuration For the FF1200, use Table 3-12 to calculate the radial slide tilt angle and corre- sponding dowel pin depth. 3-12. FF1200 ABLE RADIAL SLIDE TILT ANGLE CONVERSION Slide angle Dowel pin depth Slide angle Dowel pin depth 0.10°...
  • Page 66 For exact slide tilt angles not shown in the table, use the following calculation to determine the dowel pin depth change: • For the FF1200: dowel pin depth = 7.2" (182.88 mm) x sin (tilt angle) • For the FF2400 or FF3600: dowel pin depth = 17.27" (438.66 mm) x...

  • Page 67: Operation

    Do the following to configure the FF1200-FF2400-FF3600 for machining a face on a flat flange: 1. Assemble the FF1200-FF2400-FF3600 on the workpiece (see Section 3.3 on page 28).

  • Page 68: Configure For Machining On A Tapered Flange

    2 (out): axial feed 4.1.2 Configure for machining on a tapered flange The FF1200-FF2400-FF3600 can face or groove a flange with a taper of up to 1.5° with its precision tilting radial slide. Do the following to face or groove a tapered flange: 1.

  • Page 69: Pre - Operation Checks

    8. Hand tighten the axial gib RADIAL GIB lock screw, if facing, or the LOCK SCREW radial gib lock screw, if grooving. 4-2. R (FF1200 IGURE ADIAL GIB LOCK SCREW SHOWN 9. Adjust the cutting tool to the desired cutting depth (see Section 3.4.1 on page 45 ).

  • Page 70: Operation

    7. Adjust the oil drip rate as needed. (Figure 4-4). NOTICE For best machine performance and service life, CLIMAX recommends that the PCU oil drip rate not be adjusted below 6 drips per minute. WARNING Do not operate the machine if the bearing heats up significantly (that is, more than approximately 15ºF (10ºC) above the ambient temperature).

  • Page 71: Pcu Components

    Operation EMERGENCY START STOP BUTTON BUTTON OIL DRIP REGULATOR RATE DIAL AIR SUPPLY LOCK-OUT SPEED ADJUSTMENT VALVE FILTER RESERVOIR 4-4. PCU IGURE COMPONENTS 4-2. PCU ABLE CONTROL IDENTIFICATION Number Component Air supply lock-out Regulator Start button Emergency stop button Oil drip rate dial Speed adjustment valve Oil reservoir Filter...

  • Page 72: Stop The Machine

    Do not attempt to manually adjust the cutting tool angle or change the feed box settings during operation. Attempting to operate the feed box controls by hand or with hand tools while the machine is running may result in severe injury. Page 58 FF1200-FF2400-FF3600 Operating Manual...

  • Page 73: Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING IN THIS CHAPTER: 5.1 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59 AINTENANCE CHECKLIST 5.2 A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -60...

  • Page 74: Approved Lubricants

    Approved lubricants PPROVED LUBRICANTS CLIMAX recommends using the following lubricants at the locations indicated. Failure to use the appropriate lubricants can result in damage and premature machine wear. CAUTION Avoid damage, premature machine wear, and protect your warranty by using only approved lubricants.

  • Page 75: Maintenance Tasks

    PCU is lost and restored. Do the following to check the PCU drop-out circuit: 1. Check that the PCU is connected to a shop air supply and the FF1200- FF2400-FF3600. 2. Check that the air-supply lock-out is open (pulled up) (Figure 2-6 on page 14).

  • Page 76: Lubricate The Rdu Bearing

    (24 mL) of Mobil Mobilith SHC 460 grease or equivalent. NOTICE Do not over-lubricate the RDU bearing. Excess lubrication could leak from the bearing space and damage the rotary drive belt. 5-1. RDU IGURE BEARING GREASE FITTING Page 62 FF1200-FF2400-FF3600 Operating Manual...

  • Page 77: Resetting The Cam Arm

    The key will eventually turn into the feed direction knob and stop advancing. Once this happens, the FF1200-FF2400-FF3600 will not be able to feed the tool, regard- less of the cutting resistance. Do the following to readjust the feed box so that it is operational:...

  • Page 78: Troubleshooting

    3. The air regulator is open and not broken (Figure 4-4 on page 57). 4. There is air pressure entering and leaving the PCU. Check the air pressure by disconnecting the hose quick disconnects and checking for air bleed (Figure 4-4 on page 57). Page 64 FF1200-FF2400-FF3600 Operating Manual...

  • Page 79: The Machine Bearing Is Overheating

    Troubleshooting 5. All the valves are open (Figure 4-4 on page 57). 6. All the quick disconnects are fully engaged (Figure A-1 on page 72 through Figure A-1 on page 72, depending on the machine model, and Fig- ure A-24 on page 95). 7.

  • Page 80: The Machine Isn't Cutting Flat

    15 minutes to make sure that the machine is warmed up to operating temperature. 2. Check the machine for level (see Section 3.3.5.1 on page 39). 3. Tram the turning arm, as necessary (see Section 3.4.2 on page 45). Page 66 FF1200-FF2400-FF3600 Operating Manual...

  • Page 81: Storage And Shipping

    LPS-3 for long-term storage) to prevent corrosion. 7. Store the machine in a stable position on a stand or in storage container a according to your company policies. 8. Store the FF1200-FF2400-FF3600 in its original shipping box. TERM STORAGE Do the following for long-term storage: 1.

  • Page 82: Shipping

    Shipping HIPPING The FF1200-FF2400-FF3600 can be shipped in its original shipping container (see Figure 6-1, Figure 6-2, and Figure 6-3). 6-1. FF1200 IGURE SHIPPING CONTAINER 6-2. FF2400 6-3. FF3600 IGURE SHIPPING CONTAINER IGURE SHIPPING CONTAINER Page 68 FF1200-FF2400-FF3600 Operating Manual...

  • Page 83: Decommissioning

    Decommissioning ECOMMISSIONING To decommission the FF1200-FF2400-FF3600 before disposal, remove the drive assembly from the RDU and dispose of the drive assembly separately from the rest of the machine components. Refer to Appendix A for component assembly infor- mation. P/N 95936, Rev. 0...
  • Page 84 Decommissioning This page left intentionally blank Page 70 FF1200-FF2400-FF3600 Operating Manual...

  • Page 85: Appendix Aassembly Drawings

    (P/N 78264) - - - - - - - - - - - - - - - - - - - - - - - - - -97 IGURE ASSEMBLY PARTS LIST A-27. FF1200 1.07 (P/N 80570) - - - - - - - - - - - - - - - - - - - - -98 IGURE HP STRAIGHT AIR MOTOR A-28.

  • Page 86: Ff1200 Principal Components

    PARTS LIST ITEM P/N: DESCRIPTION 78911 ASSY CHUCK FOOT 12 79192 ASSY RADIAL AND AXIAL SLIDE 79752 ASSY RDU 0-12 INCH OD FF 80570 ASSY MOTOR AIR 1.07HP STRAIGHT A-1. FF1200 IGURE PRINCIPAL COMPONENTS Page 72 FF1200-FF2400-FF3600 Operating Manual...

  • Page 87: Ff2400 Principal Components

    PARTS LIST ITEM P/N: DESCRIPTION 78979 ASSY CHUCK FOOT 24 79903 ASSY RDU 0-24 INCH OD FF 80632 ASSY MOTOR AIR 2.2HP STRAIGHT 80683 ASSY AXIAL RADIAL & AXIAL SLIDE 0-24 A-2. FF2400 IGURE PRINCIPAL COMPONENTS P/N 95936, Rev. 0 Page 73...

  • Page 88: Ff3600 Principal Components

    PARTS LIST ITEM P/N: DESCRIPTION 80017 ASSY RDU 0-36 INCH 80097 ASSY CHUCK FOOT 36 80632 ASSY MOTOR AIR 2.2HP STRAIGHT 80702 ASSY AXIAL & RADIAL SLIDE 0-36 INCH A-3. FF3600 IGURE PRINCIPAL COMPONENTS Page 74 FF1200-FF2400-FF3600 Operating Manual...

  • Page 89: Ff1200 Rotational Drive Unit Assembly (P/N 79752)

    A-4. FF1200 (P/N 79752) IGURE ROTATIONAL DRIVE UNIT ASSEMBLY P/N 95936, Rev. 0 Page 75...

  • Page 90: Ff1200 Rotational Drive Unit Assembly Parts List (P/N 79752)

    PLATE MASS CE 35009 SCREW M6 X 1.0 X 20 SHCS 35505 SCREW M6 X 1.0 X 30 SHCS 56300 LABEL CLIMAX LOGO .66 X 1.75 59035 LABEL WARNING - WEAR EYE PROTECTION 59039 LABEL WARNING LIFT POINT ROUND 1.5" 59042...

  • Page 91: Ff2400 Rotational Drive Unit Assembly (P/N 79903)

    A-6. FF2400 R (P/N 79903) IGURE OTATIONAL DRIVE UNIT ASSEMBLY P/N 95936, Rev. 0 Page 77...

  • Page 92: Ff2400 Rotational Drive Unit Assembly Parts List (P/N 79903)

    LABEL WARNING LIFT POINT ROUND 1.5" 59042 LABEL WARNING - HAND CRUSH/MOVING PARTS 59044 LABEL WARNING - CONSULT OPERATOR'S MANUAL 70226 LABEL CLIMAX LOGO 1.5 X 5.5 75520 BELT POLYCHAIN 8mm PITCH X 12mm WIDE X 280 TEETH 79647 BRG SLEWING ASSY 0-24 IN 79749...

  • Page 93: Ff3600 Rotational Drive Unit Assembly (P/N 80017)

    A-8. FF3600 (P/N 80017) IGURE ROTATIONAL DRIVE UNIT ASSEMBLY P/N 95936, Rev. 0 Page 79...

  • Page 94: Ff3600 Rotational Drive Unit Assembly Parts List (P/N 80017)

    LABEL WARNING LIFT POINT ROUND 1.5" 59042 LABEL WARNING - HAND CRUSH/MOVING PARTS 59044 LABEL WARNING - CONSULT OPERATOR'S MANUAL 70226 LABEL CLIMAX LOGO 1.5 X 5.5 76006 BELT POLYCHAIN 8MM PITCH X 12MM WIDE X xxx TEETH 79749 ASSY DRIVE WITH FEED CONTROL 79924...

  • Page 95: Rdu Drive With Feed Control Assembly (P/N 79749)

    PARTS LIST ITEM P/N: DESCRIPTION 21798 WASHER 5/16 FLTW HARDENED 35009 SCREW M6 X 1.0 X 20 SHCS 50458 SCREW M8 X 1.25 X 20mm SHCS 61225 SCREW M8 X 1.25 X 40MM SHCS 68514 SCREW M6 X 1.0 X 16MM SSSFP 72753 SCREW M8 X 1.25 X 50MM SHCS 74296...

  • Page 96: Ff1200 Radial And Axial Slide Assembly (P/N 79192)

    A-11. FF1200 (P/N 79192) IGURE RADIAL AND AXIAL SLIDE ASSEMBLY Page 82 FF1200-FF2400-FF3600 Operating Manual...

  • Page 97: Ff1200 Radial And Axial Slide Assembly Parts List (P/N 79192)

    SLIDE DOVETAIL 3 IN WIDE X 7.63 IN LONG 79257 BEARING BLOCK DUAL LEADSCREW 80407 ASSY TOOL HEAD 80682 PLATE SERIAL YEAR MODEL MASS CE 2.0 X 2.63 A-12. FF1200 (P/N 79192) IGURE RADIAL AND AXIAL SLIDE ASSEMBLY PARTS LIST P/N 95936, Rev. 0 Page 83...

  • Page 98: Ff2400 Radial And Axial Slide Assembly (P/N 80683)

    A-13. FF2400 (P/N 80683) IGURE RADIAL AND AXIAL SLIDE ASSEMBLY Page 84 FF1200-FF2400-FF3600 Operating Manual...

  • Page 99: Ff2400 Radial And Axial Slide Assembly Parts List (P/N 80683)

    PARTS LIST ITEM P/N: DESCRIPTION 10437 BRG THRUST .500 ID X .937 OD X .0781 10588 SCREW DRIVE #2 x 1/4 HOLE SIZE .089 11736 WASHER THRUST .500 ID X .937 OD X .030 14315 PIN DOWEL 3/32 DIA X 1/2 29152 PLATE MASS CE 35009...

  • Page 100: Ff3600 Radial And Axial Slide Assembly (P/N 80702)

    A-15. FF3600 (P/N 80702) IGURE RADIAL AND AXIAL SLIDE ASSEMBLY Page 86 FF1200-FF2400-FF3600 Operating Manual...

  • Page 101: Ff3600 Radial And Axial Slide Assembly Parts List (P/N 80702)

    RING O 1/16 X 13/16 ID X 15/16 OD 67546 NUT M8 X 1.25 STDN ZINC PLATED 70227 LABEL CLIMAX LOGO 2 X 8 74291 SCREW M8 X 1.25 X 35 SSSFP 74632 SCREW M8 X 1.25 X 30 OAL X 10 THD L STAINLESS 75302 LEADSCREW RADIAL FEED 0-24 &...

  • Page 102: Feed Box Assembly (P/N 79194)

    A-17. F (P/N 79194) IGURE EED BOX ASSEMBLY Page 88 FF1200-FF2400-FF3600 Operating Manual...

  • Page 103: Feed Box Assembly Parts List (P/N 79194)

    PARTS LIST ITEM P/N: DESCRIPTION 10436 WASHER THRUST .500 ID X .937 OD X .060 11165 WASHER THRUST .625 ID X 1.125 OD X .060 11739 WASHER THRUST .750 ID X 1.250 OD X .0312 11823 WASHER THRUST .625 ID X 1.125 OD X .030 12360 KEY 1/8 SQ X .37 12895...

  • Page 104: Igure A-19. Tool Head Assembly (P/N 80407)

    A-19. T (P/N 80407) IGURE OOL HEAD ASSEMBLY Page 90 FF1200-FF2400-FF3600 Operating Manual...

  • Page 105: Igure A-20. Tool Head Assembly Parts List (P/N 80407)

    PARTS LIST ITEM P/N: DESCRIPTION 14335 BUSHING OILITE 1/2 ID X 5/8 OD X 3/8 16594 BALL NYLON 3/16 DIA 20772 NUT M6 X 1.0 STDN ZINC PLATED 22402 WASHER THRUST 1.000 ID X 1.562 OD X .095 23669 RING SNAP 13/16 ID 26828 PLUNGER BALL PUSHFIT 27812...

  • Page 106: Igure A-21. Ff1200 Chucking Foot Assembly (P/N 78911)

    FINGER SETUP FFOD 78917 NUT M22 X 1.5 JAMN ZINC PLATED 78924 SCREW M6 X 1.0 X 20MM SHCS CAPTIVE 8 THD STAINLESS 80083 LABEL 0-12 INCH CHUCK RANGES A-21. FF1200 (P/N 78911) IGURE CHUCKING FOOT ASSEMBLY Page 92 FF1200-FF2400-FF3600 Operating Manual...

  • Page 107: Igure A-22. Ff2400 Chucking Foot Assembly (P/N 78979)

    PARTS LIST ITEM P/N: DESCRIPTION 12959 PIN ROLL Ø3/16 X 1 42969 SCREW M10 X 1.5 X 12MM SSSFP 43182 SCREW M12 X 1.75 X 65mm SHCS 78915 JAW CHUCK FOOT 78916 FINGER SETUP FFOD 78924 SCREW M6 X 1.0 X 20MM SHCS CAPTIVE 8 THD STAINLESS 78980 HOUSING CHUCK FOOT 24 78981...

  • Page 108: Igure A-23. Ff3600 Chucking Foot Assembly (P/N 80097)

    SCREW ADJUSTING CHUCK FOOT 24 36 78984 NUT 1-3/8-12 JAMN 79003 WASHER THRUST .787 ID X 1.378 OD X .108 HOUSING PILOTED 80088 LABEL 0-36 INCH CHUCK RANGES A-23. FF3600 (P/N 80097) IGURE CHUCKING FOOT ASSEMBLY Page 94 FF1200-FF2400-FF3600 Operating Manual...

  • Page 109: Igure A-24. Pneumatic Drive Assembly (P/N 76027)

    PARTS LIST ITEM P/N: DESCRIPTION 13208 FTG QD COUPLER 1/2B 1/2 NPTF PNEUMATIC 36328 VALVE BALL 1/2 NPTF X 1/2 NPTF OVAL HANDLE 37008 HOSE ASSY 801 1/2 X 1/2 NPTM X 1/2 NPTMS X 96 76030 FTG NIPPLE 1/2 NPTM X 2 INCH BRASS 78264 PNEUMATIC CONDITIONING UNIT 1/2 IN LOW PRES.

  • Page 110: Igure A-25. Pneumatic Conditioning Unit (Pcu) Assembly (P/N 78264)

    ASSEMBLED SCALE 1 : 5 A-25. P (PCU) (P/N 78264) IGURE NEUMATIC CONDITIONING UNIT ASSEMBLY Page 96 FF1200-FF2400-FF3600 Operating Manual...

  • Page 111: Igure A-26. Pcu Assembly Parts List (P/N 78264)

    PARTS LIST ITEM P/N: DESCRIPTION 10160 SCREW 1/4-20 X 3/4 SHCS 11365 SCREW 1/4-20 X 3/4 BHSCS 12616 FTG PLUG 1/8 NPTM SOCKET 13489 WASHER 5/16 FLTW SAE 14726 SCREW 10-32 X 1/4 SHCS 19729 NUT 5/16-18 NYLON INSERT LOCKNUT 22235 FTG BARB #10-32 X 1/8 HOSE 27895...

  • Page 112: F (P/N 80570)

    LABEL WARNING - WEAR EAR PROTECTION 74585 MOTOR AIR 1.07HP 382 RPM FS 177 RPM MAX 54TQ STALL 80569 LABEL AIR MOTOR DIRECTION AND PRESSURE A-27. FF1200 1.07 (P/N 80570) IGURE HP STRAIGHT AIR MOTOR Page 98 FF1200-FF2400-FF3600 Operating Manual...

  • Page 113: Igure A-28. Ff2400 And Ff3600 2.2 Hp Straight Air Motor (P/N 80632)

    PARTS LIST ITEM P/N: DESCRIPTION 13209 FTG QUICK COUPLER 1/2B 1/2 NPTM MALE AIR 35670 FTG SWIVEL AIR 1/2 NPTM X 1/2 NPTF 59037 LABEL WARNING - WEAR EAR PROTECTION 80569 LABEL AIR MOTOR DIRECTION AND PRESSURE 80614 MOTOR AIR 486 RPM FS 208 RPM MAX 160 NM TQ 3 BOLT FLANGE 3/4" SHAFT A-28.

  • Page 114: Hp Right Angle Air Motor (P/N 80618)

    LABEL WARNING - WEAR EAR PROTECTION 80617 MOTOR AIR RIGHT ANGLE 448 RPM FS 219 RPM MAX 101 NM TQ 3 BOLT FLANGE 3/4" SHAFT A-29. 2.2 (P/N 80618) IGURE HP RIGHT ANGLE AIR MOTOR Page 100 FF1200-FF2400-FF3600 Operating Manual...

  • Page 115: Able A-1. Ff1200 Spare Parts Kit (P/N 78263)

    A-1. FF1200 S (P/N 78263) ABLE PARE PARTS KIT Part number Description 10437 BRG THRUST .500 ID X .937 OD X .0781 (VMI) 11736 WASHER THRUST .500 ID X .937 OD X .030 (VMI) 12895 PIN ROLL 3/32 DIA X 3/4...

  • Page 116: Able A-2. Ff2400 Spare Parts Kit (P/N 81453)

    A-1. FF1200 S (P/N 78263) (C ABLE PARE PARTS KIT ONTINUED Part number Description 74657 NUT M6 X 1.0 WING 74658 SCREW M6 X 1 X 25MM SSSDP 74836 SCREW 1/2-13 X 3/8 SSSFP 76480 KEY 8MM X 12MM X 30MM RADIUS BOTH ENDS W/ M5 THREAD 76599 SCREW M6 X 1.0 X 40MM KNURLED HEAD...
  • Page 117 A-2. FF2400 (P/N 81453) (C ABLE SPARE PARTS KIT ONTINUED Part number Description 74248 ARM CAM FOLLOWER 74658 SCREW M6 X 1 X 25MM SSSDP 76480 KEY 8MM X 12MM X 30MM RADIUS BOTH ENDS W/ M5 THREAD 74634 BRG CAM FOLLOWER SHAFT MOUNT 8 mm ID X 24 mm OD X 10 mm 67573 SCREW M8 X 1.25 X 50MM SSSHDP 74632...

  • Page 118: Able A-3. Ff3600 Spare Parts Kit (P/N 81454)

    44519 SCREW M12 X 1.75 X 30MM SSSFP 80210 SP ASSY SETUP FINGER 76755 KNOB FEED KNURLED 2.5 OD X 1/2 -13 ID THDS 74292 GIB .365 X .125 X 3 4 SS UNEVEN SP Page 104 FF1200-FF2400-FF3600 Operating Manual...

  • Page 119: T P/N 78262

    A-3. FF3600 S (P/N 81454) (C ABLE PARE PARTS KIT ONTINUED Part number Description 79194 ASSY FEED BOX 14315 PIN DOWEL 3/32 DIA X 1/2 75303 DRIVE SHAFT 0-24 & 36 INCH 11736 WASHER THRUST .500 ID X .937 OD X .030 (VMI) 22402 WASHER THRUST 1.000 ID X 1.562 OD X .095 (VMI) 12895...
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  • Page 121: Appendix Bschematics

    APPENDIX B SCHEMATICS E-STOP START SHUTOFF B-1.P (P/N 78264) IGURE NEUMATIC SCHEMATIC P/N 95936, Rev. 0 Page 107...
  • Page 122 This page intentionally left blank Page 108 FF1200-FF2400-FF3600 Operating Manual...

  • Page 123: Appendix Csds

    APPENDIX C Contact CLIMAX for the current safety data sheets. P/N 95936, Rev. 0 Page 109...
  • Page 124 This page intentionally left blank Page 110 FF1200-FF2400-FF3600 Operating Manual...

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