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Climax LM5200 Operating Manual

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LM5200
LINEAR MILLING MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE: 11017900 – 15121870
ORIGINAL INSTRUCTIONS
LM5200 Milling Machine
P/N 66188
July 2019
Revision 5

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Summary of Contents for Climax LM5200

  • Page 1 LM5200 LINEAR MILLING MACHINE OPERATING MANUAL SERIAL NUMBER RANGE: 11017900 – 15121870 ORIGINAL INSTRUCTIONS LM5200 Milling Machine P/N 66188 July 2019 Revision 5...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions Warranty Information About this Manual CE Information General Information Rigging and Lifting Operational Dimensions Components Frequently Asked Questions Receiving the Machine Datum Surfaces Bed Assembly Machine Setup Operation Maintenance Disassembly and Storage Specifications Exploded Views and Parts Lists WARNING For maximum safety and performance, read and understand the entire manual and all related safety instructions before using this equipment.

  • Page 4: Safety Precautions

    The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions. Climax Portable Machining and Welding Systems, 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.
  • Page 5 If the machine or parts are damaged, have must be moved or lifted with approved rigging and the machine repaired before use. practices. Climax accepts no responsibility for the WARNING LABELS selection of lifting equipment. Always follow your plant’s procedures for lifting heavy objects. Do not...
  • Page 6 IMPORTANT Provides critical information for the completion of a task. There is no associated hazard to people or the machine. INFORMATION Provides important information regarding the machine. Page 4 LM5200 Operating Manual...
  • Page 7 This page intentionally left blank P/N 66188, Rev. 5 Page 5...
  • Page 8 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 6 LM5200 Operating Manual...
  • Page 9 Risk assessment checklist Use these checklists as part of your on-site risk assessment and include any additional considerations that may pertain to your specific application. 1. R ABLE ISK ASSESSMENT CHECKLIST BEFORE SET Before Set-up I took note of all the warning labels on the machine. ...
  • Page 10 Part Number 65487 – Mass Tag Part Number 35772 – Ball Valve Handle Part Number 27307 – Warning Label Part Number 61839 – Climax Logo Part Number 37572 – PE Ground Part Number 46902 – Warning Hot Surface Part Number 62888 – Lift Point Only...
  • Page 11 Part Number 36094 – Speed Controller Part Number 37576 – Electrical Warning Nameplate Part Number 41949 – Speed Controller Part Number 30081 – 230V Nameplate CE Part Number 32585 – 120V Part Number 34734 – Warning Label P/N 66188, Rev. 5 Page 9...

  • Page 12: Warranty Information

    Climax will, at its option, either repair or replace the defective machine at no charge and will return the machine with shipping prepaid.

  • Page 13: About This Manual

    The machine is designed for milling and drilling operations in linear and gantry modes. All parts meet Climax Portable Machining & Welding Systems’ strict quality standards. For maximum safety and performance you must read and understand the entire manual before operating the machine.

  • Page 14: Ce Information

    Risks and hazards associated with the use of this equipment are clearly marked on the machine or referenced in the operating manual in accordance with International Standards. If you have any questions or concerns, contact Climax before operating this equipment. The Declared Sound Power Level is: = 73.9 dB(A)
  • Page 15 P/N 66188, Rev. 5 Page 13...

  • Page 16: General Information

    General Information The LM5200 Milling Machine revolutionizes both the capabilities and functionality of portable mills. The machine is extremely rigid, with modular bed design • Innovative configuration options allow setup for both conventional milling and gantry • milling in one machine •...

  • Page 17: Rigging And Lifting

    Rigging and Lifting WARNING Falling or uncontrolled swinging of machinery can cause serious injury or be fatal to the operator and bystanders. Lift the machine only by the properly designated lifting eyes. Do not lift the assembled machine by the machining arm.
  • Page 18 Lifting Eyes Ram ONLY Lift Points Example of Vertical Lifting Bed Lifting Eye Lifting Points Page 16 LM5200 Operating Manual...
  • Page 19 1. To prevent damage to the milling head, carefully remove the milling head with a sling before lifting the ram. 2. Center the machining arm (ram) over the beds before lifting. 3. Test lift slowly and adjust the center of gravity as necessary for controlled lifting. 4.

  • Page 20: Operational Dimensions

    Operational Dimensions Page 18 LM5200 Operating Manual...
  • Page 21 P/N 66188, Rev. 5 Page 19...
  • Page 22 Page 20 LM5200 Operating Manual...
  • Page 23 Overhead View P/N 66188, Rev. 5 Page 21...
  • Page 24 Overhead View ** Ram at Maximum Recommended Offset Page 22 LM5200 Operating Manual...
  • Page 25 End View Side Milling P/N 66188, Rev. 5 Page 23...
  • Page 26 Overhead Milling ** Ram at Maximum Recommended Offset Spindle Travel Page 24 LM5200 Operating Manual...
  • Page 27 Standard Mounting Pattern Gantry Mounting Pattern P/N 66188, Rev. 5 Page 25...

  • Page 28: Components

    Components Control cables are available in 10, 20 or 30 meter lengths Page 26 LM5200 Operating Manual...
  • Page 29 66609 ASSY SUB PLATE 96 INCH BED LENGTH CONVENTIONAL LM5200 Gantry Milling Sub Plates 66610 ASSY SET SUB PLATES 48 INCH BED LENGTH GANTRY LM5200 66611 ASSY SET SUB PLATE 72 INCH BED LENGTH GANTRY LM5200 66612 ASSY SET SUB PLATE 96 INCH BED LENGTH GANTRY LM5200...

  • Page 30: Frequently Asked Questions

    DRO option for the bed or ram axis. If a customer has DRO requirements this capability can be explored through the specials process. Is air power available? The LM5200 has air power available as direct drive or right-angle for the HSK spindle, but the LM6200 does not.
  • Page 31 For maximum rigidity the LM5200 can machine to 12” (304.8 mm) from the side of the bed to the center of the spindle, and the LM6200 can machine to 28” (711.2 mm) from the side of the bed to the center of the spindle.
  • Page 32 How do I lengthen my bed? Contact Climax to purchase a bed lengthening kit and a longer ballscrew if necessary. Be sure to let us know if you will need the additional length in Gantry configuration as well.

  • Page 33: Receiving The Machine

    Receiving the Machine The machine was run tested and thoroughly inspected before leaving the factory. When leaving the factory, the machine is packaged well for the demands of normal transportation. Climax cannot, however, guarantee the condition upon arrival of the machine.

  • Page 34: Datum Surfaces

    The surface of bed alignment tools have a ground surface. The top of the bed sections is a ground surface. Page 32 LM5200 Operating Manual...

  • Page 35: Bed Assembly

    The following standard and gantry bed assembly instructions depict a 72 inch long LM6200 bed assembly; the process is the same for the LM5200. Actual bed length may vary. Standard Bed Assembly 1.
  • Page 36 6. Place the second bed alignment tool (Item 7) on the sections as shown in Figure 2. Tighten the fasteners on the assembled sections first to 65 ft lb. Then tighten the fasteners on the new section to 65 ft-lb. Page 34 LM5200 Operating Manual...
  • Page 37 Figure 3 7. Tighten the 6 M16 fasteners to 200 ft-lb to hold the sections together. 8. Install a bed connection plate (Item 4) as shown in Figure 2, and tighten the fasteners to 40 ft-lb. 9. Attach a dial indicator with a magnetic base to one of the linear rails and check the alignment of the two A points, and the two B points as shown in Figure 3.
  • Page 38 4. Push the bed sections together and install 3 M16 fasteners (item 3), and 3 M16 fasteners (Item 7) into the 48 inch bed section and 48 inch gantry plate. Tighten the fasteners to 10 ft-lb, then loosen them and retighten until they are just touching. Page 36 LM5200 Operating Manual...
  • Page 39 5. Place a bed alignment tool (Item 10) on the sections as shown in Figure 5, and tighten the fasteners to 65 ft-lb. 6. Tighten the 6 M16 fasteners installed in step 4 to 200 ft-lb to hold the sections together. 7.
  • Page 40 For longer gantry bed assemblies, repeat the previous steps adding 48 inch bed sections until the desired length is obtained, and then finish with a 24 inch bed section. Make sure to always use a 48 inch gantry plate (Item 9) to connect two bed sections. Page 38 LM5200 Operating Manual...
  • Page 41 Ballscrew Assembly The ballscrew assembly can be placed on either bed half. The following procedure can be used on either end of the ballscrew. Tightening the bearing preload nut on either end of the ballscrew will remove all slack. Once the ballscrew is adjusted, the hex on both ends should be protruding about the same amount.

  • Page 42: Machine Setup

    Be very careful not to over tighten any leveling screws! This could cause the bed to warp. Warping becomes obvious when the saddle binds at the warped point of the rail. Contact Climax immediately if you suspect the bed is warped. Do not attempt to straighten the bed or the rails.
  • Page 43 Shims can also be used under the bed to assist in leveling. If the setup area is not level, you may need to prepare special mounts that fit your application. There are numerous ways to set up the bed next to the work piece. Rigidity is the most important factor to take into consideration.
  • Page 44 This section contains information necessary for installation of the linear mill ram tether kit on the LM5200/6200 linear mill. The ram tether kit should be installed on the Linear Mill whenever the machine is configured with the ram oriented vertically.
  • Page 45 IMPORTANT If installation of the linear mill ram tether kit cannot be completed on your machine for any reason, contact Climax before operating the machine with the ram in a vertical orientation. Ram Hazard Warning Label Check that the two ram hazard warning labels (P/N 78937, Figure 12) are applied to the ram in the locations identified in Figure 12.
  • Page 46 Table 4. Swivel base lifting eye torque values Model Swivel Base Lifting Eye Torque LM5200 7 ft-lb (10 Nm) LM6200 20 ft-lb (27 Nm) Figure 15. Slide block and swivel base lifting eye installation Page 44 LM5200 Operating Manual...
  • Page 47 8. Connect the chain end to the hoist ring shackle on the ram (Figure 17 on page 4645). 9. Install the hoist ring shackle on the swivel base lifting eye (Figure 17 on page 46). 10. Attach one end link of the chain to the shackle (Figure 17 on page 46).
  • Page 48 To remove the Ram Tether Kit from the linear mill, complete the following tasks. 1. Do the installation tasks in Section Installing the Ram Tether Kit on page 43 in reverse order. 2. Install the original clamp block on the linear mill bed. Page 46 LM5200 Operating Manual...
  • Page 49 INFORMATION Unless a new machine configuration requires its removal, the ram safety kit clamp block that was installed in Section Installing the Ram Tether Kit on page 43 can remain in place on the machine and function as a regular clamp block. Unless a new machine configuration requires its removal, the swivel base lifting eye that was installed in Section Installing the Ram Tether Kit on page 43 can remain installed on the ram.
  • Page 50 1. Attach a dial indicator with a magnetic base to the end of the spindle. Example from the LM6000 2. If the drive motor is installed, remove it from the spindle gearbox to enable easy hand- rotation of the spindle. Page 48 LM5200 Operating Manual...
  • Page 51 3. Position the milling assembly over the bed using the ram feed system. 4. Sweep the top datum surface of the bed with the indicator by rotating the spindle. INFORMATION The bottom datum surface of the ram can also be used for indicating. 5.
  • Page 52 3. Position the gantry side of the bed, and rough align it using a tape measure. 4. Place the ram on the saddle plates, and tighten the ram clamps on the drive side as shown in Figure 13. Leave the ram clamps loose on the gantry side. Page 50 LM5200 Operating Manual...
  • Page 53 Figure 20 5. Use a precision leveling tool on the top datum surface of the ram to adjust the gantry side of the bed until it is coplanar with the drive side. The beds must be within 0.004 inch for every 12 inches the rails are separated. The following diagrams show the correct alignment, maximum angular misalignment, and maximum offset allowed.
  • Page 54 4. Tighten down the ram clamps on the gantry side when no more adjustment is needed. When complete, the ram should glide smoothly along the full length of the bed. A tight spot indicates an area that is out of alignment. Page 52 LM5200 Operating Manual...

  • Page 55: Operation

    Operation WARNING To avoid serious personal injury, do not reach inside the machine, and keep clear of moving parts while it is operating. CAUTION 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.
  • Page 56 Verify that the rigging has been removed from the machine. Do not remove the lifting • eyes. Ensure setup tools are removed. • Verify that the machine can move the full length without collisions. • Ensure the milling head is properly setup. • Page 54 LM5200 Operating Manual...
  • Page 57 • Ensure the milling cutter is securely mounted. • Verify the feed direction and milling rate are set correctly. • Check that all fasteners are tight. Verify that any turning or other movable parts are clear of obstructions. • Ensure that all cables and hoses are secure and not in the path of moving parts. •...
  • Page 58 Retract the milling head from the work piece, and stop the spindle. • Press the E-stop button. • Lockout the HPU before removing the cutter, replacing inserts, or performing maintenance. CAUTION Do not stop the spindle when the feed is running or broken inserts will result. Page 56 LM5200 Operating Manual...

  • Page 59: Maintenance

    Maintenance CAUTION Failure to properly maintain the machine will result in premature wear or damage to the machine. Damaged caused by improper or inadequate machine maintenance is not covered by the machine limited warranty. Cleaning and Lubrication • Clean the machine after each use to remove dirt, grease, metal chips, and moisture. Wipe dry with clean materials.
  • Page 60 Continued use 5.44 @ 100C while cutting * If an approved lubricant cannot be used, contact Climax for an equivalent alternative. Lubrication for THK Railing THK, manufacturer of the rail assembly, recommends the rail block be lubricated every 65 hours of operating time with 2.6cc of AFA grease.

  • Page 61: Disassembly And Storage

    Apply LPS lubricant to unpainted surfaces to prevent corrosion. • Store in the container provided. • Place desiccant bags or vapor wrap around the machine to absorb moisture. • Climax advises changing the desiccant bags in the storage crate every 18 months. P/N 66188, Rev. 5 Page 59...

  • Page 62: Specifications

    62407 (4.9 CU IN 2000 SERIES) 53457 (8.0 CU IN 2000 SERIES) 47394 (14.9 CU IN 2000 SERIES) 47395 (18.7 CU IN 2000 SERIES) 47396 (24.0 CU IN 2000 SERIES) 47221 (29.8 CU IN 2000 SERIES) Page 60 LM5200 Operating Manual...

  • Page 63: 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 not authorized in writing by Climax to perform service on the machine. Tool Kit P/N 64202 PART NO.
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