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Summary of Contents for Climax FLANGE FACER
- Page 1 FF4000 FLANGE FACER OPERATING MANUAL SERIAL NUMBER RANGE: 11017900 - 15121870 ORIGINAL INSTRUCTIONS FF4000 Flange Facer shown P/N 35425 May 2019 Revision 2...
- Page 3 At CLIMAX, we value your opinion. 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 For quick and accurate service, please provide your representative with info@cpmt.com...
- Page 4 CLIMAX GLOBAL LOCATIONS Page B FF4000 Operating Manual...
- Page 5 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 6 CE DOCUMENTATION LACEHOLDER FOR CE DECLARATION OF INCORPORATION Page D FF4000 Operating Manual...
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Page 7: Table Of Contents
Contents Safety Guidelines ....................1 Machine Specific Safety Practices ................ 2 Labeling Guidelines ....................3 Introduction ......................6 About this manual ....................7 Receiving Inspection .................... 8 Recommended tools ..................... 9 Setup ........................10 Operation ......................17 Disassembly ....................... 21 Maintenance ....................... - Page 8 This page is intentionally left blank Page F FF4000 Operating Manual...
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Page 9: Safety Guidelines
The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions. Climax Portable Machining & Welding Systems 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 10: Machine Specific Safety Practices
Machine Specific Safety Practices This list includes safety practices applicable to Climax’s Portable Machines. 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. -
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 Machine Tools are specifically designed to perform precise material-removal operations. Stationary Machine Tools include lathes and milling machines and are typically found in a machine shop. They are mounted in a fixed location during operation and are considered to be a complete, self-contained machine.
- Page 13 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. ...
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Page 14: Introduction
Introduction The Model FF4000 is a compact, lightweight, portable flange-facing and pipe beveling machine notable for its 2-piece “Quick-Lock” ID-mount chuck. Its primary application is for restoration of flanges from 3” to 19” (76 to 483 mm) diameter. Secondary operations include beveling, squaring, counter boring and cutting weld- prep configurations on tube and pipe. -
Page 15: About This Manual
About this manual This manual describes the most effective setup and operation of your Model FF4000 Flange Facer. All parts meet Climax Portable Machining & Welding Systems’ strict quality standards. For maximum safety and performance, read the entire manual before operating this machine. -
Page 16: Receiving Inspection
In accordance with normal practice, be sure to inspect the machine for any damage that may have occurred in shipping. Check parts received against the invoice or packing slip and promptly notify Climax should there be any discrepancies. Page 8... -
Page 17: Recommended Tools
Recommended tools Climax includes a general tool kit for use in operating the machine. Additionally, you may require other items of equipment specific to your job-site and particular setup. Supplied with the machine: Dead blow hammer Spanner wrench Hex key wrench set Other tools you could have on hand: Pliers for pulling chips away from the machine. -
Page 18: Setup
Setup CAUTION Avoid bodily injury from moving machinery. Turn off and disconnect the air supply before machine setup. Tool head installation Install a tool head (beveling or facing), with the arrow side away from the main body. Align the bayonet pins in the tool head with the slots on the body. Push and turn to lock. - Page 19 Clamp blades are marked with their size. Select the proper set of clamp blades from the following table: Clamp blade set selection Bore diameter inches Part number (set of (mm) 3.0 – 3.65 (76 – 93) No chuck blade 3.65 - 4.30 (93 - 109) 35525 4.25 - 4.90 (108 - 124) 35526...
- Page 20 Setting tool bits Facing head • Select and install a suitable tool bit into the tool head. • Tighten the setscrews. • For production jobs, set and test the settings on a test work piece. Beveling head • Select the tool bit, or combination of bits, and slip them into the tool head. •...
- Page 21 Mounting the machine CAUTION To avoid damage to the clamp blades, be sure the machine is mounted far enough inside the work piece to clear the cutters. • Turn the star-shaped draw-rod knob counterclockwise to secure the blades inward. • Install the machine in the pipe/tube end, and turn the draw rod knob clockwise to spread the clamp blades in the bore.
- Page 22 Air line connection NOTE Use only nonrestrictive air line fittings and secure the machine to the work piece before connecting the air supply. CAUTION To prevent serious injury from moving machinery, use quick disconnect fittings provided between the air supply line and the ball valve. Close and lock out air valve before connecting the air supply line to the motor.
- Page 23 Starting the machine This label is attached to the handle of the FF4000. The cutting arm rotates directly below the handle. Do not hold on to this handle during operation! CAUTION SEVERING HAZARD: DO NOT HOLD THE HANDLE DURING OPERATION! The FF4000 is equipped with a 1.45 hp (1.08 Kw) air motor and a ball-type shut off valve.
- Page 24 • To move the tool head toward the work piece turn the feed handles clockwise. • To feed away from the work piece turn the feed handles counterclockwise. A notable feature of the Climax FF4000 Flange Facer includes a feed mechanism with both left-hand and right-hand screw threads. While providing a more compact feed system, this innovative design effectively doubles the length of travel for the tool head.
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Page 25: Operation
Operation Pre-start checks CAUTION To prevent serious bodily injury from moving machinery, turn off and disconnect the air supply before performing pre-start checks. • Be sure tool bits are sharp. • Check that moving parts move freely. • Fill the air lubricator with air oil that includes antioxidants and rust inhibitors such as Mobil ALMO525. - Page 26 Feed direction The facing head feeds automatically in either direction. Internal one-way clutches drive a pinion feed shaft along the rack. After pushing the feed shaft in on one side or the other, the cutting tool will feed in the direction indicated by the arrow on the side of the head.
- Page 27 Beveling CAUTION Prevent serious bodily injury from moving machinery by turning off and disconnecting the air supply before proceeding. • Remove the chuck and facing head, if necessary. Remember, striking with a dead blow hammer in the direction of the engraved arrow loosens the bayonet lock.
- Page 28 CAUTION The machine is NOT securely clamped until the draw rod knob is pushed into the feed handle and turned for final tightening. For final tightening, push the draw rod knob into the feed handle and use the extra leverage to tighten the chuck. NOTE During machining, set screws on the mandrel gib can be tightened moderately to minimize backlash.
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Page 29: Disassembly
Disassembly CAUTION Prevent serious bodily injury from moving machinery by turning off and disconnecting the air supply before disassembly. • Back off the tool bits 1/4" to 1/2" away from the work piece. • Loosen the draw rod knob by turning it counterclockwise and gently rock the tool to loosen the clamping chuck. -
Page 30: Maintenance
Maintenance Lubricants LUBRICANT WHERE USED Light oil Unpainted surfaces Cutting oil Tool bits, work piece Air tool oil Air lubricator oil cup Page 22 FF4000 Operating Manual... -
Page 31: Storage
• To prevent corrosion, spray unpainted surfaces, using WD-40 for short-term storage, Cosmoline for long-term storage. • Disassemble the Flange Facer and place it with any tools and accessories in the case provided. • Include desiccant or vapor wrap to absorb moisture. -
Page 32: 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 Portable Machining & Welding Systems to perform service on the machine. - Page 33 FF4000 MAIN ASSEMBLY BALLOON NO QTY PART DESCRIPTION 49593 FF4000 BASE UNIT 34936 ASSY FACING HEAD 19" DIA 35439 ASSY HEAD BEVELING 2.00-12.75 DIA 35427 ASSY CHUCK HEAD FF4000 P/N 35425, Rev. 2 Page 25...
- Page 34 FF4000 MAIN AS S EMBL Y Page 26 FF4000 Operating Manual...
- Page 35 P/N 35425, Rev. 2 Page 27...
- Page 36 Page 28 FF4000 Operating Manual...
- Page 37 35542 ASSY DRIVE PNEUMATIC FF4000 BALLOON No PART DESCRIPTION 18468 MOTOR AIR INGERSOLL 1.45HP 120 RPM @ MAX HP 33691 MUFFLER FF4000 36825 VALVE BALL 1/2 OVAL HANDLE ASSY W/ LABEL 35670 FTG SWIVEL 1/2 NPTM X 1/2 NPTF 13209 FTG QUICK COUPLER 1/2B 1/2 NPTM MALE AIR NOT SHOWN 34866 AIRTOOL OIL COMPLETE NOT SHOWN 13208 FTG QUICK COUPLER 1/2B 1/2 NPTF FEMALE AIR NOT SHOWN 28826 PNEUMATIC CONDITIONING UNIT 1/2 IN...
- Page 38 Page 30 FF4000 Operating Manual...
- Page 39 35427 ASSY CHUCK HEAD FF4000 BALLOON No PART DESCRIPTION 35916 SCREW M5 X 0.8 X 10 SHCS 33530 RETAINER CHUCK 33531 PLATE RETAINER 33529 JAW CHUCK 10850 PIN ROLL 3/16 DIA X 3/4 33528 CHUCK HEAD 15174 PIN DOWEL 3/8 DIA X 5/8 33532 BOLT CHUCK P/N 35425, Rev.
- Page 40 Page 32 FF4000 Operating Manual...
- Page 41 SPRING COMP .148 OD X .023 WIRE X .44 LONG (KB) 11763 PIN DOWEL 3/16 DIA X 3/4 16407 PIN DOWEL 3/8 DIA X 3/4 35036 ARM FLANGE FACER 19 DIA 34992 LEVER FEED (KB) 35595 KNOB KNURLED DOMED 1-1/2 OD 3/8-16 TAP STEEL (KB) 18689...
- Page 42 11729 PIN DOWEL 1/4 DIA X 3/4 41299 CARRIAGE TOOL HOLDER FF3000/FF4000 35911 SCREW M6 X 1.0 X 25MM SSSCP 45034 SCREW M6 X 1.0 X 12MM SSSDPPL 35005 GIB .47 X .15 X 2.0 1018 2 SS X 1.0 (KB) 35600 PIN DOWEL 3/16 DIA X 1-1/2...
- Page 43 34936 FACING HEAD ASSEMBLY P/N 35425, Rev. 2 Page 35...
- Page 44 35439 ASSY HEAD BEVELING 2.00-12.75 DIA BALLOON No PART DESCRIPTION 33619 HEAD BEVELING 2-12.75 IN 33563 BUSHING OILITE 2 ID X 2-1/4 OD X 1 11027 PIN DOWEL 3/8 DIA X 1 35368 SCREW M10 X 1.5 X 12 SSSCP 35541 SET STARTER FORM TOOLS Page 36 FF4000 Operating Manual...
- Page 45 P/N 35425, Rev. 2 Page 37...
- Page 46 Page 38 FF4000 Operating Manual...
- Page 47 34980 ASSY HEAD BEVELING 1.25-6.63 DIA BALLOON No PART DESCRIPTION 35557 HEAD BEVELING 1.25-7.00 DIA 35368 SCREW M10 X 1.5 X 12 SSSCP 11027 PIN DOWEL 3/8 DIA X 1 NOT SHOWN 35541 SET STARTER FORM TOOLS P/N 35425, Rev. 2 Page 39...
- Page 48 35424 KIT TOOL FF4000 PART DESCRIPTION 35516 HAMMER DEAD BLOW 1-3/4 DIA HEAD 34181 WRENCH HEX SET FOLD UP 5/64 TO 1/4 9 PIECES 34482 WRENCH SPANNER 3" FIXED HEAD PIN STYLE Page 40 FF4000 Operating Manual...
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