Climax KM4000 Operating Manual
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Climax KM4000 Operating Manual

Key mill machine
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KM4000
KEY MILL MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE
BEGINNING WITH 14001731
ORIGINAL INSTRUCTIONS
KM4000 Key Mill Machine
P/N 16328
June 2019
Revision 7

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Summary of Contents for Climax KM4000

  • Page 1 KM4000 KEY MILL MACHINE OPERATING MANUAL SERIAL NUMBER RANGE BEGINNING WITH 14001731 ORIGINAL INSTRUCTIONS KM4000 Key Mill Machine P/N 16328 June 2019 Revision 7...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS GENERAL SAFETY  ................................... II   SAFETY PRACTICES ................................ III   LABELING GUIDELINES ................................. IV   CE DATA .................................... VII     WARNING LABELS  .................................. 1 WARRANTY .................................... 3   INTRODUCTION .................................. 3   SETUP .......................................  1 0   OPERATION .....................................  1 5   MAINTENANCE ..................................  2 0   STORAGE ....................................  2 3  ...

  • Page 4: General Safety

    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 5: Safety Practices

    Most of the machine components are heavy and must MAINTENANCE be moved or lifted with approved rigging and practices. Climax accepts no responsibility for the selection of Be sure the machine components are free of debris lifting equipment. Always follow your plant’s and properly lubricated prior to use.

  • Page 6: Labeling Guidelines

    IMPORTANT Provides critical information for the completion of a task. There is no associated hazard to people or the machine. Provides important information regarding the machine. Page iv KM4000 Operating Manual...
  • Page 7 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 8  I checked that all affected personnel understand and are clear of the danger zone.  I evaluated and mitigated any other potential risks specific to my work area. Page vi KM4000 Operating Manual...

  • Page 9: Ce Data

    CE Data Hearing protection is required The Declared Sound Power Level is: 88.8 The Declared Operator Sound Pressure Level is: 89.4 The Declared Bystander Sound Pressure Level is: 84.5 P/N: 16328, Rev. 7 Page vii...
  • Page 10 Page viii KM4000 Operating Manual...

  • Page 11: Warning Labels

    Warning Labels The following warning labels should be on your machine. If any are defaced or missing, contact Climax immediately for replacements. Machine labels are listed in Table 1. Machine label locations are shown in Figure 1. Table 1. KM4000 labels...
  • Page 12 Figure 1 - KM4000 label locations Page 2 KM4000 Operating Manual...

  • Page 13: 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 14: Introduction

    The two-inch side travel allows cutting wide pockets or slots with a single end mill. The Model KM4000 Key Mill will mount on shafts up to 24 inches(609 mm) in diameter (with optional extra chain) and may be used anywhere along the shaft. With the optional shim kit the machine can be used on shafts as small as 4 inches (100 mm) in diameter.
  • Page 15 Electric Power The electric version of the KM4000 has a 1 hp (.75 kW), 1750-rpm motor rated at either 115 volt or 230 volt. Check the serial number plate on the motor to find the voltage. The motor operates on either 50 or 60 cycle AC or on DC current.
  • Page 16 Pneumatic Power The pneumatic version of the KM4000 has a 2 hp (1.49 kW) air motor. Spindle free speed is continuously variable up to 900 rpm and is adjusted by opening or closing the needle valve. The motor requires 105 ft /min (1m /min) of air at 80 psi.
  • Page 17 Hydraulic Power A wide variety of hydraulic power options are available. Please contact your Climax sales representative for details. The table below lists operating specifications of the hydraulically powered version of the KM4000 using standard mineral-based hydraulic oil. Maximum working pressure...
  • Page 18 The KM4000 hydraulic power schematic drawing is shown in Figure 6. Figure 6 - KM4000 Hydraulic Power Schematic Diagram The end mill turning direction on a hydraulically powered KM4000 depends on hydraulic line connections. Refer to Page 8 KM4000 Operating Manual...
  • Page 19 Figure 7 - KM4000 Hydraulic Power Schematic Diagram P/N: 16328, Rev. 7 Page 9...

  • Page 20: Setup

    5. Connect speed controller to the power source. Set spindle motor on/off switch to ON. Apply power by switching speed controller ON. CAUTION Do NOT use on/off switch on spindle motor when speed control is connected. Controller damage may result and void all warranties. Page 10 KM4000 Operating Manual...
  • Page 21 Pneumatic Checks 1. Fill the air lubricator on the APU with air oil. Use Marvel Air Tool Oil lubricator oil or equivalent. 2. Drain the air filter. 3. Close the ball valve before connecting the key mill to the air supply. 4.
  • Page 22 5. Level the machine. Place a level on the machined upper surface of the base to be sure the key mill is level. This is very important when cutting in-line keyways. IMPORTANT Careful centering and leveling of the key mill will ensure that all keyways will be in line. Page 12 KM4000 Operating Manual...
  • Page 23 Stub end mounting The Climax KM4000 key mill can be mounted to stub ends as short as 8" (200 mm). 1. Turn the cutter end of the key mill toward the middle of the shaft.
  • Page 24 The vertical adjustment leadscrew adjusts the depth of the end mill. Crank the leadscrew clockwise to move the end mill down. Crank the leadscrew counterclockwise to move the end mill up. One complete turn of the leadscrew will move the tool .100" (2.50 mm on metric machines). Page 14 KM4000 Operating Manual...

  • Page 25: Operation

    Operation CAUTION Always wear eye and ear protection when operating the key mill. Connect the key mill by following the procedure outlined below. Electric Power Connection WARNING The electric motor is not watertight. To avoid injury by shock or explosion, do not operate electric motors in damp or volatile conditions.
  • Page 26 The air line should be at least 0.5" in length. Starting and stopping the Machine The U.S. style KM4000 is equipped with needle and lockout valves. Use only nonrestrictive fittings on all air lines. CLOSE...
  • Page 27 WARNING The gear box knob rotates at up to 875 RPM during operation. Keep fingers away from the gear box knob to avoid entanglement and pinching injury. To stop the machine: 1. Turn the needle valve clockwise all the way. No colored bands will be visible when the valve is completely closed.
  • Page 28 11. Remove the key mill from the shaft. Wide Keyways Extra wide keyways, up to 3.5" (88 mm), can be cut with the KM4000 key mill. For key width measuring, the cross slide leadscrew dial is calibrated in 0.001" increments. For very accurate cutting, the operator may want to verify the measurements with a dial indicator.
  • Page 29 Long Keyways To cut in-line keyways: 1. Secure the shaft so it will not rotate. V-blocks may be used to hold long shafts. Secure the shaft to the V-blocks with “C” clamps. 2. Mount the key mill to the shaft as described in “Machine setup”. 3.

  • Page 30: Maintenance

    Before and after operating the machine, clean the dovetail ways and lubricate with way oil. Leadscrew Assembly During operation, frequently clean chips away from the leadscrew with a soft brush. If necessary, lightly oil the leadscrew. Page 20 KM4000 Operating Manual...
  • Page 31 Gear Box Assembly, Spindle and Quill The gearbox is packed with heavy gear grease. Every 500 hours, repack as follows: 1. Remove the adjustment knob. 2. Remove the crank. 3. Remove the snap ring, finger spring washer, thrust washer, and dial. 4.
  • Page 32 To extend the life of the air motor do the following:  Route the air supply through a lubricator and air filter.  Use nonrestrictive 1/2" air lines and fittings supplied by Climax. Periodically check the air system to be sure air pressure is adequate.

  • Page 33: Storage

    Storage Proper storage of the key mill will prevent undue deterioration or damage. Before storing, clean the machine with solvent to remove grease, metal chips, and moisture. Drain the air filter on pneumatic models. Spray the machine with a moisture-protective material to prevent rusting. Store the key mill in the container provided and include desiccant or vapor wrap to absorb moisture.

  • Page 34: Spare Parts

    Hydraulic power unit 10199 1/4" Hex wrench 10200 1/8" Hex wrench 10203 Crank Tool kit 10467 End mill - 3/4" dia. x 3/4" shank 10470 End mill - 20 mm dia. x 20 mm shank Page 24 KM4000 Operating Manual...

  • Page 35: Specifications

    Specifications INCH METRIC Height min 12.25" 312 mm Height max 15.25" 388 mm Vertical spindle travel 3.0" 76 mm Length min 18.5” 470 mm Length max 24.5" 622 mm Longitudinal spindle travel 7.85" 199 mm Width min 14.0" 356 mm Width max 16.0"...

  • Page 36: 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 Systemsl. to perform service on the machine.
  • Page 37 P/N: 16328, Rev. 7 Page 27...
  • Page 38 10485 SLIDE TOP ASSY INCH KM4000 CPM BALLOON PART DESCRIPTION 10502 TOPSLIDE INCH KM4000 PM2000 PM3000 PM4000 10138 SCREW 5/16-18 X 1 SHCSPL 10829 RING SNAP 1/2 OD 10465 KEY 1/8 SQ X .75 SQ BOTH ENDS 16201 SHAFT KM4000 10433 GEAR WORM 12DP 1.0 PD RH SINGLE THREAD...
  • Page 39 13736 SLIDE CROSS ASSY KM4000 BALLOON PART DESCRIPTION 10454 BASE KM4000 10444 GIB KM4000 10189 SCREW 1/4-20 X 5/8 SSSHDPNI 10139 OILER BALL VALVE DRIVE IN 10474 SCREW 3/8-16 X 1-1/2 SHCS P/N: 16328, Rev. 7 Page 29...
  • Page 40 Page 30 KM4000 Operating Manual...
  • Page 41 P/N: 16328, Rev. 7 Page 31...
  • Page 42 38119 ASSY LEADSCREW TOP SLIDE KM4000 PM2000 PM3000 PM4000 BALLOON PART DESCRIPTION 10443 NUT BRASS 38117 LEADSCREW TOP SLIDE KM4000 PM2000 PM3000 13175 WASHER THRUST .875 ID X 1.437 OD X .060 10144 WASHER THRUST 1.000 ID X 1.562 OD X .060 13174 BRG THRUST .875 ID X 1.437 OD X .0781...
  • Page 43 P/N: 16328, Rev. 7 Page 33...
  • Page 44 19645 SPINDLE & QUILL ASSY INCH 3rd KM4000 CPM BALLOON PART DESCRIPTION 19494 SPINDLE INCH 3rd KM4000 CPM 16463 OBS USE 37405 (SCREW MODIFIED 1/2-20) 15669 SEAL 1.500 ID X 1.874 OD X .250 19016 BRG NEEDLE 1-1/2 ID X 1-7/8 OD X .625 OPN GR...
  • Page 45 P/N: 16328, Rev. 7 Page 35...
  • Page 46 19648 LEADSCREW VERT ADJ ASSY INCH 3rd KM4000 CPM BALLOON PART DESCRIPTION 19492 LEADSCREW VERT ADJ INCH 3rd KM4000 CPM 10365 BRG BALL .6693 ID X 1.5748 OD X .4724 2 SEALS 10165 COLLAR 10166 PIN ROLL 1/8 DIA X 1...
  • Page 47 P/N: 16328, Rev. 7 Page 37...
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  • Page 54 Page 44 KM4000 Operating Manual...
  • Page 55 34142 CAP MOTOR END ASSY W/ 2-POLE CONNECTOR 120V BALLOON PART DESCRIPTION 12574 CONDUIT NUT 1/2 NPT 31734 PLUG 1/2 DIA PLASTIC 31736 BOX CORD ENTRANCE REMOTE SPEED CONTROL 34255 CONNECTOR 2-POLE 13AMP MALE 1/2 NPT PANEL MT NOT SHOWN 15022 CONNECTOR PLUG FEMALE SNAP BULLET 16-14 GA NOT SHOWN...
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  • Page 57 P/N: 16328, Rev. 7 Page 47...
  • Page 58 10368 SP KEY WOODRUFF 2nd & 3rd NOT SHOWN 34791 SP PLATE BEARING RETAINING NOT SHOWN 10357 SP SCREW BRUSH HOLDER 2nd & 3rd NOT-SHOWN 16501 SP SPINDLE LOCK ASSY NOT-SHOWN 16500 SP WASHER FLAT Page 48 KM4000 Operating Manual...
  • Page 59 35783 MOTOR ELECTRIC 230V MILWAUKEE 5455 BALLOON PART DESCRIPTION 12543 SP SCREW 3rd 12544 SP BOX GEAR MODIFIED 3rd 12545 SP BRG NEEDLE 3rd 12546 SP GEAR INTERMEDIATE ASSY 3rd 10233 SP BRG BALL 1st 2nd & 3rd 12547 SP DIAPHRAGM 3rd 12548 SP BRG BALL MILWAUKEE 5455 ARMATURE UPPER 12553...
  • Page 60 Page 50 KM4000 Operating Manual...
  • Page 61 P/N: 16328, Rev. 7 Page 51...
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  • Page 66 Page 56 KM4000 Operating Manual...
  • Page 67 12843 POWER UNIT HYD & 20 FT HOSES BALLOON PART DESCRIPTION 12848 POWER UNIT HYDRAULIC 5 GPM 12833 FTG ADAPTER 3/8 NPTM X 9/16 JICM 12844 HOSE ASSY 560H 3/8 X 3/8 NPTM X 9/16 JICFX240 12845 FTG QUICK COUPLER 3/8B 3/8 NPTF MALE 12846 FTG QUICK COUPLER 3/8B 3/8 NPTF FEMALE 10593...
  • Page 68 Page 58 KM4000 Operating Manual...
  • Page 69 16263 LEADSCREW ASSY CROSS SLIDE INCH KM4000 BALLOON PART DESCRIPTION 15668 RING SNAP 43/64 OD INVERTED 15666 WASHER THRUST .669 ID X 1.181 OD X .030 15667 WASHER SPRING FINGER .688 ID X 1.164 OD 10169 DIAL INCH 10451 10165...
  • Page 70 Page 60 KM4000 Operating Manual...
  • Page 71 P/N: 16328, Rev. 7 Page 61...
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  • Page 75 Contact CLIMAX for the current Safety Data Sheets. P/N: 16328, Rev. 7 Page 65...
  • Page 76 Page 66 KM4000 Operating Manual...

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