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Climax FF1000 Operating Manual

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Climax FF4000 Flange Facer
FF1000
FLANGE FACER
OPERATING MANUAL
SERIAL NUMBER RANGE:
11017900 - 15121870
ORIGINAL INSTRUCTIONS
FF1000 Flange Facer shown
P/N 32139
May 2019
Revision 2

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  • Page 1 Climax FF4000 Flange Facer FF1000 FLANGE FACER OPERATING MANUAL SERIAL NUMBER RANGE: 11017900 - 15121870 ORIGINAL INSTRUCTIONS FF1000 Flange Facer shown P/N 32139 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...
  • Page 4 CLIMAX GLOBAL LOCATIONS Page 2 FF1000 Operating Manual...

  • Page 5: Limited Warranty

    CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has been performed properly. This warranty is available to the customer purchasing parts or labor for a period of 90 days after delivery of the part or repaired machine or 180 days on used machines and components.
  • Page 6 CE DOCUMENTATION Page 4 FF1000 Operating Manual...

  • Page 7: About This Manual

    Introduction The information in this manual is up to date at time of printing. Because Climax is committed to continued product improvement, the machine you receive may be slightly different than the one described here. About this manual WARNING Moving machine parts can seriously injure untrained operators.
  • Page 8 IMPORTANT Provides critical information for the completion of a task. There is no associated hazard to people or the machine. NOTE Provides important information regarding the machine. Page 6 FF1000 Operating Manual...

  • Page 9: General Safety Guidelines

    Proper care is your Keep all cords and hoses away from moving responsibility. Contact Climax immediately for parts during operation. Do not clutter the area replacement manuals or safety decals.

  • Page 10: General Safety Practices

    There are no systems or components on this and must be moved or lifted with approved machine that are capable of producing rigging and practices. Climax accepts no hazardous EMC, UV or other radiation responsibility for the selection of lifting hazards.
  • Page 11 A-weighted sound pressure level 89 dBA A-weighted sound power level 96.5 dBA Warning labels The labels shown are attached to your machine. Contact Climax immediately for replacements if any are defaced or missing. WARNING P/N 32139, Rev. 2 Page 9...
  • Page 12 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 10 FF1000 Operating Manual...
  • 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. ...
  • Page 14 Description The FF1000 Flange Facer is intended to perform facing operations. Modular construction allows the machine to perform a variety of operations. The machine consists of:  Power module: Drive box assembly Quill support assembly Vertical adjustment leadscrew assembly Air motor assembly...
  • Page 15 Setup Preparation WARNING To avoid serious bodily injury, turn off and lock out the motor before setting up or adjusting the machine. 1. Mount the power module to the mounting bell. 2. Tighten the mounting screws. 3. Mount the feed cam onto the end of the quill housing. 4.
  • Page 16 1. Slightly loosen the level clamping screws. 2. With the indicator on a diameter, adjust the centering screw in the centering/leveling plate until centered. 3. Verify the adjustment and correct if needed. 2. Remove the setup fingers and indicator. Page 14 FF1000 Operating Manual...

  • Page 17: Tool Setup

    3. Insert the air motor shaft into the worm carrier shaft until the motor flange fits snugly against the drive box. 4. Tighten the motor mounting screws. Climax strongly recommends using the air filter and lubricator supplied with the machine. The lubricator should be set to deliver oil air at a rate of 2-4 drops per minute.
  • Page 18 2. Push the lockout valve lever until the word CLOSED and the lockout can be seen from the bottom of the valve. Be sure the lever is pushed all the way in. 3. Lock out the machine. 4. Disconnect the air supply line. Page 16 FF1000 Operating Manual...
  • Page 19 Starting and stopping CE compliant machines NOTE Use non-restrictive fittings for air connections. To start the machine: 1. Be sure the emergency valve assembly is connected to the air motor. 2. Turn the air supply valve OFF all the way. 3.
  • Page 20 (in the power module tool kit). 4. To ensure full movement to the desired position, jog the crank as you move the feed direction knob. 5. Tighten the feed direction knob with a screwdriver. Page 18 FF1000 Operating Manual...

  • Page 21: Operation

    Operation WARNING Wear ear and eye protection while operating the machine. 1. Turn off and lock out the machine. 2. Be sure the incoming air valve system is closed. WARNING Rotating machinery can seriously injure the operator. Stop and lock out the machine before connecting the air supply line.
  • Page 22 27. Shut the incoming air valve. Lock out the machine. 28. Reset the feed direction to NEUTRAL. 29. Retract the tool bit by manually turning the vertical feed shaft assembly counterclockwise. 30. Repeat these steps as necessary. Page 20 FF1000 Operating Manual...
  • Page 23 Disassembly WARNING To avoid serious personal injury from rotating machinery, turn off and disconnect the power supply before disassembling the machine. 1. Turn the air valve OFF all the way. 2. Shut the incoming air valve. 3. Lock out the machine. 4.

  • Page 24: Optional Accessories

    2. Close the incoming air valve. Lock out the machine. 3. Turn the air supply valve OFF all the way. 4. Route the air supply line through the pneumatic conditioning unit. Page 22 FF1000 Operating Manual...
  • Page 25 NOTE Climax strongly recommends using the filter and lubricator supplied with the machine. Set the lubricator to deliver oil at a rate of 2-4 drops per minute. CAUTION To avoid air motor damage and increase air motor performance, use the filter and lubricator provided.
  • Page 26 90 psi (620 kPa).  Adjust the air motor speed by adjusting the needle valve. CAUTION To avoid damaging the motor, do not adjust the motor speed by changing the in-line air pressure from 90 psi (620 kPa). Page 24 FF1000 Operating Manual...
  • Page 27 Grind the tool bits as needed during operation. If using carbide tools; replace the inserts and chip breakers as needed during operation. For tool bit replacement information, contact your Climax factory representative by calling Climax toll free at 1-800-333-8311. Power feed module The power feed module needs no maintenance if used according to the instructions.
  • Page 28 Store the machine in the containers provided. Place desiccant bags or vapor wrap around the machine to absorb moisture. To replace a storage container, order Part No. 18475 (large - holds 12" mounting bell) or Part No. 10860 (small). Page 26 FF1000 Operating Manual...

  • Page 29: Spare Parts

    Spare Parts NOTE Have a supply of HSS tool bits or carbide inserts and chip breakers on hand. Parts listed below include items most frequently replaced due to wear, loss, or damage. To prevent unscheduled down time you may want to stock these parts. SPARE PARTS PART DESCRIPTION...
  • Page 30 Screw 5/16-18 x 1/2 SHCS 10601 5/16" hex wrench 1/8" x 6" T-handle hex 10600 wrench 10972 8" Safety screen assembly 12" Safety screen 10976 assembly Mounting bell assembly 30960 Setup fingers 30961 6" jaw 30962 3" jaw Page 28 FF1000 Operating Manual...
  • Page 31 SPARE PARTS PART DESCRIPTION WHERE USED Tool bit 1/4" square x 2" 10882 Facing head Tool bit 3/8" square x 3" 10883 Screw 5/16-18 x 3/4" 10516 FHSCS 14035 7/8" OD Snap ring 3/32" x 11/16" ID x 7/8" OD 14348 O-ring 1/16"...

  • Page 32: Exploded Views & 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 Portable Machining & Welding Systems to perform service on the machine. Page 30 FF1000 Operating Manual...
  • Page 33 30969 BOX DRIVE ASSY 2nd 200 RPM 7.5:1 RATIO FF1000 BALLOON No PART DESCRIPTION 10745 BOX DRIVE MAIN FF1000 10891 BRG BALL .7874 ID X 1.8504 OD X .5512 W/SEALS 10791 SPACER WORM DRIVE 10858 GEAR WORM 8DP 1.5PD 1.75 FACE QUAD LEAD...
  • Page 34 Page 32 FF1000 Operating Manual...
  • Page 35 13886 SUPPORT QUILL ASSY 2 IN HIGH BALLOON No PART DESCRIPTION 10748 SUPPORT QUILL 2 IN. LONG 10956 SHAFT FEED 10820 BRG BALL .5906 ID X 1.2598 OD X .3543 W/SEALS 10813 RING SNAP 1-1/4 ID BEVELED 10840 RING O 1/16 X 1/2 ID X 5/8 OD 10853 DIAL 10829...
  • Page 36 11054 KEY 1/4 X 3/8 X 1.20 RADIUS BOTH ENDS 10825 BRG ROLLER 2.0011 ID X 2.5619 OD X 1.250 30731 SPINDLE FF1000 W/O #40 TAPER 10854 KEY 1/4 SQ X .37 SQ BOTH ENDS Page 34 FF1000 Operating Manual...
  • Page 37 P/N 32139, Rev. 2 Page 35...
  • Page 38 Page 36 FF1000 Operating Manual...
  • Page 39 14389 LEADSCREW VERT ADJUSTMENT 3/4 IN. TRAVEL BALLOON No PART DESCRIPTION 10808 BRG BALL .3937 ID X 1.1811 OD X .3543 10960 CARRIER ASSY 3/4 IN. TRAVEL 2 IN. CLAMP 10807 BRG BALL .7874 ID X 1.6535 OD X .4724 W/SEALS 17857 RING SNAP INTERNAL 1.653 BORE (42 mm) 12983 MOTOR AIR ASSY STANLEY MODULATHE...
  • Page 40 KEY 3/16 X .135 X 1.00 SQ BOTH ENDS 29175 VALVE ASSY EMERGENCY AIR SHUTOFF 29445 OBS USE 15970 15915 HOSE ASSY 801 1/2 X 1/2 NPTM X 1/2 NPTMS X 72 NOT SHOWN 22546 LABEL AIR MOTOR Page 38 FF1000 Operating Manual...
  • Page 41 P/N 32139, Rev. 2 Page 39...
  • Page 42 29175 VALVE ASSY EMERGENCY AIR SHUTOFF BALLOON No PART DESCRIPTION 10516 SCREW 5/16-18 X 3/4 FHSCS 29089 BASE MOUNTING CLIMAX AIR VALVE 27128 BODY AIR SHUT OFF VALVE 29444 FTG ADAPTER MODIFIED 15675 FTG ADAPTER 7/8 SAEM ORING X 1/2 NPTF...
  • Page 43 P/N 32139, Rev. 2 Page 41...
  • Page 44 10888 SCREW 1/4-20 X 1 FHSCS 10847 PIN ROLL 1/8 DIA X 3/4 10843 SCREW 1/4-20 X 3/4 FHSCS 39588 CARRIER TOOL 10775 GIB CARRIER TOOL 11855 SCREW 8-32 X 3/8 SSSDPNI 10834 SCREW 1/4-20 X 3/4 SSSCP Page 42 FF1000 Operating Manual...
  • Page 45 30719 BELL MTG ASSY 8 IN MODEL FF1000 2nd BALLOON No PART DESCRIPTION 30960 SET SETUP FINGERS FF1000 2nd 30791 BELL MTG 8 IN 2nd GEN FF1000 30962 SCREW 3/4-10 X 3 SQHSSCP 30961 SCREW 3/4-10 X 6 SQHSSCP 30963...
  • Page 46 Page 44 FF1000 Operating Manual...
  • Page 47 13899 BOX GEAR ASSY FACING HEAD FF1000 BALLOON No PART DESCRIPTION 10957 HOUSING FEED DRIVE ASSY 10863 GEAR REVERSE 10856 RING SNAP 1/4 OD 10794 BRG ROLLER CLUTCH .39 ID X .63 OD X .787 10862 GEAR CLUTCH FEED 10967...
  • Page 48 Page 46 FF1000 Operating Manual...
  • Page 49 31863 BIT TOOL HSS 3/8 X 1.3 LH ROUGHING SINGLE 11367 CRANK ASSY 10857 INDICATOR DIAL 32139 MANUAL INSTRUCTION - FF1000 2ND GEN 10881 MOUNT DIAL INDICATOR 10880 PIN ROLL 1/4 DIA X 5/8 10800 SCREW 1/4-20 X 1/2 SHCS...
  • Page 50 This page is intentionally left blank Page 48 FF1000 Operating Manual...

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