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Climax SHARK FIN DEFENDER Operating Manual

Clamshell guard hands-free kit
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DEFENDER™
SHARK FIN™
CLAMSHELL GUARD HANDS-FREE KIT
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 97475
April 2021
Revision 2

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Summary of Contents for Climax SHARK FIN DEFENDER

  • Page 1 DEFENDER™ SHARK FIN™ CLAMSHELL GUARD HANDS-FREE KIT OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 97475 April 2021 Revision 2...
  • 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 Defender Clamshell Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 97475, Rev. 2 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

    TABLE OF CONTENTS HAPTER ECTION 1 INTRODUCTION ............1 .
  • Page 8 TABLE OF CONTENTS (CONTINUED) HAPTER ECTION 6 STORAGE AND SHIPPING ........... 29 .
  • Page 9 LIST OF FIGURES IGURE 1-1 Label locations..............8 2-1 Operator pendant (P/N 96374) controls .
  • Page 10 This page intentionally left blank Page iv Defender Clamshell Operating Manual...
  • Page 11 LIST OF TABLES ABLE 1-1 Sound levels ..............3 1-2 Risk assessment checklist before set-up .
  • Page 12 This page intentionally left blank Page vi Defender Clamshell Operating Manual...

  • Page 13: Introduction

    INTRODUCTION IN THIS CHAPTER: 1.1 H - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OW TO USE THIS MANUAL 1.2 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...

  • Page 14: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS CLIMAX leads the way in promoting the safe use of portable machine tools and valve testers. 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 precautions contained in this manual, as well as your employer’s safety...

  • Page 15: Machine - Specific Safety Precautions

    Lock-out/tag-out – Lock-out and tag-out the machine before performing maintenance. Moving parts – CLIMAX machines have numerous exposed moving parts and interfaces that can cause severe impact, pinching, cutting, and other injuries. Except for stationary operating controls, avoid contact with mov- ing parts by hands or tools during machine operation.

  • Page 16: Risk Assessment And Hazard Mitigation

    ISK ASSESSMENT AND HAZARD MITIGATION Machine Tools are specifically designed to perform precise material-removal oper- ations. 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 17: 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. However, these checklists are typical of the types of risks the assembler and operator should consider. Use these checklists as part of your risk assessment: 1-2.

  • Page 18: Labels

    ABELS 1.7.1 Label identification The following warning and identification labels should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements. 1-4. D ™ ABLE EFENDER LABELS P/N 96876 P/N 96877, 96878 H&S tool hori- H&S Tool vertical...

  • Page 19: Label Location

    1-5. D ABLE EFENDER LABEL PART NUMBERS Part number Description 97068 LABEL DEFENDER CLEAR AFC-18 97069 LABEL DEFENDER CLEAR AFC-20 97053 LABEL DEFENDER CLEAR AFC-24 19.5 X 2.375 97054 LABEL DEFENDER CLEAR AFC-26 97055 LABEL DEFENDER CLEAR AFC-28 97056 LABEL DEFENDER CLEAR AFC-30 97057 LABEL DEFENDER CLEAR AFC-32 97058...
  • Page 20 1-1. L IGURE ABEL LOCATIONS Page 8 Defender Clamshell Operating Manual...

  • Page 21: Overview

    OVERVIEW IN THIS CHAPTER: 2.1 F - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 EATURES AND COMPONENTS 2.2 C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10...

  • Page 22: Controls

    ONTROLS The Defender™ controls are all located on the operator pendant (P/N 96374, shown in Figure 2-1) or on the pneumatic conditioning unit (PCU). MOTOR START BUTTON TRIPPER EMERGENCY ENGAGE/ STOP BUTTON DISENGAGE SWITCH 2-1. O (P/N 96374) IGURE PERATOR PENDANT CONTROLS 2-1.
  • Page 23 LOCK OUT VALVE TRIPPER CONNECTION REGULATOR OPERATOR PENDANT LUBRICATOR CONNECTION AIR PILOT VALVE OUTLET MOTOR SPEED CONTROL 2-2. PCU IGURE CONTROLS 2-2. PCU ABLE CONTROLS IDENTIFICATION Number Component Function Isolates air pressure from the machine and provides the ability to lock the valve Lock-out valve closed before performing maintenance.
  • Page 24 Emergency shutdown To stop machine operation immediately, press the button on the EMERGENCY STOP operator pendant (see Figure 2-1 on page 10). Before restarting the Defender™, check the following: 1. Close the speed adjustment valve on the PCU. 2. Twist and pull the button up.

  • Page 25: Setup

    Keep the shipping container and all packing materials for future storage and shipping of the machine. The machine ships from CLIMAX with a heavy coating of LPS 3. The recom- mended cleaner is LPS PreSolve Orange Degreaser. All parts must be cleaned before use.
  • Page 26 The tool slide may be installed already, but it is easier to mount the guards before mounting the tool slide. 2. Check that the pneumatic conditioning unit (PCU) E-Stop is in the off posi- tion, and that the regulator is set to minimum. 3.

  • Page 27: Connecting The Pcu

    6. If using a 7" (178 mm) or TRIPPER 10" (254 mm) tripper post, POST install the Shark Fin™ guard assembly onto the tripper post. The Shark Fin™ should be installed as close to the tripper rocker as possible for proper fit. Note that 4"...
  • Page 28 Make sure to fully install the hose into the PushLok fitting. 3-4. C IGURE ONNECTION TO THE PNEUMATIC CYLINDER CLIMAX recommends using cable ties or otherwise restraining the pneumatic tube to the motor hose to prevent damage to the tube. Page 16...

  • Page 29: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17 OPERATION CHECKS 4.2 O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17...

  • Page 30: Stopping The Machine

    3. Use the switch as required to feed the tool slide and advance the TRIPPER cut (see Section 4.2.4). 4.2.2 Stopping the machine Do the following to stop the machine (see Figure 2-1 on page 10 and Figure 2-2 on page 11): 1.

  • Page 31: Maintenance

    AINTENANCE CHECKLIST Before and after each use, remove debris, oil, and moisture from machine surfaces. 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.

  • Page 32: Maintenance Tasks

    5-1. A ABLE PPROVED LUBRICANTS Biodegradable Lubri- Viscosity Application Area Lubricant Quantity cant (cSt) LPS PreSolve Orange degreaser Machine surfaces As required (cleaner to remove LPS 3) AINTENANCE TASKS Maintenance tasks are described in the following sections. 5.3.1 Check the PCU oil reservoir levels Do the following to check the PCU oil reservoir levels: 1.
  • Page 33 8. WARNING Do not operate the machine if the PCU starts in step 9. Contact CLIMAX for service recommendations. If the machine unexpectedly restarts, it could cause severe personal injury or death. P/N 97475, Rev. 2...

  • Page 34: Defender Kits

    EFENDER KITS Table 5-2 shows the applicable kits and tripper sizes for each size of H&S Clam- shell. Call CLIMAX for more information on obtaining a kit. 5-2. D ABLE EFENDER KITS 4" (102 mm) 7" (178 mm) 10" (254 mm)
  • Page 35 For example: Table 5-3 shows the 4" tripper kit and Table 5-4 shows the Defender guard kit for the AFC 8. 5-3. AFC-8 4" (102 (P/N 97176) ABLE TRIPPER KIT Part number Description Quantity 97206 DEFENDER GUARD KIT AFC-8 KIT DEFENDER 1/2 NPT AIR CONTROL ASSY W/ 4 IN TRIP- 97274 97475 MANUAL INSTRUCTION 7911-S1...

  • Page 36: Afc Defender Kit Parts

    5.4.1 AFC Defender kit parts 5-1. AFC-14 D (P/N 97209) IGURE EFENDER GUARD KIT EXPLODED VIEW Page 24 Defender Clamshell Operating Manual...
  • Page 37 5-5. AFC-14 D (P/N 97209) ABLE EFENDER GUARD KIT Item Part number Description Quantity 88963 SCREW 1/4-20 X 1/2 BHSCS FLANGED see Table 5-6 96384 LABEL WARNING NOT A LIFT POINT ROUND see Table 5-6 RING GUARD MOTOR SIDE see Table 5-6 LABEL DEFENDER CLEAR see Table 5-6 RING GUARD NON MOTOR SIDE...

  • Page 38: Bfc Defender Kit Parts

    If the PCU or operator pendant malfunctions, call CLIMAX to order one of these replacement kits. Each kit contains the operator pendant, pneumatic conditioning unit, and desig- nated pneumatic tripper assembly. 5-7. AFC ABLE PNEUMATIC CONTROL KITS Tripper size Part number Description 4"...
  • Page 39 The parts lists for each pneumatic control kit are shown in the following tables. 5-11. 4" (102 (P/N 98734) ABLE TRIPPER PNEUMATIC CONTROL KIT Part number Description Quantity 96374 OPERATOR PENDANT HANDS FREE CLAMSHELL CONTROLS PNEUMATIC CONDITIONING UNIT WITH SMC FRL & 97045 PRESTOLOK CONNECTOR 98031...
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  • Page 41: Storage And Shipping

    STORAGE AND SHIPPING IN THIS CHAPTER: 6.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29 TORAGE 6.1.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29...

  • Page 42: Shipping

    HIPPING The Clamshell guard hands-free kit can be shipped in its original shipping con- tainer. ECOMMISSIONING To decommission the Clamshell guard hands-free kit prior to disposal, remove the drive assembly from the RDU and dispose of the drive assembly separately from the rest of the machine components.

  • Page 43: Appendix Aassembly Drawings

    APPENDIX A ASSEMBLY DRAWINGS Drawing list A-1. C ™ (P/N 96742) - - - - - - - - - - - - - - - - - - - - - - - 32 IGURE LAMSHELL HARK GUARD ASSEMBLY A-2.

  • Page 44: Igure A-1. Clamshell Hark In Guard Assembly (P/N 96742)

    PARTS LIST ITEM P/N: DESCRIPTION 20175 NUT 5/16-18 JAM 96453 CLAMSHELL FIN GUARD 96743 SPRING PLUNGER 5/16-18 THD BRASS KNOB 96750 FIN GUARD MOUNTING BRACKET 96751 SCREW NO 10 X 3/4 SELF TAPPING 410SS 96752 SCREW 10-24 X 3/16 SSSDP NYLON TIP 96881 LABEL H&S CLEAR 3.75 X 1.125 A-1.

  • Page 45: Igure A-2. Operator Pendant Assembly 1 (P/N 96374)

    A-2. O 1 (P/N 96374) IGURE PERATOR PENDANT ASSEMBLY P/N 97475, Rev. 2 Page 33...

  • Page 46: Igure A-3. Operator Pendant Assembly 1 (P/N 96374)

    BACK VIEW OF MOUNTING PANEL SCALE 1 / 2 A-3. O 1 (P/N 96374) IGURE PERATOR PENDANT ASSEMBLY Page 34 Defender Clamshell Operating Manual...

  • Page 47: Igure A-4. Operator Pendant Assembly 1 (P/N 96374)

    PARTS LIST ITEM P/N: DESCRIPTION 76356 (NOT SHOWN) TUBE POLYURETHANE 4MM OD X 2.5MM ID 78947 SELF-LOCKING HEX NUT DIN985-M4-8-ZN 96364 FLUSH PUSH BUTTON 3 PORT 1/8 PORT SIZE 96365 TWIST SELECTOR SWITCH 2 POSITION 1/8 PORT SIZE BLACK 96366 FTG ELB 4MM PUSH LOK TUBE X 1/8 NPTM 140PSI MAX 96367 MANIFOLD PUSH LOK 4MM 6 OUTLET X 6MM 2 OUTLET...

  • Page 48: Igure A-5. Pcu Assembly (P/N 97045)

    PARTS LIST ITEM P/N: DESCRIPTION 14704 FTG NIPPLE 1/2 NPTM X 1/2 NPTM 38065 WASHER M4 FLTW DIN 125 76356 (NOT SHOWN) TUBE POLYURETHANE 4MM OD X 2.5MM ID GREEN 78947 SELF-LOCKING HEX NUT DIN985-M4-8-ZN 82177 FTG - STRAIGHT - UNI 1/4 X 4MM TUBE PUSH NICKEL 96358 INLINE FLOW CONTROL VALVE 1/2 NPTF 1000PSI MAX 96366...

  • Page 49: Igure A-6. Pcu Manufacturer Parts (P/N 96917)

    PARTS LIST ITEM CLIMAX P/N: DESCRIPTION MANUFACTURER MANUFACTURER P/N ADAPTER PIPE 1/2 INCH NPT FOR SMC SIZE 40 FRL E400-N04-A SPACER WITH BRACKET FOR SMC SIZE 40 FRL Y400T-A SPACER FOR SMC SIZE 40 FRL Y400-A FTG ADAPTER STRAIGHT 1/8 NPT X 5/32 TUBING PRESS FIT...

  • Page 50: Igure Mm Pneumatic Tripper Assembly Afc (P/N 5001144)

    PARTS LIST ITEM P/N: DESCRIPTION 10160 SCREW 1/4-20 X 3/4 SHCS 10657 SHCS 5/16-18 X 3/4 10800 SCREW 1/4-20 X 1/2 SHCS 12894 NUT 1/4-20 JAMN 48648 FTG ELBOW 1/8 NPTM X 1/4 TUBE PRESTOLOK 5001001 TRIPPER PIN 5001003 TRIPPER BASE 5001004 4 IN TRIPPER STAND 5001008...

  • Page 51: Igure Mm Pneumatic Tripper Assembly Afc (P/N 5001177)

    PARTS LIST ITEM P/N: DESCRIPTION 5001002 1/4-20 UNC JAM NUT 5001007 7 IN TRIPPER STAND 5001070 5/16-18 x 3/4 SOCKET HEAD CAP SCREW 5001420 1/4-20 X 1/2 SOCKET HEAD CAP SCREW 48648 FTG ELBOW 1/8 NPTM X 1/4 TUBE PRESTOLOK 5001001 TRIPPER PIN 5001003...

  • Page 52: Igure A-9. Bcf-56 Defender Guard Kit Assembly (P/N 97221)

    A-9. BCF-56 D (P/N 97221) IGURE EFENDER GUARD KIT ASSEMBLY Page 40 Defender Clamshell Operating Manual...

  • Page 53: Igure A-10. Bcf-66 Defender Guard Kit Assembly (P/N 97222)

    A-10. BCF-66 D (P/N 97222) IGURE EFENDER GUARD KIT ASSEMBLY P/N 97475, Rev. 2 Page 41...

  • Page 54: Igure A-11. Bcf-72 Defender Guard Kit Assembly (P/N 97223)

    A-11. BCF-72 D (P/N 97223) IGURE EFENDER GUARD KIT ASSEMBLY Page 42 Defender Clamshell Operating Manual...

  • Page 55: Igure A-12. Bcf-86 Defender Guard Kit Assembly

    A-12. BCF-86 D (P/N 97501 IGURE EFENDER GUARD KIT ASSEMBLY P/N 97475, Rev. 2 Page 43...
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  • Page 57: Appendix Bschematics

    APPENDIX B SCHEMATICS B-1. P IGURE NEUMATIC CONDITIONING UNIT SCHEMATIC P/N 97475, Rev. 2 Page 45...
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  • Page 59: Appendix Csds

    APPENDIX C Contact CLIMAX for the current Safety Data Sheets. P/N 97475, Rev. 2 Page 47...
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