Page 1: Table Of Contents
Maintenance Storage Spare parts Machine Dimensions Exploded Views and Parts Lists Climax Model FF6000 shown with the removable single plane chuck Copyright © 2007 Climax Portable Machine Tools, Inc. Corporate Headquarters European Headquarters Request an electronic copy of this manual, Climax Portable Machine Tools, Inc.
Page 3: General Safety Guidelines
Risks expected in a regular maintenance shop are intensified when an active job-site presents extra hazards. CLIMAX Portable Machine Tools 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 4: Safety Practices Specific To Flange Facers
Safety Practices Specific to Flange Facers Safety Practices Specific to Flange Facers This list includes safety practices applicable to Climax Model FF6000 Flange Facer. 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 5: Warning Labels
Warning labels Warning labels Warning labels Warning labels The following warning labels are attached to your machine upon delivery. If any labels are defaced or missing, contact Climax immediately for replacements. Copyright © 2005 Climax Portable Machine Tools, Inc. Page 5...
Page 7: Labeling Guidelines In This Manual
Provides critical information for the completion of a task. Do not disregard an Important note. However, there is no associated hazard to people or machine. NOTE NOTE NOTE NOTE Provides important information remember regarding the machine. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 7...
Page 9: Limited 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 10: Introduction
Introduction Introduction The Climax Model FF6000 enables you to repair flanges on-site and in-line. The FF6000 Flange Facer can be used in a wide variety of flange facing applications. The modular design and versatile setup allow you to be creative in solving difficult flange facing problems.
Page 11: Features
& pinion system. Down feed rates from .076 - .254mm (.003” - .010”) per revolution are provided by the down-feed actuator system. Tool holder accepts 13mm or 1/2 “square tool bits. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 11...
Page 12: Machine Description
Machine Description Machine Description The Model FF6000 is an ID-(Inside Diameter) mounted portable flange facer. Its compact design makes it an ideal on-site maintenance tool. The machine fits into bores with IDs from 14" to 34" (356 to 863 mm) and can face flanges from 14" out to 42" (356 to 1066 mm) diameter.
Page 13 Machine Images Model FF6000 with double plane chuck Model FF6000 with removable single plane chuck Model FF6000 with Double Plane Chuck Figure 2 – Double plane chuck callout Copyright © 2004 Climax Portable Machine Tools, Inc. Page 13...
Page 14 Model FF6000 with Removable Single Plane Chuck Tool Holder Rotary Union Tool Holder Radial Feed Feed Shaft Air Motor Shaft Feed Cam Tool Head Counterweight Turning Bar Plate Adaptor Leg Extension Adjustable Foot for Leveling Setup Finger (only 1 shown)
Page 15: Receiving Your Machine
Receiving your Machine Inspect the machine for shipping damage. Be sure you received the parts listed on the invoice. Contact Climax immediately if there are any errors or questions about this machine. Copyright © 2004 Climax Portable Machine Tools, Inc.
Page 16: Setup
Setup Setup Setup Setup Setup of the Climax FF6000 Flange Facer consists of the following steps: Chuck setup Setting machine into the work piece Centering the Machine Leveling the machine to the work piece Tool bit setup Depending on the chuck you’re going to use, use the following procedures to set up each step.
Page 17 14. Secure the counterweight with the three square-headed screws. The safety flat on the counterweight bar assures good contact between the screws and the bar. 15. Install the counterweight retaining screw into the bar at the counterweight end. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 17...
Page 18 Be sure the chuck jaws are locked solidly in the bore. The jaws need to be smaller than the ID of the work piece. 3. Ensure that the setup fingers are securely mounted. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 18...
Page 19 Be sure all hoist and rigging is clear of the machine before you use the machine. Hoist and rigging can get entangled and cause damage and injury. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 19...
Page 20 1. Measure the work piece bore diameter. 2. Select the chuck jaws and jaw spacers that will fit the bore. Refer to section “Single Plane Chuck Components” to pick the appropriate ID arrangement. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 20...
Page 21 Optional Brace Foot: Not applicable Center Plate: Part 41622 23. 5” to 26” Extension Leg: 39857 (3.3”) (508 to 660 Adjustable foot: Part 39860 Optional Brace Foot: Part 39858 (5.3”) Center Plate: Part 41622 Copyright © 2004 Climax Portable Machine Tools, Inc. Page 21...
Page 22 To go from 34.25 to 35 inches (870 to 889 mm), add a (part number 42022) 3/8 inch thick spacer between the leg extension (39859) and the chuck center plate. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 22...
Page 23 1. Use the centering attachment and a dial indicator to align one pair of legs. 2. Align the opposing legs. 3. Re-verify that the initial legs you centered are still centered. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 23...
Page 24 IMPORTANT IMPORTANT If centering and levelling are critical then mount an indicator on the tuning bar and use the adjustments on the single plane chuck to fine tune the measurements. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 24...
Page 25 IMPORTANT IMPORTANT IMPORTANT Climax recommends that you use high-speed steel tool bits. To set up the tool bit Select a pre-ground tool bit from the tool kit, or grind your own 1/2" square (12 mm) tool bit. See Figure 3: “Tool bit geometry” for correct rake and clearance angles.
Page 26: Operation
2-4 drops per minute Starting and stopping the machine The FF6000 Flange Facer is equipped with an air control valve, shown below. The air control valve regulates the rotation speed of the Model FF6000.
Page 27 9. Turn the crank handle clockwise to feed the tool head outward away from the main body. Turn the crank handle counterclockwise to feed the tool head in toward the main body. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 27...
Page 28 Automatic radial feed is infinitely variable from .003" to .032" (.08 to .81 mm) per revolution. The feed ratchet is activated as the feed box rotates around the cam. Increase feed speed, by turning the finger screw counter-clockwise (out). Copyright © 2004 Climax Portable Machine Tools, Inc. Page 28...
Page 29 2. Turn the finger screw counterclockwise to set an increased feed. Turn the finger screw clockwise to decrease feed rate. 3. Be sure the air control valve is completely closed before reconnecting the air line. Figure 10 – To adjust the radial feed Copyright © 2004 Climax Portable Machine Tools, Inc. Page 29...
Page 32 4. Rotate the swivel until the tool bit is at the desired cutting angle. Retighten the socket-head cap screws. 5. Using the crank handle, manually feed the tool downward until the tool bit is just above the work piece. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 32...
Page 33 12. Disconnect the air supply line. 13. Check that the tool is cutting at the desired angle. 14. If required, adjust the tool head or machine, reconnect the air supply line, and finish cutting. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 33...
Page 35: Optional Assemblies
TO END OF BACKFACING ATTACHMENT Figure 15 – Angle Cuts To back face machine up to 45” (1145 mm)diameter, it is necessary to use the large bore turning bar assembly. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 35...
Page 36 4. Reorient the tool holder so that the tool can be correctly inserted for clockwise rotation (when viewed from the top of the machine). BACK FACING ATTACHMENT 42025 MAX 6 (152) MIN 1 (25) Figure 16 – Back facing dimension requirements Copyright © 2004 Climax Portable Machine Tools, Inc. Page 36...
Page 37 Figure 17 – Side cut tool holder This tool holder is simply used in place of the standard FF6000 tool holder. It can also be useful for deep counter bores. Copyright © 2004 Climax Portable Machine Tools, Inc.
Page 38 Grinding attachment Climax offers a grinding attachment as an optional accessory for those applications demanding greater precision and finer surface finish. The air powered grinding assembly mounts to the end of the turning bar. It includes pneumatic couplers, clamps, grinding wheel, and complete instructions.
Page 39: Maintenance
Every 100 hours, remove the gearbox assembly from the main body and generously grease all parts. Gearbox parts need not be disassembled for servicing. Turning bar assembly maintenance Lightly oil the turning bar every time the flange facer is used. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 39...
Page 40 Tool holder maintenance Lightly oil the tool holder each time the flange facer is used. Periodically remove the tool holder and grease the worm gear. Copyright © 2004 Climax Portable Machine Tools, Inc. Page 40...
Page 41: Storage
Storage Storage Figure 20 – Climax Model FF6000 Properly stored in its crate Proper storage of the flange facer will prevent undue deterioration or damage. Before storing the machine, clean it with solvent to remove grease, metal chips, and moisture.
Page 43: Spare Parts
19043 Screw 1/4-20 x 1-3/4" BHSCS Radial feed assembly 11696 Screw 1/2-13 X 3" SHCS 13912 Screw 1/2-13 X 1-1/2" SSSCP Chuck assembly 14830 Jaw cover plate 14846 Setup finger Copyright © 2004 Climax Portable Machine Tools, Inc. Page 43...
Page 46: 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 who has not been authorized in writing by Climax Portable Machine Tools Inc. to perform service on the machine.18904 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 US STYLE BALLOON NO.
Page 47 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 Machine Tools Inc. to perform service on the machine.18904 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 US STYLE BALLOON NO.
Page 48 29471 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 CE STYLE BALLOON No. PART DESCRIPTION 11163 BRG CONE 5.0000 ID X 1.0313 WIDE 11162 BRG CUP 6.6875 OD X .8125 WIDE 11164 SEAL 6.750 ID X 8.000 OD X .500 14640 PLUG SOFT SHALLOW 2-1/4 DIA...
Page 49 29471 BODY MAIN ASSEMBLY MECHANICAL FEED FF6000 CE STYLE BALLOON No. PART DESCRIPTION 16502 BALL NYLON 7/16 DIA 19225 BALL NYLON 1/4 DIA 18905 SPINDLE 4 BOLT FF6000 23233 KEY 1/2 SQ X 1.81 RADIUS ONE END 29152 PLATE MASS SEE DWG...
Page 51 16416 CHUCK ASSEMBLY 14" TO 34" DIA FF6000 BALLOON No. PART DESCRIPTION 32784 CHUCK FF6000 STANDARD 1 PIECE 32785 PLUG - CHUCK BOTTOM 14830 PLATE JAW COVER 11826 SCREW 1/2-13 X 1-1/4 HHCS 14846 FINGER SETUP 13912 SCREW 1/2-13 X 1-1/2 SSSCP 14829 SPACER JAW 1 IN.
Page 53 14333 BAR TURNING ASSEMBLY 25.5 STANDARD FF6000 BALLOON No. PART DESCRIPTION 14331 BAR TURNING 25.5 - STANDARD MODEL FF6000 14332 RACK TURNING BAR FF6000 10560 SCREW 10-32 X 3/8 FHSCS 11190 KEY 1/2 X 3/4 X 23.48 RADIUS BOTH ENDS Copyright ©...
Page 54 SPRING COMP .60 OD X .063 WIRE X 1.75 LONG 26531 GUARD SAFETY FF6000 MECH. FEED 26949 SCREW 5/8-11 X 1-3/4 SSSCP 26948 NUT 5/8-11 X 1-3/4 COUPLING 18307 PIN COTTER Copyright © 2004 Climax Portable Machine Tools, Inc. Page 54...
Page 56 RING SNAP 1 OD 15079 WASHER THRUST 1.000 ID X 1.562 OD X .030 18316 RATCHET DOWN FEED 10532 BRG ROLLER CLUTCH 1 ID X 1-5/16 OD X 1.063 14135 LUG DRIVE Copyright © 2004 Climax Portable Machine Tools, Inc. Page 56...
Page 58 BRG NEEDLE 1/4 ID X 7/16 OD X .438 OPEN 14112 ADAPTER FEED SHAFT 11050 SCREW 10-32 X 3/16 SSSCP 33010 WASHER BELLEVILLE 1/4 ID X 1/2 OD X .022 THK 11080 WASHER 3/8 FLTW SAE Copyright © 2004 Climax Portable Machine Tools, Inc. Page 58...
Page 60 14106 POWER UNIT ASSEMBLY AIR INGERSOLL BALLOON No. PART DESCRIPTION 11207 MOTOR AIR MODIFIED INGERSOLL 120 RPM FF6000 14771 SCREW 5/16-18 X 3/4 BHSCS 14326 GEAR DRIVE 11206 SCREW 5/16-18 X 5/16 SSSCP 11224 KEY 3/16 SQ X 1.50 SQ BOTH ENDS Copyright ©...
Page 62 BALLOON No. PART DESCRIPTION 14875 CHUCK CORE 32-60 DIA FF6000 14824 SPACER LEG 5 IN. 14845 SCREW 5/8-11 X 7 SHCS 12646 SCREW 1/2-13 X 1-1/4 SHCS 14791 ARM CHUCK Copyright © 2004 Climax Portable Machine Tools, Inc. Page 62...
Page 64 15004 BAR TURNING ASSEMBLY LARGE BORE FF6000 BALLOON No. PART DESCRIPTION 15005 BAR TURNING 35.5 LARGE BORE FF6000 14332 RACK TURNING BAR FF6000 10560 SCREW 10-32 X 3/8 FHSCS 11190 KEY 1/2 X 3/4 X 23.48 RADIUS BOTH ENDS 15006 BAR COUNTERWEIGHT LARGE BORE FF6000 Copyright ©...
Page 65 WRENCH HEX 3/16 X 6 T-HANDLE 11270 WRENCH HEX 3/32 SHORT ARM 11919 WRENCH HEX 3/8 SHORT ARM 10601 WRENCH HEX 5/16 SHORT ARM 10600 WRENCH HEX 5/32 SHORT ARM Copyright © 2004 Climax Portable Machine Tools, Inc. Page 65...

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