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Climax KM3000 Manual

Key mill machine
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KM3000/
KM4000
KEY MILL MACHINE
P/N 104075
May 2023
Revision 0

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  • Page 1 KM3000/ KM4000 KEY MILL MACHINE P/N 104075 May 2023 Revision 0...
  • 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 KM3000 KM4000 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 This page intentionally left blank Page D KM3000 KM4000 Operating Manual...

  • Page 7: Table Of Contents

    KM3000/KM4000 pneumatic power ........
  • Page 8 4.6.4 KM3000/KM4000 end mill feed (vertical adjustment) ....... 42 4.6.5 KM4000 wide keyways .
  • Page 9 TABLE OF CONTENTS (CONTINUED) HAPTER ECTION 6 STORAGE AND SHIPPING ..........53 .
  • Page 10 This page intentionally left blank Page iv KM3000 KM4000 Operating Manual...
  • Page 11 A-4 KM3000/KM4000 pneumatic assembly parts list (P/N 85123) ....... 60...
  • Page 12 B-2 Hydraulic schematic ............. . 103 Page vi KM3000 KM4000 Operating Manual...
  • Page 13 5-2 KM3000/KM4000 approved lubricants ........
  • Page 14 This page intentionally left blank Page viii KM3000 KM4000 Operating Manual...

  • Page 15: Introduction

    The first page of each chapter includes a summary of the chapter contents to help you locate specific information. The appendices contain supplemental product information to aid in setup, operation, and maintenance tasks. Read this entire manual to familiarize yourself with the KM3000/KM4000 before attempting to set it up or operate it. AFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual.

  • Page 16: 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 17: Machine - Specific Safety Precautions

    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. Remove gloves and secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts.

  • Page 18: Risk Assessment And Hazard Mitigation

    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 Porta- ble Machine Tool and the workpiece as a whole. Page 4 KM3000 KM4000 Operating Manual...

  • Page 19: 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 Portable Machine Tool. However, these checklists are typical of the types of risks the assembler and operator should con- sider.

  • Page 20: Labels

    ABELS The following warning and identification labels should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements. 1-4. KM3000/KM4000 ABLE LABELS P/N 53464 P/N 59037 Warning label: Warning label: hot surface wear ear protec-...

  • Page 21: Overview

    2.1.1 KM3000 features and components The KM3000 portable key mill machine is designed to cut keyways in shafts. The automatically centering V-base is quick and easy to set up. The universal type motor and triple gear reduction produce plenty of torque for most operations.
  • Page 22 • Precision ground quill housing assures smooth operation • The KM3000 only needs 1.5" (38 mm) of shaft for clamping. • The KM3000 clamps shafts up to 10.5" (266 mm) diameter with optional chain clamp • Slotted V-base allows you to cut right to the end of the shaft •...

  • Page 23: Km4000 Features And Components

    2-1. KM3000 ABLE COMPONENT IDENTIFICATION Number Component Slide assembly Clamping mechanism Spindle and quill 2.1.2 KM4000 features and components The KM4000 key mill machine is designed to cut extra wide keyways, stress relief pockets, motor mount slots, and more. Built for rugged duty, the machine features permanently lubricated reduction gears so the machine can be operated at any angle.

  • Page 24: Controls

    ONTROLS 2-2. KM3000 IGURE MOTOR The KM3000/KM4000 key mill machine is available in electric, pneumatic and hydraulic versions. 2.2.1 KM3000/KM4000 electric power Table 2-2 lists operating specifications of the electrically powered version of the KM3000/KM4000. 2-2. E ABLE LECTRIC POWER SPECIFICATIONS...
  • Page 25 CAUTION To avoid damaging the motor, the KM3000 should be used with a circuit breaker sized to prevent the motor from running above the maximum current.

  • Page 26: Km3000/Km4000 Pneumatic Power

    2. Close the speed adjustment valve. 3. Pull the emergency stop button up. 4. Press the start button (repeat step 1 if necessary). The KM3000/KM4000 controls are located on the PCU, shown in Figure 2-4 on page 13. Page 12...
  • Page 27 2-4. IGURE COMPONENTS 2-6. PCU ABLE CONTROLS IDENTIFICATION Number Component Function Air hose quick dis- Connects the PCU to the operator’s compressed air source. connect Isolates air pressure from the machine and provides the ability to lock the valve Air supply lock-out closed before performing maintenance.

  • Page 28: Km3000/Km4000 Hydraulic Power

    Table 2-7 lists operating specifications of the hydraulically powered version of the KM3000 using standard mineral-based hydraulic oil. CAUTION A hydraulically powered KM3000 operating with flame retardant, water/ glycol-based hydraulic fluid has operating specifications different from those listed below. Consult the hydraulic fluid manufacturer data for operating specifications.

  • Page 29: Km3000 Dimensions

    CAUTION To avoid damaging the power unit pump, connect the hydraulic motor to the power unit before turning it on. The end mill turning direction on a hydraulically powered KM3000 depends on hydraulic line connections (see Figure 2-5). 2-5. HPU...
  • Page 30 2-6. KM3000 IGURE DIMENSIONS Page 16 KM3000 KM4000 Operating Manual...
  • Page 31 Full travel Vertical adjusting screw Vertical travel 1.5–4.5" (38.1–114.3 mm) standard clamp. Up to 10.5" (266.7 mm) with the optional chain clamp. Down to 0.75" (19.1 mm) with the optional shim kit. PECIFICATIONS 2-10. KM3000/KM4000 ABLE SPECIFICATIONS KM3000 KM4000 Overall length: 12.50"...

  • Page 32: Specifications

    If the front clamp is used on diameters smaller than 2.6" (66 mm), the machine will produce undesired work results. CLIMAX electrical equipment is suitable for use in the physical environment and operating conditions specified below. When the physical environment or the oper- ating conditions are outside those specified, consult CLIMAX before putting the electrical equipment into service.
  • Page 33 2-11. E ABLE LECTRICAL SPECIFICATIONS 200% of nominal Voltage impulses: 1.5 milliseconds (ms) maximum duration Voltage interruption: 3 ms maximum with 1 second between Voltage dip (brownout): 20% of peak volts for 1 second maximum Voltage supplied from batteries: ±10% of nominal Voltage interruption (DC): 5 ms maximum Ambient temperature (operating):...
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  • Page 35: 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 36: Lifting And Rigging

    IFTING AND RIGGING The KM3000 may be lifted from the crate by hand. The KM4000 must be lifted using the supplied lifting eyes. WARNING For the KM4000: When moving the machine and setting it up on the workpiece, support the machine by its lifting eyes with proper rigging.

  • Page 37: Km3000 Standard Shaft Mounting

    Repeat until all gib screws are set. Do the following for standard shaft mounting with the KM3000: 1. Using the rearmost mounting holes, secure the key mill to the shaft with clamp blocks.

  • Page 38: Km4000 Standard Shaft Mounting

    (81.6 Nm.) KM4000 STANDARD SHAFT MOUNTING WARNING Support the machine with rigging while securing it to the workpiece. Failure to do so will allow the machine to fall, causing death or serious crushing injury. Page 24 KM3000 KM4000 Operating Manual...
  • Page 39 Do the following for standard shaft mounting with the KM4000: 1. Use a hoist to set the key mill on the shaft. Because the key mill has sealed lubrication, it can be mounted in any position. 2. Mount the chain clamp assemblies to the clamp blocks on the side of the base.

  • Page 40: Km3000 Stub - End Mounting

    With the KM4000, shafts up to 24" (609 mm) in diameter can be machined using the optional chain clamp assembly. With the KM3000, shafts up to 10.5" (267 mm) in diameter can be machined using the optional chain clamp assembly.
  • Page 41 Figure 3-4 shows the large shaft mounting for the KM3000. 3-4. KM3000 IGURE LARGE SHAFT MOUNTING 3-1. L ABLE ARGE SHAFT MOUNTING IDENTIFICATION Number Component Greater rigidity is obtained with the chain clamp toward the rear of the key mill For greater clearance, attach the large clamp block away from the motor.

  • Page 42: Km3000 Small Shaft Mounting

    Check that the shaft is in the open part of the throat only. If it extends into the rear or the base, it will not align with the key mill. Contact CLIMAX for a shim kit (P/N 11669). 3.10 KM4000 SMALL SHAFT MOUNTING When mounting the KM4000 to shafts less than 7"...

  • Page 43: Km3000/Km4000 Bench Vise Mounting

    One turn of the hand crank will feed the top slide 0.067" (1.69 mm). Note that the KM3000 is capable of traverse and vertical feed. The cross-slide kit included is for mounting, not machining. The KM4000 is capable of traverse, vertical, and cross-slide feed.
  • Page 44 The key mill has a maximum vertical adjustment height of 1.75" (44 mm) from the bottommost position. Cranking the key mill above this height will cause the vertical adjustment leadscrew to unthread from the base. 3-7. V IGURE ERTICAL AND HORIZONTAL FEED CONFIGURATION Page 30 KM3000 KM4000 Operating Manual...

  • Page 45: Operation

    YDRAULIC CHECKS 4.2 KM3000/KM4000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -33 OPERATION 4.2.1 E...

  • Page 46: Electric Checks

    4.1.1 Electric checks Check electrical parts for damage. Repair or replace any damaged parts. Check that the motor control trigger is in the off position. Plug the machine into a properly grounded outlet. Page 32 KM3000 KM4000 Operating Manual...

  • Page 47: Pneumatic Checks

    (toward the pump motor) on top of the case housing. Be sure the power unit wiring matches the electric source. Be sure the power unit is level. Clean all hydraulic fittings before connecting them. KM3000/KM4000 OPERATION 4.2.1 Electric power: starting the machine...

  • Page 48: Electric Power: Stopping The Machine

    10: 1. Push the emergency stop lever down until the word CLOSED and the lock- out can be seen from the bottom of the valve. Be sure the lever is pushed all the way. Page 34 KM3000 KM4000 Operating Manual...

  • Page 49: Pneumatic Power: Stopping The Machine

    2. Turn the needle valve clockwise all the way. When the valve is completely closed, no colored bands will be visible. 3. Connect the air supply line through the filter and lubricator to the motor. WARNING Rotating machinery can seriously injure the operator. Secure the machine to the work piece before connecting the air supply line.

  • Page 50: Km3000/Km4000 Electric Machines

    Using air that is not filtered or lubricated can damage the air motor. Avoid damage by routing incoming air through the filter and lubricator. The air line should be at least 0.5" (13 mm) in diameter. Page 36 KM3000 KM4000 Operating Manual...

  • Page 51: Km3000/Km4000 Hydraulic Machine

    11. After the keyway has been cut, raise the end mill clear of the work. 4.3.3 KM3000/KM4000 hydraulic machine With the end mill properly mounted on the shaft, do the following: 1. Connect hoses for the hydraulic motor to the power unit.

  • Page 52: Km3000/Km4000 Keyway Cutting

    The vertical feed has no built-in top position stop. Do not Do not allow the vertical feed to feed all the way out of the frame. Doing so may result in death or severe crushing injury. 9. Loosen the end mill socket set screw in the spindle. Page 38 KM3000 KM4000 Operating Manual...

  • Page 53: Km4000 Lateral Feed ( Cross Slide )

    10. Remove the end mill from the spindle. 11. Remove the key mill from the shaft. KM4000 LATERAL FEED CROSS SLIDE Hand crank the cross slide leadscrew. One complete turn of the leadscrew will move the key mill 0.100" (2.50 mm on metric machines). 4-3.

  • Page 54: Km3000/Km4000 Special Applications

    KM3000/KM4000 SPECIAL APPLICATIONS The KM3000/KM4000 is well suited for machining unusual keyways and other exceptional on-site milling jobs. The KM3000/KM4000 works well on almost any operation calling for the milling of slots, flats, elongated holes, or other like fea- tures.

  • Page 55: Km3000/Km4000 Axially Aligned Keyways

    4.6.2 KM3000/KM4000 axially aligned keyways Do the following for axially aligned keyways: 1. Secure the shaft so it will not rotate. 2. Referring to Figure 4-5 on page 41, mount the key mill on top of the shaft, setting it level as described in Section 3.4 on page 23.

  • Page 56: Km3000/Km4000 Rotated Keyways

    6. Cut the other keyway. 4.6.4 KM3000/KM4000 end mill feed (vertical adjustment) 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 0.100"...

  • Page 57: Km4000 Wide Keyways

    4.6.5 KM4000 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" (0.025 mm) increments. For precisely accurate cutting, verify the measurements with a dial indicator. Do the following to cut wide keyways: 1.
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  • Page 59: Maintenance

    5.3.3...

  • Page 60: Approved Lubricants

    Check periodically that air pressure is 80 psi (5.5 bar.) Section 5.3.9 on page 49 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 61: Maintenance Tasks

    5-2. KM3000/KM4000 ABLE APPROVED LUBRICANTS Lubricant Brand Application Area Air tool oil Mobil Almo 525 Air lubricator oil cup Lubricant Jet Lube 550 Cutting bit set screw in quill Mobil VACTRA #2 Way oil Dovetail ways Heavy-Medium Way Oil Hydraulic system...

  • Page 62: Km3000/Km4000 Slide Assemblies

    KM3000/KM4000 vertical adjustment screw Occasionally lubricate the vertical adjustment screw threads with Jet Lube 550. 5.3.5 KM3000/KM4000 gearbox, spindle, quill assembly The gearbox is packed with Mobil Mobilith SHC 22 grease. Every 500 hours, repack the gearbox by doing the following: 1.

  • Page 63: Km3000/Km4000 Replacing Motor

    7. Put a coat of grease over gears and in all crevices. 5.3.7 KM3000/KM4000 installing the vertical leadscrew and cover Do the following to install the vertical leadscrew and cover: 1. Place the vertical adjusting lead screw into the gearbox.

  • Page 64: Km3000/Km4000 Hydraulic Power Systems

    When new, change the filter after the first 72 hours of operation to remove any impurities in the system. From then on, replace the filter every 150–200 hours. Use a high-quality filter. CLIMAX recommends a 10-micron industrial-grade fil- ter. If the filtering system has a change-warning gauge, change the filter as often as the gauge indicates.

  • Page 65: Chain Clamp

    • When the oil becomes contaminated • When the power unit is operated at high temperatures for extended periods • At least every two years Fluid level should never drop below the red bar on the level/temperature gauge. Add only clean filtered fluid to the system. Do not return leaked fluid to the unit. 5.3.10.3 KM4000 hydraulic hoses and fittings Before operation, inspect all hydraulic hoses and fittings for damage, kinks, leaks,...
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  • Page 67: Storage And Shipping

    STORAGE AND SHIPPING TORAGE Proper storage of the key mill machine will extend its usefulness and prevent undue damage. Before storing, do the following: 1. Clean the machine with solvent to remove grease, metal chips, and mois- ture. 2. Drain all liquids from the pneumatic conditioning unit. Store the key mill machine in its original shipping container.
  • Page 68 This page intentionally left blank Page 54 KM3000 KM4000 Operating Manual...

  • Page 69: Appendix Aassembly Drawings

    APPENDIX A ASSEMBLY DRAWINGS Drawing list A-1. KM3000/KM4000 (P/N 103548) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56 IGURE ASSEMBLY A-2.

  • Page 70: Igure A-1. Km3000/Km4000 Assembly (P/N 103548)

    (P/N 103867) - - - - - - - - - - - - - - - - - - - - - - - - - - 100 ABLE YDRAULIC INCH SPARE PARTS KIT CONFIGURATION 103698 SHOWN A-1. KM3000/KM4000 (P/N 103548) IGURE ASSEMBLY Page 56 KM3000 KM4000 Operating Manual...

  • Page 71: Igure A-2. Km3000/Km4000 Assembly Configurations And Parts List (P/N 103548)

    PARTS LIST ITEM P/N: DESCRIPTION 16011 (NOT SHOWN) CRATE 9 X 24 X 11-7/8 KM3000 5/8 PLY HINGED 34181 (NOT SHOWN) WRENCH HEX SET FOLDING 5/64 - 1/4 9 PCS CLIMAX LOGO 46759 PLATE SERIAL YEAR MODEL CE 2.0 X 2.63...

  • Page 72: Igure A-3. Km3000/Km4000 Pneumatic Assembly (P/N 85123)

    AVAILABLE CONFIGURATIONS PART NO. DESCRIPTION 16002 MODEL KM3000 INCH AIR 16005 MODEL KM3000 METRIC AIR A-3. KM3000/KM4000 (P/N 85123) IGURE PNEUMATIC ASSEMBLY Page 58 KM3000 KM4000 Operating Manual...

  • Page 73: Igure A-4. Km3000/Km4000 Pneumatic Assembly Parts List (P/N 85123)

    PARTS LIST P/N 16002 ITEM P/N: DESCRIPTION 13737 (NOT SHOWN) KIT TOOL KM3000 KM4000 PM4000 15651 SPINDLE & QUILL ASSY INCH 3RD KM3000 15655 ASSY LEADSCREW VERT ADJ INCH 3RD KM3000 28839 BASE AND TOP SLIDE ASSY W/ BAR CLAMP...

  • Page 74: Igure A-5. Km4000 Chart Assembly (P/N 103884)

    (NOT SHOWN) CRATE 18 X 19 X 13-5/8 KM4000 5/8 PLY HINGED 104075 (NOT SHOWN) MANUAL INSTRUCTION KM3000 KM4000 KEY MILL 34181 (NOT SHOWN) WRENCH HEX SET FOLDING 5/64 - 1/4 9 PCS CLIMAX LOGO (KB) SEE CHART ASSY TOPSLIDE WELDON SHANK ELECTRIC INCH/METRIC KM4000 PM4200 SEE CHART ASSY LEADSCREW CROSS SLIDE A-5.

  • Page 75: Igure A-6. Km4000 Label Locations (P/N 103884)

    59039 29152 59037 78824 78741 78748 53464 46759 79848 59039 79575 LABEL POSITIONS A-6. KM4000 (P/N 103884) IGURE LABEL LOCATIONS P/N 104075, Rev. 0 Page 61...

  • Page 76: Igure A-7. Topslide Eldon Shank Inch

    A-7. T (P/N 103899) IGURE OPSLIDE ELDON SHANK INCH V ELECTRIC ASSEMBLY Page 62 KM3000 KM4000 Operating Manual...

  • Page 77: Igure A-8. Topslide Eldon Shank Inch

    SCREW 5/16-18 X 1-1/4 SHCS 13174 BRG THRUST .875 ID X 1.437 OD X .0781 13175 WASHER THRUST .875 ID X 1.437 OD X .060 15618 SHAFT ASSY 2ND KM3000 15999 PLUG HOLE 1-3/4 DIA MODIFIED 29152 PLATE MASS CE 37981...

  • Page 78: Th Generation Hydraulic Keymill Assembly (P/N 34933)

    ASSY LEADSCREW VERT ADJ INCH 3RD KM3000 28839 BASE AND TOP SLIDE ASSY W/ BAR CLAMP 34935 GEARBOX, KEYMILL 4th GENERATION HYDRAULIC 35002 MOTOR ASSY HYD KM3000 4TH GEN GEAR BOX A-9. 4 (P/N 34933) IGURE TH GENERATION HYDRAULIC KEYMILL ASSEMBLY Page 64...

  • Page 79: Rd Generation Hydraulic Keymill Assembly (P/N 35088)

    PARTS LIST ITEM P/N: DESCRIPTION 16011 (NOT SHOWN) CRATE 9 X 24 X 11-7/8 KM3000 5/8 PLY HINGED 21031 ASSY POWER UNIT INCH HYD 274 RPM @ 5 GPM KM3000 28839 BASE AND TOP SLIDE ASSY W/ BAR CLAMP 34181...

  • Page 80: Igure A-11. Base And Top Slide Assembly (P/N 28839)

    GIB .4915 X .1562 X 6.76 0-1 6 SS X 1.25 15647 CLAMP ASSY STANDARD KM3000 15656 ASSY TOP SLIDE INCH 2ND KM3000 16011 CRATE 9 X 24 X 11-7/8 KM3000 5/8 PLY HINGED (NOT SHOWN) 29152 PLATE MASS CE 38091 ASSY LEADSCREW TOP SLIDE KM3000 A-11. B...

  • Page 81: Igure A-12. Base And Top Slide Assembly Metric (P/N 30459)

    GIB .4915 X .1562 X 6.76 0-1 6 SS X 1.25 15647 CLAMP ASSY STANDARD KM3000 16025 ASSY TOP SLIDE METRIC 2ND KM3000 16325 MANUAL INSTRUCTION KM3000 KEY MILL 4TH GEN (NOT SHOWN) 29152 PLATE MASS CE 38091 ASSY LEADSCREW TOP SLIDE KM3000 A-12. B...

  • Page 82: Igure A-13. Clamp Assembly (P/N 15647)

    ITEM P/N: DESCRIPTION 10197 NUT 3/4-10 STDN ZINC PLATED 10198 WASHER THRUST .750 ID X 1.250 OD X .123 10422 ASSY CLAMP BOLT KM3000 15504 CASTING BLOCK CLAMP SMALL 15643 CLAMP BAR 15670 SCREW 1/2-13 X 1 LHSCS A-13. C...

  • Page 83: Igure A-14. Top Slide Assembly (P/N 75077)

    AVAILABLE CONFIGURATIONS PART NO DESCRIPTION 15656 ASSY TOP SLIDE INCH 2ND KM3000 16025 ASSY TOP SLIDE METRIC 2ND KM3000 PARTS LIST ITEM P/N: DESCRIPTION 11735 SCREW 5/16-18 X 1-1/4 SHCS 15507 SLIDE TOP INCH 2ND KM3000 16026 SLIDE TOP METRIC 2ND KM3000...

  • Page 84: Igure A-15. Top Slide Leadscrew Assembly (P/N 38091)

    WASHER THRUST .875 ID X 1.437 OD X .060 15999 PLUG HOLE 1-3/4 DIA MODIFIED 37981 NUT SELF LOCKING BRG ADJ SZ 4 38092 LEADSCREW TOPSLIDE KM3000 38116 COLLAR LEADSCREW BEARING A-15. T (P/N 38091) IGURE OP SLIDE LEADSCREW ASSEMBLY Page 70 KM3000 KM4000 Operating Manual...

  • Page 85: Igure A-16. Km4000 Cross Slide Leadscrew Inch Assembly (P/N 16263)

    PARTS LIST ITEM P/N: DESCRIPTION 10165 COLLAR 10166 PIN ROLL 1/8 DIA X 1 10169 DIAL INCH 10365 BRG BALL .6693 ID X 1.5748 OD X .4724 2 SEALS LEAD NUT 10449 10451 NUT BEARING RETAINER 10453 SCREW 3/8-16 X 1 1/4 SHCS 15666 WASHER THRUST .669 ID X 1.181 OD X .039 15667...

  • Page 86: Igure A-17. Km4000 Cross Slide Leadscrew Metric Assembly (P/N 16264)

    WASHER THRUST .669 ID X 1.181 OD X .039 10451 NUT BEARING RETAINER 10166 PIN ROLL 1/8 DIA X 1 15667 WASHER SPRING FINGER .688 ID X 1.164 OD 10170 DIAL METRIC A-17. KM4000 (P/N 16264) IGURE CROSS SLIDE LEADSCREW METRIC ASSEMBLY Page 72 KM3000 KM4000 Operating Manual...

  • Page 87: Igure A-18. Gearbox Spindle Drivetop Assembly (P/N 34403)

    10167 SEAL 1.000 ID X 1.375 OD X .250 15517 GEAR SPUR 16DP 56T 20PA .43 X .97LG STEEL 34284 GEARBOX 4TH GENERATION KM3000 34285 GEARBOX COVER KM3000 79848 LABEL WARNING - CUTTING OF FINGERS OR HAND ROTATING BLADE GRAPHIC 1.13 TALL TRIANGLE YELLOW...

  • Page 88: Ratio Assembly (P/N 103341)

    GEAR SPUR 16DP 16T 20PA .38LG STEEL 103781 WASHER THRUST 3/8 ID X 3/4 OD X 1/16 OILITE 103792 SEAL .8125 ID X 1.250 OD X .18 A-19. G (P/N 103341) IGURE EARBOX RATIO ASSEMBLY Page 74 KM3000 KM4000 Operating Manual...

  • Page 89: Igure A-20. Vertical Leadscrew Assembly (P/N 75096)

    RING SNAP .672 OD X .035 THICK INVERTED 19492 LEADSCREW VERT ADJ INCH 3RD KM4000 CPM 4.67 INCH (19648) 15635 LEADSCREW VERT ADJ INCH 3RD KM3000 2.50 INCH (15655) 16020 LEADSCREW VERT ADJ METRIC 3RD KM3000 2.50 INCH (16021) 19634 LEADSCREW VERT ADJ METRIC 3RD KM4000 CPM 4.67 INCH (19649)

  • Page 90: Igure A-21. Spindle And Quill Assembly (P/N 15651)

    ITEM P/N: DESCRIPTION 10150 BRG BALL .7874 ID X 1.8504 OD X .5512 15514 ASSY QUILL 2ND KM3000 1.75 TRAVEL 15518 SPINDLE INCH 5/8 3RD KM3000 15669 SEAL 1.500 ID X 1.874 OD X .250 37405 SCREW 1/2-20 X .425 END MILL SET SCREW A-21.

  • Page 91: Igure A-22. Spindle And Quill Assembly Metric (P/N 16022)

    PARTS LIST ITEM P/N: DESCRIPTION 10150 BRG BALL .7874 X 1.8504 X .5512 2/SHLDS 15514 ASSY QUILL 2ND KM3000 1.75 TRAVEL 15669 SEAL 1.500 ID X 1.874 OD X .250 16023 ASSY SPINDLE 16MM METRIC 3RD KM3000 A-22. S (P/N 16022)

  • Page 92: Igure A-23. Electric Motor Assembly (P/N 103702)

    NFIS ADAPTER METABO ANGLE POLISHER 103811 KNOB ADJUSTMENT 2 INCH KNURLED LOW PROFILE SEE CHART GEAR SPUR SEE CHART CHART NFIS MOTOR ELEC 103886 SCREW 5/8-11 X 1 SSSCN A-23. E (P/N 103702) IGURE LECTRIC MOTOR ASSEMBLY Page 78 KM3000 KM4000 Operating Manual...

  • Page 93: Igure A-24. Pneumatic Conditioning Unit Assembly 1 (P/N 101920)

    PCU REPLACEMENT PARTS: MFG=AVENTICS SERIES 652 AIR PREP UNIT COMPONENTS A T652AT502468001 = END PLATES B P652AT502466001 = BODY CONNECTOR C P699AT502467001 = BRACKET ATTACHMENT FOR BODY CONN 8652A3M04011100 = SHUT OFF VALVE D M652AY524218002 = SIDE COVER PLASTIC E M2MN = METAL SILENCER 8652APAM4FA00GA = FILTER/REGULATOR F M652AU440511003 = BOWL POLYMIDE G M699AQ501862001 = DRAIN COCK...

  • Page 94: Igure A-25. Pneumatic Conditioning Unit Assembly 2 (P/N 101920)

    DETAIL B DETAIL A SCALE 1/3 SCALE 1/3 SEE DETAIL A (START PB) SEE DETAIL B (STOP PB) A-25. P 2 (P/N 101920) IGURE NEUMATIC CONDITIONING UNIT ASSEMBLY Page 80 KM3000 KM4000 Operating Manual...

  • Page 95: Igure A-26. Pneumatic Conditioning Unit Schematic And Parts List (P/N 101920)

    STOP 6.0" 6.0" START 6.0" 1 3 5 ASSEMBLED VIEW 4.0" SCALE 1 : 8 SHUT OFF MFG PN MFG PN 8652APAM4FA00GA 8652A3M04011100 MFG PN MFG PN 8652A5E04NA0000 8652AL0M40A0000 PARTS LIST ITEM P/N: DESCRIPTION 11315 WASHER #10 FLTW BLACK OXIDE 12648 SCREW 10-24 X 3/4 SHCS 14726...

  • Page 96: Igure A-27. Pneumatic Motor Assembly (P/N 38708)

    A-27. P (P/N 38708) IGURE NEUMATIC MOTOR ASSEMBLY Page 82 KM3000 KM4000 Operating Manual...

  • Page 97: Igure A-28. Pneumatic Motor Assembly Parts List (P/N 38708)

    38710 RING SNAP 1.850 OD SPIRAL MEDIUM DUTY 38711 RING SNAP 25/32 OD X .031 TH SPIRAL MEDIUM DUTY 38715 MOTOR MODIFIED AIR KM3000 KM4000 520 RPM 59044 LABEL WARNING - CONSULT OPERATOR'S MANUAL 78741 LABEL WARNING CRUSH FOOT 78748 LABEL WARNING FLYING DEBRIS/LOUD NOISE A-28.

  • Page 98: Igure A-29. Hydraulic Key Mill Gearbox (P/N 34935)

    SEAL 1.000 ID X 1.375 OD X .250 12418 SCREW 1/4-20 X 5/8 SHCS 15517 GEAR SPUR 16DP 56T 20PA .43 X .97LG STEEL 34284 GEARBOX 4TH GENERATION KM3000 34285 GEARBOX COVER KM3000 75048 PLATE SERIAL YEAR MODEL CE 2.0 X 2.63 79848 LABEL WARNING - CUTTING OF FINGERS OR HAND ROTATING BLADE GRAPHIC 1.13 TALL TRIANGLE...

  • Page 99: Igure A-30. Box Gear Assembly (P/N 21022)

    SCREW 8-32 X 5/8 SHCS 10167 SEAL 1.000 ID X 1.375 OD X .250 15517 GEAR SPUR 16DP 56T 20PA .43 X .97LG STEEL 34284 GEARBOX 4TH GENERATION KM3000 34285 GEARBOX COVER KM3000 75048 PLATE SERIAL YEAR MODEL CE 2.0 X 2.63 79328 LABEL WARNING - CONSULT OPERATOR'S MANUAL GRAPHIC .75 DIA...

  • Page 100: Igure A-31. Hydraulic Motor Assembly (P/N 35002)

    LABEL WARNING - CUTTING OF FINGERS OR HAND ROTATING BLADE GRAPHIC 1.13 TALL TRIANGLE YELLOW 80041 ASSY HOSE 3/8 X 1/2 QD MALE X #6 JICF X 24 CE A-31. H (P/N 35002) IGURE YDRAULIC MOTOR ASSEMBLY Page 86 KM3000 KM4000 Operating Manual...

  • Page 101: Igure A-32. Hydraulic Motor Assembly (P/N 81521)

    A-32. H (P/N 81521) IGURE YDRAULIC MOTOR ASSEMBLY P/N 104075, Rev. 0 Page 87...

  • Page 102: Igure A-33. Chain Clamp Assembly (P/N 10378)

    15505 BASE REF. PARTS LIST ITEM P/N: DESCRIPTION 27364 CHAIN CLAMP ASSY 10-1/2 DIA KM3000 2ND A-33. C (P/N 10378) IGURE HAIN CLAMP ASSEMBLY Page 88 KM3000 KM4000 Operating Manual...

  • Page 103: Igure A-34. Km4000 Chain Clamp Assembly (P/N 10491)

    PN 13262 NOTES 1 BREAK CHAIN INTO 20 INCH LENGTHS (QTY 4) PARTS LIST ITEM P/N: DESCRIPTION 10206 ROCKER CHAIN CLAMP 10197 NUT 3/4-10 STDN ZINC PLATED 10198 WASHER THRUST .750 ID X 1.250 OD X .123 10462 CLAMP BAR 15504 CASTING BLOCK CLAMP SMALL 15670...

  • Page 104: Igure A-35. Chain Clamp Assembly Diameter (P/N 27364)

    CHAIN WRENCH 3/4 PITCH .240 DIA PIN (VMI) 10198 WASHER THRUST .750 ID X 1.250 OD X .123 15670 SCREW 1/2-13 X 1 LHSCS A-35. C 10-1/2 (P/N 27364) IGURE HAIN CLAMP ASSEMBLY DIAMETER Page 90 KM3000 KM4000 Operating Manual...

  • Page 105: Igure A-36. Km4000 Base Assembly (P/N 13262)

    PARTS LIST ITEM P/N: DESCRIPTION 10189 SCREW 1/4-20 X 5/8 SSSHDPPL 10452 GIB .615 X .375 X 8.97 0-1 9 SS X 1.0 10454 BASE KM4000 HYD 10460 EYE LIFTING 3/8-16 X 1-1/4 THREAD 1300 LBS 59039 LABEL WARNING LIFT POINT ROUND 1.5" A-36.

  • Page 106: Igure A-37. Cross Milling Adapter (Km4000 Base Shown ) (P/N 10381)

    10454 BASE REF. PARTS LIST ITEM P/N: DESCRIPTION 10255 CROSS MILLING ADAPTER 19950 SCREW 1/2-13 X 3 1/4 SHCS A-37. C (KM4000 ) (P/N 10381) IGURE ROSS MILLING ADAPTER BASE SHOWN Page 92 KM3000 KM4000 Operating Manual...

  • Page 107: Igure A-38. Shim Kit Assembly (P/N 11669)

    REF. ONLY PARTS LIST ITEM P/N: DESCRIPTION 10160 SCREW 1/4-20 X 3/4 SHCS 11668 SHIM SET SMALL DIA MILLING KM3000 (KB) 19605 (NOT SHOWN) DRAWING INSTRUCTIONS SHIM INSTALLATION KM3000 A-38. S (P/N 11669) IGURE HIM KIT ASSEMBLY P/N 104075, Rev. 0...

  • Page 108: Able A-1. Km4000 120V Inch Spare Parts Kit (P/N 103963)

    The following critical parts may occasionally need to be replaced due to loss, wear, or damage, and are available for purchase from CLIMAX. A-1. KM4000 120V (P/N 103963) ABLE INCH SPARE PARTS KIT Part number Description Quantity 10134 COLLAR 11/16 DIA SHAFT WITH 5/16-18 SET SCREW...

  • Page 109: Able A-2. Km4000 230V Inch Spare Parts Kit (P/N 103964)

    BRG NEEDLE 1-1/2 ID X 1-7/8 OD X .625 OPEN GR 19492 LEADSCREW VERT ADJ INCH 3RD KM4000 CPM 4.67 INCH (KB) 104074 MANUAL INSTRUCTION KM3000 KM4000 KEY MILL 37405 SCREW MODIFIED 1/2-20 X .425 END MILL SCREW 37981 NUT SELF LOCKING BRG ADJ SZ 4...
  • Page 110 BRG THRUST .875 ID X 1.437 OD X .0781 13175 WASHER THRUST .875 ID X 1.437 OD X .060 13542 BRG ANGULAR CONTACT .787 ID X 1.850 OD X .551 15618 SHAFT ASSY 2ND KM3000 (KB) Page 96 KM3000 KM4000 Operating Manual...

  • Page 111: Able A-3. 120V Inch Spare Parts Kit (P/N 75012)

    BRG NEEDLE 1-1/2 ID X 1-7/8 OD X .625 OPEN GR 19634 LEADSCREW VERT ADJ METRIC 3RD KM4000 CPM 4.67 INCH 104074 MANUAL INSTRUCTION KM3000 KM4000 KEY MILL 37405 SCREW MODIFIED 1/2-20 X .425 END MILL SCREW 37981 NUT SELF LOCKING BRG ADJ SZ 4...

  • Page 112: Able A-4. 230V Metric Spare Parts Kit (P/N 68419)

    BRG THRUST .875 ID X 1.437 OD X .0781 13175 WASHER THRUST .875 ID X 1.437 OD X .060 15635 LEADSCREW VERT ADJ INCH 3RD KM3000 2.50 INCH (KB) 15647 CLAMP ASSY STANDARD KM3000 15657 SHAFT ASSY TRAVERSE DRIVE 2ND KM3000...

  • Page 113: Able A-5. Pneumatic Inch Spare Parts Kit (P/N 103866)

    WASHER THRUST .875 ID X 1.437 OD X .060 15647 CLAMP ASSY STANDARD KM3000 15657 SHAFT ASSY TRAVERSE DRIVE 2ND KM3000 16020 LEADSCREW VERT ADJ METRIC 3RD KM3000 2.50 INCH (KB) 104074 MANUAL INSTRUCTION KM3000 KM4000 KEY MILL 27366 CHAIN WRENCH 3/4 PITCH .240 DIA PIN 27385...
  • Page 114 BRG THRUST .875 ID X 1.437 OD X .0781 13175 WASHER THRUST .875 ID X 1.437 OD X .060 15635 LEADSCREW VERT ADJ INCH 3RD KM3000 2.50 INCH (KB) 15647 CLAMP ASSY STANDARD KM3000 15657 SHAFT ASSY TRAVERSE DRIVE 2ND KM3000...
  • Page 115 ABLE YDRAULIC INCH SPARE PARTS KIT Part number Description Quantity 15657 SHAFT ASSY TRAVERSE DRIVE 2ND KM3000 104074 MANUAL INSTRUCTION KM3000 KM4000 KEY MILL 20379 GEAR SPUR MOTOR 26T 16DP 1.625PD HYD MOTOR 27366 CHAIN WRENCH 3/4 PITCH .240 DIA PIN...
  • Page 116 This page intentionally left blank Page 102 KM3000 KM4000 Operating Manual...

  • Page 117: Appendix Bschematics

    APPENDIX B SCHEMATICS Schematic list B-1. P (P/N 59246) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 IGURE NEUMATIC SCHEMATIC B-2.
  • Page 118 This page intentionally left blank Page 104 KM3000 KM4000 Operating Manual...

  • Page 119: Appendix Csds

    APPENDIX C Contact CLIMAX for the current Safety Data Sheets. P/N 104075, Rev. 0 Page 105...
  • Page 120 This page intentionally left blank Page 106 KM3000 KM4000 Operating Manual...

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