Climax CM6200 Operating Manual Download Page 172

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Page 154

CM6200 Operating Manual

ABLE

A-1. S

PARE

PARTS

Qty

Part number

Description

62606

HOIST RING M24 X 3 X 38MM 70 ID X 130 OD 225 OAL 9250 LBS 4200 KG
SWIVEL

58202

SCREW 16MM DIA X 20MM X M12 X 175 SHLDCS

Hose Tower / Encoder Guard

62616

TOWER HOSE CM6200

57874

SCREW M8 X 125 X 60MM SHCS

62615

GUARD ENCODER CM6200

Turning Arm Clamps

62601

ASSY CLAMP ARM CM6200

62602

ASSY CLAMP ARM SAFETY

46222

SCREW M16 X 20 X 45MM SHCS

Drag Brakes

27172

WASHER SPRING BELLEVILLE 5/8 X 1-1/4 X 040

11693

WASHER 5/8 FLTW SAE

62612

STUD THREADED M16 X 2 X 100MM FULL THREAD

62613

NUT M16 X 20 JAMN

46232

BAR BRAKE CLAMP

54165

SHOE BRAKE 16M CIRCULAR MILL

Milling

62255

SLIDE RAIL THK SHS25 442MM LG PRELOADED METAL SCRAPERS 2
BLOCKS

62426

BALL SCREW NUT 20MM X 5MM LEAD 33 MM OD EICHENBERGER
ROUND

62431

BALL SCREW MILLING HEAD 275 BRG 8" STROKE

62719

TOOL 1" KEYED SHAFT MANUAL OPERATOR

51859

SCALE DIGITAL 8 INCH VERTICAL MOUNT

62645

WRENCH SOCKET 38MM 12 PT 1/2 DRIVE

53459

ASSY MOTOR HYD 80 CU IN 2000 SERIES W/ 12" QD MALE

53458

ASSY MOTOR HYD 96 CU IN 2000 SERIES W/ 12" QD MALE

46950

ASSY MOTOR HYD 119 CU IN 2000 SERIES W/ 12" QD MALE

46375

ASSY MOTOR HYD 149 CU IN 2000 SERIES W/ 12" QD MALE

46549

ASSY MOTOR HYD 187 CU IN 2000 SERIES W/ 12" QD MALE

Summary of Contents for CM6200

Page 1: ...CM6200 CIRCULAR MILLING MACHINE CM6200 OPERATING MANUAL ORIGINAL INSTRUCTIONS P N 63674 May 2021 Revision 9...

Page 2: ......

Page 3: ...ns about CLIMAX products or services please call CLIMAX or e mail info cpmt com For quick and accurate service please provide your representative with the following Your name Shipping address Telephon...

Page 4: ...Page B CM6200 Operating Manual CLIMAX GLOBAL LOCATIONS...

Page 5: ...P N 63674 Rev 9 Page C CE DOCUMENTATION...

Page 6: ...Operating Manual Standard No EN 3744 EN 11201 The Declared Sound Power Level is LWA 74 4 dBA The Declared Operator Sound Pressure Level is LpA 65 2 dBA The Declared Bystander Sound Pressure Level is...

Page 7: ...tory representative and return the part or repaired machine shipping pre paid to the factory CLIMAX will at its option either repair or replace the defective part and or correct any defect in the labo...

Page 8: ...Page F CM6200 Operating Manual This page intentionally left blank...

Page 9: ...2 3 MACHINE ENVELOPE AND OPERATING DIMENSIONS 17 2 4 SPECIFICATIONS 19 2 4 1 Weight specifications 19 2 4 2 Hydraulic motor specifications 19 3 SETUP 21 3 1 RECEIPT AND INSPECTION 21 3 2 PREPARING THE...

Page 10: ...ramming 55 4 2 CONTROL PENDANT 59 4 2 1 Coordinate systems 59 4 2 2 Machine controls overview 60 4 2 3 Main menu 64 4 2 4 Machine setup 66 4 2 5 Incremental move 68 4 2 6 Absolute move 69 4 2 7 Increm...

Page 11: ...p out circuit 98 5 2 3 Maintain the rotary table and drive assembly 99 5 2 4 Replacing the PLC battery 99 5 2 5 Drag brake settings 100 5 2 6 Adjusting the drag brake 100 5 3 RECOMMENDED LUBRICANTS 10...

Page 12: ...age iv CM6200 Operating Manual TABLE OF CONTENTS CONTINUED CHAPTER SECTION PAGE APPENDIX A ASSEMBLY DRAWINGS 119 APPENDIX B SCHEMATICS 159 APPENDIX C SDS 177 APPENDIX D MR J4 SERVO AMPLIFIER MANUAL 17...

Page 13: ...30 3 13 Jacking screw 30 3 14 Jacking screw groove leveling foot 31 3 15 Non leveling jacking foot 32 3 16 OD mount leg assembly 33 3 17 OD mount centering plate 34 3 18 OD chucking leg dimensions 35...

Page 14: ...4 22 Incremental move screen 68 4 23 Absolute move screen 69 4 24 Incremental velocity move screen 70 4 25 Absolute velocity move screen 71 4 26 Status screen 74 4 27 System info screen 75 4 28 DRO b...

Page 15: ...N 62537 137 A 19 Plate swivel milling head assembly P N 63250 138 A 20 Milling head and drawbolt assembly P N 73354 139 A 21 Milling head 2 29 32 brg 8 stroke 50 taper P N 72277 140 A 22 Milling head...

Page 16: ...P N C00088 168 B 10 MR J3 schematic sheet 3 P N C00088 169 B 11 MR J4 layout P N A00093 170 B 12 MR J4 control panel assembly exterior P N B000394 171 B 13 MR J4 control panel assembly interior P N B...

Page 17: ...ical CM6200 identification 45 3 11 Leveling chuck foot identification 48 4 1 Milling head mounting plate identification 58 4 2 Maximum SFPM SMPM capable from the hydraulic motor at 60 Hz and 20 gpm 76...

Page 18: ...Page x CM6200 Operating Manual This page intentionally left blank...

Page 19: ...ntal product information to aid in setup operation and maintenance tasks Read this entire manual to familiarize yourself with the CM6200 before attempting to set it up or operate it 1 2 SAFETY ALERTS...

Page 20: ...g a risk assess ment of each job site before setting up and operating this machine Intended use Use this machine in accordance with the instructions and precautions in this manual Do not use this mach...

Page 21: ...nd it During testing the machine produced the following sound lev els1 Sound power 74 4 dBA Operator sound pressure 65 2 dBA Bystander sound pressure 65 3 dBA Hazardous environments Do not operate the...

Page 22: ...are mounted in a fixed location during operation and are considered to be a complete self contained machine Stationery Machine Tools achieve the rigidity needed to accomplish material removal operati...

Page 23: ...fall paths involved in lifting and rigging operations I have taken pre cautions to keep workers away from the identified fall path I considered how this machine operates and identified the best place...

Page 24: ...sing contact CLIMAX immediately for replacements TABLE 1 3 LABEL IDENTIFICATION P N 27462 Single point machine warn ing label P N 29152 Mass plate P N 29154 CLIMAX serial number year and model number...

Page 25: ...otection warning label P N 59039 Lift point warn ing label P N 59044 Read opera tors manual warning label P N 62884 Flange facer impact hazard danger label P N 64156 Counter weight and arm position la...

Page 26: ...label see the manual for lift instructions P N 80510 Warning label danger of cut fingers in rotat ing blade P N 82157 Torque warning label P N 82163 Warning label hand crush P N 82164 Warning label b...

Page 27: ...9 1 8 ITEMS REQUIRED BUT NOT SUPPLIED Torque wrench Level Dial indicator Support blocks Scab plates steel plates that are bolted clamped or welded to the flange or web of a workpiece to mount or secu...

Page 28: ...Items required but not supplied Page 10 CM6200 Operating Manual This page intentionally left blank...

Page 29: ...needed components The CM6200 is designed to perform various machining operations on a circular workpiece such as a flange The machine consists primarily of a rotary table with a precision circular bea...

Page 30: ...l machining applications Chucking design Tubular rigid chucking system with a level in place and adjustable feet designed for simple and speedy setup Modular design Allows many of the machine componen...

Page 31: ...lable hydraulic motor when single point machining that is flange facing TABLE 2 1 ROTARY TABLE SPEEDS WHEN SINGLE POINT MACHINING Motor P N Hydraulic motor displacement Maximum speeda at 20 gpm a Maxi...

Page 32: ...RM HOIST RINGS HOIST RINGS DRAG BRAKE ADJUSTABLE CHUCK ASSEMBLY RADIAL TRAVEL BRAKE AXIAL TRAVEL BRAKE 6 1 7 5 8 9 10 11 3 2 4 TABLE 2 2 ID MOUNT IDENTIFICATION Number Component 1 Machining arm 2 Hose...

Page 33: ...Machine components P N 63674 Rev 9 Page 15 FIGURE 2 2 ROTATION DIRECTION FOR HYDRAULIC MOTOR ROTATION TABLE AND MILLING HEAD PORT A PORT B PORT A PORT B...

Page 34: ...SAFETY SHIELD CENTERING PLATE LEVELING PLATE COUNTERWEIGHT ASSEMBLY ADJUSTABLE CHUCK ASSEMBLY MACHINING ARM HOIST RINGS 6 1 7 5 8 3 2 4 TABLE 2 3 OD MOUNT COMPONENT IDENTIFICATION Number Component 1 A...

Page 35: ...6 3444 mm MINIMUM SWING CLEARANCE P73 5 1867 mm MINIMUM MILLING DIAMETER CENTER OF MILL P189 0 4800 mm MAXIMUM MILLING DIAMETER CENTER OF MILL P78 9 2004 mm MINIMUM CHUCKING DIAMETER WITHOUT LOCKNUTS...

Page 36: ...D MOUNT MACHINE DIMENSIONS 2 2 120 mm CLEARANCE W TOOLHEAD FULLY RETRACTED 210 4 5344 mm MAX 145 5 3696 mm MIN 5 0 127 mm 10 0 254 mm 42 4 1077 mm 2 0 48 3 mm P199 0 5055 mm MAXIMUM MACHINING DIAMETER...

Page 37: ...ion leading to damage to the machine or injury to personnel TABLE 2 4 SUBASSEMBLY WEIGHTS Subassembly Part Number Weight Rotary table 62028 3 493 lb 1584 kg Machining arm 72676 1 310 lb 594 kg Counter...

Page 38: ...Specifications Page 20 CM6200 Operating Manual FIGURE 2 6 HYDRAULIC MOTOR SPECIFICATIONS For temperature ranges of operating conditions refer to the HPU manual...

Page 39: ...NTING THE MACHINE VERTICALLY 41 3 8 4 OD MOUNTING THE MACHINE VERTICALLY 42 3 8 5 INVERTED MOUNTING 43 3 9 CENTERING AND LEVELING THE MACHINE 47 3 10 FIXATION OF ID MOUNT 48 3 11 INSTALLING CABLES 50...

Page 40: ...enough room to position the entire machine on or near the work piece All connections are correctly attached 3 2 2 Assessing the work area The CM6200 often is used in dangerous locations in elevated po...

Page 41: ...ON Lift the machine only by the hoist rings marked by Figure 3 1 The sub assemblies can be disassembled and individually lifted by the labeled lifting eyes on each sub assembly DANGER Do not lift the...

Page 42: ...ly to prevent hazards Vertical rigging The lifting assembly as shown in Figure 3 4 enables the machine to hang level with the ID chuck or to hang level with the OD chuck FIGURE 3 4 LIFTING ASSEMBLY ON...

Page 43: ...atal injuries to personnel Pay special attention to vertical flange installations Chucking feet must be secured to the workpiece Setup fingers and safety weld plates should be utilized when possible T...

Page 44: ...e an overview of the processes involved with setting up the CM6200 in the ID mounting configuration The OD mount setup is listed in Section 3 5 3 on page 33 Do the following to mount the machine to th...

Page 45: ...stallation process 4 Position the counterweight and machining arm in location slots that are equidistant from the machine center with the same location number in order to balance the machine 5 Secure...

Page 46: ...ny machining operations Horizontal to vertical lifting When lifting the CM6200 from horizontal to vertical position make sure that the load tested lifting assembly Figure 3 9 is correctly installed on...

Page 47: ...ree socket head set screw P N 74499 M12 x 40mm long to 29 ft lbs 40 Nm shown circled in Figure 3 11 to lock the jacking screw position Loosen this screw before making additional jacking adjustments or...

Page 48: ...the non leveling legs This arrangement may provide additional stability to the machine depending on the nature of the workpiece NOTICE If the workpiece will not accommodate the double plane setup then...

Page 49: ...caps The non leveling chuck feet must be mounted to the lower leg end caps 7 Secure the chuck arms to the hub with the bolts supplied 8 After attaching the end cap to the chuck extensions leg install...

Page 50: ...URE 3 15 NON LEVELING JACKING FOOT TABLE 3 5 ID CHUCKING LEG SETUP SPECIFICATIONS Range Workpiece inside diameter 12 5 318 mm standoff 17 5 445 mm standoff 27 5 699 mm standoff 2 5 64 mm leg 5 127 mm...

Page 51: ...53 9 3 782 3 909 mm 1 1 0 0 1 16 153 9 58 9 3 909 4 036 mm 1 1 0 1 1 17 158 9 163 9 4 036 4 163 mm 1 0 1 0 0 18 163 9 168 9 4 163 4 290 mm 1 0 1 1 0 19 168 9 173 9 4 290 4 417 mm 1 0 1 0 1 20 173 9 17...

Page 52: ...4 3 058 mm 0 1 0 0 3 112 5 2 858 mm 122 38 3 108 mm 130 4 3 312 mm 0 1 0 1 4 122 5 3 112 mm 132 38 3 362 mm 140 4 3 566 mm 0 0 1 0 5 127 5 3 239 mm 137 38 3 489 mm 145 4 3 693 mm 1 1 0 0 6 137 5 3 493...

Page 53: ...ing arm should be mounted first The CM6200 machining arm is attached to the rotary table with clamps Two of the clamps closest to the center hole of the table attach directly to the CM6200 rotary tabl...

Page 54: ...2 Repositioning the machining arm The machining arm is incrementally adjustable for versatile positioning and to clear obstructions Do the following to reposition the machining arm 1 Loosen the screw...

Page 55: ...surfaces Each numbered slot in the machining arm coincides with a numbered bolt position on the counterweight arm Make sure that you move the counterweight one bolt space for each slot you move the ma...

Page 56: ...d for machining operations Do the following to install the milling head 1 Hoist the adapter plate into place and align 2 Mount the adapter to the radial slide saddle and bolt in place 3 Align milling...

Page 57: ...e drive system from excessive force The counterweight also provides stability to the machine that creates more precise machining tolerances The counterweight has multiple settings and can be positione...

Page 58: ...ds 3 8 1 ID mounting the machine horizontally Do the following to ID mount the machine to a horizontal flange 1 Set the ID mounting chuck feet to a dimension that is 0 01 0 25 mm less per leg than the...

Page 59: ...3 26 to 230 ft lbs 310 Nm 3 8 3 ID mounting the machine vertically When mounting the CM6200 in the vertical position make sure that the lifting assembly P N 68425 in Figure 3 9 on page 28 is properly...

Page 60: ...lling from the workpiece potentially causing serious injury or death 7 Remove all tools from workpiece and machine 8 Center and level the machine on the flange as described in Section 3 9 on page 47 3...

Page 61: ...position The horizontal mount proce dure should be followed to mount the inverted ID mount Use extreme caution when rotating the machine DANGER Swinging or falling machinery could seriously injure or...

Page 62: ...e 3 27 2 Place a piece of plywood by the machine for it to rest on after lifting Figure 3 28 3 Attach the lifting device straps to four lifting eyes on the body of the chuck two on opposite sides as s...

Page 63: ...re 3 29 6 Raise the machine high enough to place blocks under the turning arm and chuck body 7 Lower the machine onto the blocks see Figure 3 30 If using two cranes re attach the straps to the bottom...

Page 64: ...lear of the floor and blocks see Figure 3 31 9 Remove the blocks 10 Raise the lower straps until the machine is completely inverted see Figure 3 32 11 Replace the blocks under the turning arm and coun...

Page 65: ...en machining outdoors or in direct sunlight be aware that temperature changes can affect final tolerances CLIMAX recommends setting up temporary shade in these circumstances Do the following to precis...

Page 66: ...t step 2 through step 6 until the machine is aligned 7 Fix the machine in place according to Section 3 10 on page 48 for ID and Section 3 5 3 on page 33 for OD 8 Recheck machine alignment If any adjus...

Page 67: ...nticipated jacking bolt clamping force which may allow the machine to shift or fall out of the workpiece Do the following to install the ID mount 1 Tighten all the leveling jacking screws to a minimum...

Page 68: ...jacking screw and it should be tightened when the machine is centered and the jacking screws are torqued to spec The intent of using the internal locking nut is to help prevent back off of the jackin...

Page 69: ...ed to the machine There is a danger of damaging the servo drive if the motor is disconnected when the HPU is powered up CAUTION To avoid damaging the power lines ensure that they are clear of moving p...

Page 70: ...Installing cables Page 52 CM6200 Operating Manual This page intentionally left blank...

Page 71: ...EAD EQUIPMENT 76 4 3 3 SAFE OPERATING RANGES 76 4 3 4 REPLACING THE MILLING ASSEMBLY 79 4 3 5 PERFORMING CIRCULAR MILLING 80 4 4 GRINDING OPTION 81 4 4 1 GRINDING ATTACHMENT SETUP 81 4 4 2 OPERATION 8...

Page 72: ...all people near the machine Before starting the machine always check for the following items The machining arm and counterweight are secured to the turntable with a torque of 110 ft lb 150 Nm CAUTION...

Page 73: ...ning arm Do the following to adjust the milling head and spindle 1 Loosen the lock 2 Adjust the milling head and spindle 3 Use the DRO to position the milling head 4 Tighten the lock before machining...

Page 74: ...he linear slide rail can serve as a reference point that is perpendicular to the milling arm 3 Extend the indicator out to make contact with the bot tom of the machine ram sur face see Figure 4 3 4 Wi...

Page 75: ...For further information contact CLIMAX 6 Note the dial reading If it is more than 0 001 0 03 mm out of tramming tolerance do the following a Loosen the four cap screws so that they are just slightly...

Page 76: ...ed in the center of the tramming plate shown in Figure 4 5 b Adjust the Y axis screws until the indica tor reads within 0 001 0 03 mm See Figure 4 6 TABLE 4 1 MILLING HEAD MOUNTING PLATE IDENTIFICATIO...

Page 77: ...the housing does not move during tensioning 9 Reinstall the spindle drive motor if necessary When ready to operate the machine note the machined surface after the first pass A crosshatched pattern is...

Page 78: ...es of rotation in the plus direction A move from 0 to 90 degrees in the minus direction results in 270 degrees of rotation in the minus direction with the final position still being the absolute 90 de...

Page 79: ...ar The default setting will be set for all of the parameters of the machine FIGURE 4 12 OPENING SPLASH SCREEN AT STARTUP NOTICE User settings are not saved when the unit is shut off Following the Spla...

Page 80: ...by pressing the RESET button to navigate to the main menu FIGURE 4 13 RESET START SCREEN If the E Stop button is still depressed when the machine is powered up the blue start RESET button will not be...

Page 81: ...EEN FIGURE 4 15 POP UP SCREEN AFTER EMERGENCY STOP INITIATION This pop up screen also appears after the E STOP is initiated After the operator resolves the fault the Start System Screen will appear Ot...

Page 82: ...y be reset After resetting the system the HMI will redirect to the Main Menu Screen CAUTION Do not disconnect any cables from the system while energized This will result in damage to the system WARNIN...

Page 83: ...of the buttons will also activate sub screens for input Further explanations on each screen are provided below Buttons are color coded to assist with recognition for different modes of operation Incr...

Page 84: ...lable in other screens but is edited here Auto Feed Reduction AFR is ENABLED by default This feature helps protects the machine from being damaged by overload If the machine encounters resis tance fro...

Page 85: ...retentive and are held in permanent memory even when the machine is discon nected from power If any of the setup parameters have not been set to a valid number the message shown in Figure 4 21 will be...

Page 86: ...L MOVE SCREEN Incremental moves are relative to the current position in the direction and speed you enter An incremental move will always be the distance entered in the input increment field and in th...

Page 87: ...absolute zero position which can be anywhere along the circumference of a 360 degree circle Not to be confused with incremen tal moves the absolute move will move to the destination entered at the di...

Page 88: ...NCREMENTAL VELOCITY MOVE SCREEN Note the color code and the identification dot for the increment versus the absolute velocity movement screens To move to any position incrementally hold down the JOG b...

Page 89: ...E 4 25 ABSOLUTE VELOCITY MOVE SCREEN Note the color and the identification dot for absolute coordinates The function is the same as the incremental screen but the move will be in relation to the absol...

Page 90: ...Control pendant Page 72 CM6200 Operating Manual 4 2 9 Pop up screens...

Page 91: ...Control pendant P N 63674 Rev 9 Page 73 4 2 10 Alarm history screens...

Page 92: ...the CM6200 FIGURE 4 26 STATUS SCREEN The status screen is normally only used for troubleshooting or when contacting CLIMAX for help with issues NOTICE Based on the requested configuration of the CM62...

Page 93: ...in functions will be enabled and visible As a result some functions shown above may not be available on the control pendant supplied 4 3 CIRCULAR MILLING WARNING Prior to machining make a visual inspe...

Page 94: ...or most operations simply turn on the DRO and press the ZERO ABS button to zero the display before making any adjustments to the milling head The DRO will display the correct distances in the digital...

Page 95: ...smpm 302 sfpm 92 1 smpm 250 sfpm 76 2 smpm 202 sfpm 61 6 smpm 161 sfpm 49 1 smpm 129 sfpm 39 3 smpm 100 sfpm 30 5 smpm 80 sfpm 24 4 smpm 4 102 mm 777 sfpm 236 8 smpm 603 sfpm 183 8 smpm 500 sfpm 152 4...

Page 96: ...4 sfpm 101 8 smpm 268 sfpm 81 7 smpm 214 sfpm 65 2 smpm 166 sfpm 50 6 smpm 133 sfpm 40 5 smpm 5 127 mm 806 sfpm 245 7 smpm 626 sfpm 109 8 smpm 518 sfpm 157 9 smpm 418 sfpm 127 4 smpm 334 sfpm 101 8 sm...

Page 97: ...er plate from the cross slide plate see Figure 4 38 which is also seen in Fig ure A 11 on page 130 3 Attach the single point tool head assembly P N 62984 to the cross slide plate 4 Attach the tool hea...

Page 98: ...ing 4 Stop the table 5 Advance the spindle toward the work until the cutter just contacts the sur face Reset the DRO 6 Feed the spindle away from the piece so that it is no longer over the surface tha...

Page 99: ...etup The grinding attachment uses the same mount adapter as the single point tool option See the exploded views Figure A 16 on page 135 Figure A 17 on page 136 or Figure A 18 on page 137 for more info...

Page 100: ...the surface finish 4 Make any necessary adjustments to the grinder settings 5 When the finish is satisfactory continue grinding the surface as required WARNING Stay clear of the grinder during operati...

Page 101: ...e turning arm in place of the milling head See Section 4 5 2 on page 89 The pneumatic feed box and adapter mounts on the end of the ball screw on the turning arm The rotary union assembly mounts to th...

Page 102: ...STALL AND REMOVE BUSHING SLEEVE PORT 3 SIDE TO FEED BOX PORT 1 SIDE TO AIR VALVE 3 1 5 6 7 8 9 10 2 4 TABLE 4 6 ROTARY UNION CONFIGURATION COMPONENT IDENTIFICATION Number Component 1 Pneumatic conditi...

Page 103: ...mber Component 1 1 8 tubing from port 3 2 1 4 tubing from air valve 3 Mounts to the ball screw on the end of the turning arm 4 Mounting arrow shows the feed direction MOUNTS TO THE BALL SCREW ON THE E...

Page 104: ...00 Operating Manual FIGURE 4 34 PNEUMATIC FEED BOX LOCATION TABLE 4 8 PNEUMATIC FEED BOX IDENTIFICATION Number Component 1 Pneumatic feed box 2 Spring point tool holder bracket SPRING POINT TOOL HOLDE...

Page 105: ...ication of the numbered parts FIGURE 4 35 ID MOUNT CONFIGURATION OF THE ROTARY UNION TABLE 4 9 ID MOUNT CONFIGURATION IDENTIFICATION Number Component 1 Bolts to the CM6200 turntable plate rotating 2 B...

Page 106: ...ount referring to Figure 4 37 1 Replace the M8 x 45 mm SHCS with M8 x 25 mm SHCS Keep the same cam in place 2 Invert the torque restrain arm and re bolt it to the turntable TABLE 4 10 OD MOUNT CONFIGU...

Page 107: ...point tool head assembly 1 Completely de energize and lock out the power source TABLE 4 11 OD MOUNT ROTARY UNION CONFIGURATION IDENTIFICATION Number Component 1 M8 x 25 mm socket head cap screw SHCS...

Page 108: ...ead assembly to the adapter see Figure 4 39 which is seen in Figure A 27 on page 146 4 5 3 Installing the hydraulic drive in the single point configuration Do the following to set up the hydraulic dri...

Page 109: ...ed to the HPU but not attached to the machine There is a danger of damaging the servo drive if the motor is disconnected when the HPU is powered up See Section 4 5 on page 82 for how to install the pn...

Page 110: ...th the two M6 x 1 0 x 60 mm SHCS When mounting check that the arrow is pointing in the intended feed direction see Figure 4 43 4 5 5 Reversing the feed box direction The feed box only feeds in one dir...

Page 111: ...in Figure 4 45 FIGURE 4 46 FEED BOX MODE POSITIONS In neutral the tool may be manually fed in either direction Hoses connected to the feed box should have approximately 12 304 8 mm of extra length co...

Page 112: ...e per revolution turn the feed rate adjustment dial to the minimum feed or to the desired setting if known 5 Using the feed on off valve turn on the feed and adjust the feed rate for the desired cut N...

Page 113: ...swing of the machining arm during operation 4 6 DISASSEMBLY WARNING If not properly secured this machine can fall and cause fatal injuries to personnel Pay special attention to vertical flange instal...

Page 114: ...the jacking screws If in the vertical or inclined position leave the lower stacking bolt in position and loosen the other jacking screws This keeps the machine from dropping when all other jacking fe...

Page 115: ...CUTTING POORLY 105 5 4 4 THE MACHINE ISN T CUTTING FLAT 106 5 4 5 THE SPINDLE ISN T TURNING 106 5 4 6 THE MACHINE STOPS SUDDENLY 106 5 4 7 THE CUT DEPTH CHANGES INVOLUNTARILY 106 5 4 8 THE SERVO SYST...

Page 116: ...the PCU drop out circuit 1 Check that the PCU is connected to an air supply and to the CM6200 2 Check that the air supply lock out is open pulled up 3 Press the START button 4 Slowly open the PCU spee...

Page 117: ...NOTICE The programmable logic controller PLC in the CM6200 control system uses a battery to maintain the program when mains power is turned off This battery must be replaced periodically or the PLC pr...

Page 118: ...resistance to the gear to reduce backlash and maintain steady velocity in vertical or special tooling applications 5 2 6 Adjusting the drag brake For vertical applications do the following to adjust...

Page 119: ...ween hardware and slides clean of chips and debris so the machine can move freely Horizontal single point machining or milling applications The drag brake must be disengaged when single pointing Howev...

Page 120: ...ilure to use the appropriate lubricants can result in damage and premature machine wear CAUTION Avoid damage premature machine wear and protect your warranty by using only approved lubricants TABLE 5...

Page 121: ...20 cc Once per year ID Wiper Seal on Rotary Table 3M Silicone Paste 051135 08946 N A N A 3 cc Once per year Main Table Gear Reducer Mobil 629 Gear Oil N A 150 40C 158 100C N A Lubricated for life unde...

Page 122: ...serious injury or death Do the following to lubricate the main ring gear while referring to Figure A 1 on page 120 1 Remove the encoder guard 2 Remove the servo motor reducer and drive pinion assembl...

Page 123: ...e drag brake is disengaged Section 5 2 6 on page 100 5 4 2 The machine isn t feeding or is slow and unresponsive If the machine isn t feeding properly check the following The pneumatic connections fro...

Page 124: ...11 on page 50 No error messages show on the pendant Section 4 2 2 on page 60 The fluid level is sufficient in the HPU Refill if necessary The spindle is clear of any elements 5 4 6 The machine stops...

Page 125: ...MR J3 servo amplifier error codes P N 63674 Rev 9 Page 107 5 5 MR J3 SERVO AMPLIFIER ERROR CODES...

Page 126: ...MR J3 servo amplifier error codes Page 108 CM6200 Operating Manual...

Page 127: ...MR J3 servo amplifier error codes P N 63674 Rev 9 Page 109...

Page 128: ...MR J3 servo amplifier error codes Page 110 CM6200 Operating Manual...

Page 129: ...MR J3 servo amplifier error codes P N 63674 Rev 9 Page 111...

Page 130: ...MR J3 servo amplifier error codes Page 112 CM6200 Operating Manual...

Page 131: ...MR J3 servo amplifier error codes P N 63674 Rev 9 Page 113...

Page 132: ...MR J3 servo amplifier error codes Page 114 CM6200 Operating Manual...

Page 133: ...MR J3 servo amplifier error codes P N 63674 Rev 9 Page 115 For MR J4 servo amplifier error codes see Appendix D...

Page 134: ...MR J3 servo amplifier error codes Page 116 CM6200 Operating Manual This page intentionally left blank...

Page 135: ...Store the CM6200 in its original shipping container Keep all packing materials for repackaging the machine 6 1 1 Short term storage Short term storage is defined as three months or less For short term...

Page 136: ...r Replace according to manufacturer instructions 3 Store the shipping container in an environment out of direct sunlight with temperature 70 F and humidity 50 6 2 SHIPPING The CM6200 can be shipped in...

Page 137: ...35 FIGURE A 17 GRINDER FOR SP CM6200 WITH GEAR REDUCER ASSEMBLY P N 63240 136 FIGURE A 18 GRINDER FOR SP PNEUMATIC P N 62537 137 FIGURE A 19 PLATE SWIVEL MILLING HEAD ASSEMBLY P N 63250 138 FIGURE A 2...

Page 138: ...RAWN 11 25 9 24 23 17 6 7 15 16 11 21 22 13 14 1 5 4 18 20 2 3 8 19 10 7 12 STAMP 5 850 1 26 ALIGN WITH HIGH SIDE OF RING GEAR YELLOW MARK ANTI SEIZE LOCTITE 242 BOTTOM ONLY MOLYKOTE III NOTES 1 ADJUS...

Page 139: ...X 60MM SHCS 57874 2 11 SCREW 16MM DIA X 20MM X M12 X 1 75 SHLDCS 58202 16 12 SCREW M8 X 1 25 X 45MM SHCS 59349 4 13 WASHER M8 FLTW 16MM OD 1 6MM THICK 59432 4 14 CLAMP ARM PINNED 62601 3 15 CLAMP SAFE...

Page 140: ...Page 122 CM6200 Operating Manual FIGURE A 3 ROTARY TABLE ASSEMBLY P N 96031 7 4 2 5 3 1 6 8 1 2 SEE SHEET 2 FOR PARTS LIST TORQUE SPECIFICATIONS MOLYKOTE 111 RED GREASE...

Page 141: ...LOCKWISE AROUND THE BEARING TIGHTEN THE BOLTS USING THE FOLLING PATTERN IN THREE STAGES 70 FT LBS 140 FT LBS 200 FT LBS NOTE TORQUE VALUES ARE FOR LUBRICATED FASTENERS ENSURE TO USE BLUE LOCTITE DURIN...

Page 142: ...1 6 4 X 4 X 4 SCREW COVER SC JUNCTION BOX N A 1 7 ASSY HARDWARE HOSE AND ENCODER GUARD CM6200 63180 1 8 KNOB FOUR ARM 2 DIA X 3 8 16 THREAD 3 4 L MODIFIED 55463 1 8 1 LABEL WARNING LOCKOUT ELECTRICAL...

Page 143: ...4 1 PLATE LIFTING CM6200 68423 1 2 SCREW M24 X 3 0 X 80MM SHCS 68426 2 3 TAG BELOW THE HOOK LIFTING INFO AND SERIAL NUMBER 69422 1 4 LABEL WARNING LIFT POINT ROUND 1 5 59039 2 9 9 1 4 3 2 BELOW THE H...

Page 144: ...460 LBS 210 KG 63954 4 7 SCREW M12 X 1 75 X 40mm SSSFP 74499 24 8 LABEL WARNING LIFT SUB ASSY ONLY GRAPHIC 2 X 3 79385 16 9 LABEL CAUTION TORQUE 150 FT LBS 203 N M GRAPHIC 3 X 1 7 82157 24 10 CAP END...

Page 145: ...6 SCREW M16 X 2 0 X 40mm SHCS 44905 4 7 SCREW M16 X 2 0 X 55mm SHCS 46222 2 8 SCREW M16 X 2 0 X 80 SHCS 58106 2 9 WASHER SPRING WAVE 1 235 OD X 961 ID X 014 58244 1 10 JAW ADJUSTER CM6200 63582 1 11 B...

Page 146: ...TY ITEM SCREW 1 4 20 X 5 8 SHCS 12418 1 1 PIN ROLL 3 16 X 1 12959 2 2 WASHER THRUST 1 250 ID X 1 937 OD X 060 16666 1 3 GRIPPER SERRATED HSS 1 DIAM X 1 2 CBORED 41644 1 4 WASHER SPRING WAVE 1 235 OD X...

Page 147: ...200 60751 8 11 PLATE WASHER OD MOUNT FF8200 60752 8 12 STUD HOLD DOWN M24 OD MOUNT FF8200 60753 8 13 STANDOFF 5 INCH OD MOUNT FF8200 60755 8 14 SCREW M24 X 3 0 X 60MM SSSFP 60756 48 15 NUT M24 X 3 0 F...

Page 148: ...erating Manual FIGURE A 11 MACHINING ARM ASSEMBLY P N 72676 DETAIL A SCALE 1 10 A 36 2 33 7 17 32 2 30 34 13 25 14 12 3 1 5 11 20 10 3 1 27 4 8 26 22 23 29 27 28 19 22 26 8 37 39 9 35 32 10 31 10 10 1...

Page 149: ...ER MILLING HEAD 62321 1 19 WASHER SPRING BELLEVILLE 1 8 ID X 1 4 OD X 013 THK 62376 12 20 ROD POLYURETHANE 1 4 DIA X 1 4 LENGTH 95 SHORE A 62378 2 21 SEAL FELT 16MM BALL SCREW 1 015 OD MILLING HEAD 62...

Page 150: ...ACHINING ARM MILLING HEAD TRAM ASSEMBLY P N 63124 PARTS LIST DESCRIPTION PART No QTY ITEM PIN DOWEL 1 2 DIA X 1 1 2 11832 4 1 SCREW M12 X 1 75 X 25mm SHCS 42094 6 2 PLATE MILL TRAMMING CM6200 62921 1...

Page 151: ...SHER FIXTURING 21MM ID X 35MM OD X 3MM CASE HARDENED 57888 8 5 SCREW M20 X 2 5 X 55mm SHCS 58743 4 6 LABEL WARNING LIFT POINT ROUND 1 5 59039 3 7 ARM COUNTERWEIGHT CM6200 62059 1 8 COUNTERWEIGHT CM620...

Page 152: ...ASSEMBLY P N 63106 ASSY EXTENSION MILLING HEAD 65840 1 5 WASHER 3 4 FLATW 12339 32 4 SCREW M16 X 2 X 60mm SSSFP 57348 16 3 SCREW M20 X 2 5 X 40MM SHCS 58203 32 2 BRACKET FACE MOUNT CM6200 62887 4 1 PA...

Page 153: ...801 1 2 X 1 2 NPTMS ENDS X 180 32196 1 6 SCREW M12 X 1 75 X 40mm SHCS 35215 4 7 LABEL DIRECTION OVAL HANDLE BALL VALVE 35772 1 8 VALVE BALL 1 2NPTF OVAL HANDLE 36328 1 9 FTG ADPTER 3 8 BSPP MALE X 3 8...

Page 154: ...BING PARFLEX 1 2 OD X 3 8 ID POLYURETHANE BLACK X 130 48281 130 4 SPLINE COUPLING BREVINI 51928 1 5 ARBOR GRINDING WHEEL CBN 10MM SHANK M8 THREAD 62624 1 6 FTG ELBOW 1 2 NPTM x 1 2 O D PRESTOLOK TUBIN...

Page 155: ...ON P N QTY ITEM ARBOR GRINDING WHEEL CBN 10MM SHANK M8 THREAD 62624 1 1 FTG ELBOW 1 2 NPTM x 1 2 O D PRESTOLOK TUBING 62681 1 2 FTG ADAPTER 12MM TUBE X 1 2 PRESTOLOK TUBING 62682 1 3 ASSY GRINDING ATT...

Page 156: ...A X 1 20398 4 1 SCREW M12 X 1 75 X 30mm SHCS 40697 8 2 PIN DOWEL 3 4 DIA X 3 46981 1 3 PLATE SWIVEL MILLING HEAD RAM SIDE 53624 1 4 SCREW M12 X 1 75 X 50MM SHCS 64281 2 5 1 RING CLAMP SWIVEL PLATE MIL...

Page 157: ...15 5 INCH V FLANGE DRAWBOLT M24X3 X 15 5 METRIC V FLANGE 62330 62331 62845 62846 1 1 MILLING HEAD 2 29 32 BRG 8 STROKE 50 TAPER 72277 1 2 2 1 COMPLETE ASSY MILLING HEAD W DRAWBOLT P N CONFIGURATION 62...

Page 158: ...PER P N 72277 46 45 47 42 19 62 23 35 41 4 6 7 40 10 59 31 36 22 54 22 53 49 60 55 56 50 55 55 60 37 34 26 8 20 32 33 28 11 11 24 2 18 57 18 55 21 61 68 3 9 3 27 3 3 9 13 14 5 51 47 1 1 20 25 65 45 15...

Page 159: ...SQ X 1 00 SQ BOTH ENDS 20273 1 14 NUT MAIN BRG PRELOAD 28219 1 15 PLATE MASS CE 29152 1 16 SCREW M12 X 1 75 X 35mm SHCS 30207 2 17 RING SNAP 1 3 16 ID 30MM 33777 2 18 SCREW M16 X 1 5 X 20mm SSSFP 346...

Page 160: ...1 OD 45MM 62322 1 51 BRACKET DRO BLOCK SPINDLE 2 75 BRG 62324 1 52 WASHER SPRING BELLEVILLE 1 8 ID X 1 4 OD X 013 THK 62376 12 53 ROD POLYURETHANE 1 4 DIA X 1 4 LENGTH 95 SHORE A 62378 2 54 SEAL FELT...

Page 161: ...ILLING HEAD EXTENSION ASSEMBLY P N 65840 SCREW M12 X 1 75 X 110 MM SHCS 61164 2 5 BOLT EYE M10 X 1 5 X 17MM LG 59625 1 4 SCREW M12 X 1 75 X 55 SHCS 46078 6 2 EXTENSION MILLING HEAD 65839 1 1 PARTS LIS...

Page 162: ...4 CM6200 Operating Manual FIGURE A 25 SERVO DRIVE ASSEMBLY P N 83156 PARTS LIST DESCRIPTION P N QTY ITEM ASSY SERVO DRIVE GEARBOX CM6200 62032 1 1 CONFIDENTIAL PROPERTY OF CLIMAX PORTABLE MACHINING WE...

Page 163: ...W M8 X 1 25 X 20mm SHCS 50458 4 4 SPLINE COUPLING BREVINI 51928 1 5 FLANGE ADAPTER 110mm PILOT SPECIAL DRILLING 51930 1 6 REDUCER 162 8 1 PLANETARY 63731 1 7 FACTORY SUPPLIED BREATHER 1 8 KEY 8mm X 7m...

Page 164: ...rating Manual FIGURE A 27 SINGLE POINT EU ASSEMBLY P N 83100 46 6 50 51 1 16 17 22 15 53 49 34 11 40 12 43 45 39 37 41 36 23 18 8 1 5 33 38 14 21 19 24 25 55 47 7 48 54 9 4 52 56 20 2 30 31 29 32 28 3...

Page 165: ...ADAPTER 1 8 TUBE F PRESTOLOCK X 1 4 NPTM STRAIGHT 63083 1 25 ADAPTER SINGLE POINT TOOL HEAD TO MILLING ARM 62984 1 26 ASSY ADAPTER FEEDBOX CM6200 62994 1 27 PIN ROLL 3 16 DIA X 3 4 10850 1 28 SCREW M...

Page 166: ...Page 148 CM6200 Operating Manual FIGURE A 29 SINGLE POINT ASSEMBLY P N 62037 17 25 25 8 5 18 18 18 2 3 29 23 20 16 FOR SHAFT ADAPTER REMOVAL 1 21 15 14 9 10 4 11 29 22 18 1 18 12 28 7 27 26 19 6 24 24...

Page 167: ...m SHCS 50458 4 12 SCREW M12 X 1 75 X 150mm SHCS 50907 1 13 TOOL HEAD ASSY FF LINE 57781 1 14 WASHER FIXTURING 21MM ID X 35MM OD X 3MM CASE HARDENED 57888 1 15 FEED BOX PNEUMATIC REMOTE FEED ADJUST 586...

Page 168: ...CONFIG ONLY SCREW M8 X 1 25 X 25MM SHCS 42494 3 4 CAM FEED 58039 1 5 UNION ROTARY HYDRAULIC 4 CHANNEL 1 2 NPTF PORTS MOD 58751 1 6 SCREW M8 X 1 25 X 45MM SHCS 59349 3 7 NOT SHOWN FOR OD CONFIG ONLY S...

Page 169: ...ATION SHUTOFF WITH 1 2 INCH PORTS 96732 1 5 AW40 N04 8Z B SMC SP REGULATOR FILTER W GAGE SIGHT GLASS 7 125 PSI 1 2 PORTS 96733 1 6 AF40P 060S SMC SP FILTER PNEUMATIC 96735 1 6 1 GC3 10AS X2103 SMC SP...

Page 170: ...LE AIR 28494 1 4 FTG ELBOW 1 4 NPTM X 1 4 NPTM 90 DEG 30502 2 5 FTG QUICK COUPLER 3 8B 1 4 NPTM MALE AIR 30936 1 6 LABEL DIRECTION OVAL HANDLE BALL VALVE 35772 1 7 FTG QUICK COUPLER 3 8B 1 2 NPTM FEMA...

Page 171: ...P N QTY ITEM FTG QD NIPPLE 1 2B ISO 16028 STYLE X SAE 10F 63427 2 1 DUST CAP QD NIPPLE 1 2B ISO 16028 STYLE RUBBER 63428 2 2 HOSE ASSY 451 1 2 X SAE 10M X 36 STRAIGHT FITTINGS CE 83181 2 3 3 2 1 NOTES...

Page 172: ...STUD THREADED M16 X 2 X 100MM FULL THREAD 8 62613 NUT M16 X 20 JAMN 2 46232 BAR BRAKE CLAMP 2 54165 SHOE BRAKE 16M CIRCULAR MILL Milling 2 62255 SLIDE RAIL THK SHS25 442MM LG PRELOADED METAL SCRAPERS...

Page 173: ...LE X SAE 10M 1 29066 BIT TOOL HSS 3 4 X 50 LH FINISH SINGLE SC 1 29067 BIT TOOL HSS 3 4 X 50 RH FINISH SINGLE SC 1 46252 WRENCH SOCKET HEX 17MM 1 2 DRIVE 1 57794 KNOB ASSY MODIFIED 2 59240 HOSE ASSY 4...

Page 174: ...BSPP MALE X 3 8 NPTF 1 57888 WASHER FIXTURING 21MM ID X 35MM OD X 3MM CASE HARDENED 1 62624 ARBOR GRINDING WHEEL CBN 10MM SHANK M8 THREAD 1 63018 SCREW M20 X 15 X 50MM SHCS Drive 1 62702 GEAR PINION...

Page 175: ...8 62687 LEG VERTICAL SUPPORT OD MOUNT CM6200 Face Mount 32 12339 WASHER 3 4 FLTW 16 57348 SCREW M16 X 20 X 60MM SSSFP 32 58203 SCREW M20 X 25 XX 40MM SHCS 4 62887 BRACKET FACE MOUNT CM6200 Servo HPU 1...

Page 176: ...M X 1 2 1 46252 WRENCH HEX BIT SOCKET 17MM X 1 2 1 46253 WRENCH HEX BIT SOCKET 12MM X 1 2 1 53197 WRENCH COMBINATION 24mm 12PT 338mmLG SATIN FINISH 1 58350 WRENCH END 46mm X 8 9 16 LONG TIGHT ACCESS 2...

Page 177: ...PANEL EXTERIOR ASSEMBLY SHEET 1 P N B00116 165 FIGURE B 7 MR J3 CONTROL PANEL INTERIOR ASSEMBLY SHEET 2 P N B00116 166 FIGURE B 8 MR J3 ASSEMBLY SHEET 1 P N C00088 167 FIGURE B 9 MR J3 SCHEMATIC SHEE...

Page 178: ...Page 160 CM6200 Operating Manual FIGURE B 1 MR J3 AND MR J4 PENDANT CABLE SCHEMATIC P N E00009...

Page 179: ...P N 63674 Rev 9 Page 161 FIGURE B 2 MR J3 SYSTEM LAYOUT P N A00033...

Page 180: ...Page 162 CM6200 Operating Manual FIGURE B 3 MR J3 AND MR J4 MILL TETHER SCHEMATIC P N B00070...

Page 181: ...P N 63674 Rev 9 Page 163 FIGURE B 4 MR J3 AND MR J4 JUNCTION BOX ASSEMBLY P N B00083...

Page 182: ...Page 164 CM6200 Operating Manual FIGURE B 5 MR J3 AND MR J4 OPERATOR PENDANT ASSEMBLY P N B00110...

Page 183: ...P N 63674 Rev 9 Page 165 FIGURE B 6 MR J3 CONTROL PANEL EXTERIOR ASSEMBLY SHEET 1 P N B00116...

Page 184: ...Page 166 CM6200 Operating Manual FIGURE B 7 MR J3 CONTROL PANEL INTERIOR ASSEMBLY SHEET 2 P N B00116...

Page 185: ...P N 63674 Rev 9 Page 167 FIGURE B 8 MR J3 SCHEMATIC SHEET 1 P N C00088...

Page 186: ...Page 168 CM6200 Operating Manual FIGURE B 9 MR J3 SCHEMATIC SHEET 2 P N C00088...

Page 187: ...P N 63674 Rev 9 Page 169 FIGURE B 10 MR J3 SCHEMATIC SHEET 3 P N C00088...

Page 188: ...Page 170 CM6200 Operating Manual FIGURE B 11 MR J4 LAYOUT P N A00093...

Page 189: ...P N 63674 Rev 9 Page 171 FIGURE B 12 MR J4 CONTROL PANEL ASSEMBLY EXTERIOR P N B000394...

Page 190: ...Page 172 CM6200 Operating Manual FIGURE B 13 MR J4 CONTROL PANEL ASSEMBLY INTERIOR P N B00394...

Page 191: ...ED DIMENSIONS ARE IN INCHES PER ASME Y14 5 15509 SCALE B SIZE CAGE CODE DWG NO SH PART NO CM6200 w IQAN PUMP MULTI VOLTAG C00 RG 5 26 18 4 A PROJECT DRAWINGS TOP LEVEL ASSEMBLY SCHEMATIC LAYOUT CONTRO...

Page 192: ...D DIMENSIONS ARE IN INCHES PER ASME Y14 5 15509 SCALE B SIZE CAGE CODE DWG NO SHEET PART NO CM6200 w IQAN PUMP CON MULTI VOLTAGES C005 RG 5 26 18 4 A PROJECT DRAWINGS TOP LEVEL ASSEMBLY SCHEMATIC LAYO...

Page 193: ...6200 w IQAN PUM MULTI VOLTA C0 RG 5 26 18 4 A SERIAL NO YEAR MODEL SUPPLY VOLTAGE LARGEST LOAD AMPS SHORT CIRCUIT CURRENT RATING kA DIAGRAM No FULL LOAD AMPS MAINS BREAKER AMP RATING 5 44 36 37 5 31 C...

Page 194: ...Page 176 CM6200 Operating Manual This page intentionally left blank...

Page 195: ...P N 63674 Rev 9 Page 177 APPENDIX C SDS Contact CLIMAX for the current list of safety data sheets...

Page 196: ...Page 178 CM6200 Operating Manual This page intentionally left blank...

Page 197: ...P N 63674 Rev 9 Page 179 APPENDIX D MR J4 SERVO AMPLIFIER MANUAL For any issues with the MR J4 servo motor junction box see the following pages...

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