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Climax FF1200, Operating Manual

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FF1200-FF2400-FF3600 Operating Manual

 TABLE OF CONTENTS (CONTINUED)

C

HAPTER

/S

ECTION

P

AGE

4.3 O

PERATION

-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  56

4.3.1

Start the machine-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  56

4.3.2

Stop the machine-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  58

4.3.3

Adjust the machine settings-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  58

5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

5.1 M

AINTENANCE

 

CHECKLIST

 -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  59

5.2 A

PPROVED

 

LUBRICANTS

 -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  60

5.3 M

AINTENANCE

 

TASKS

  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  61

5.3.1

Check the PCU oil reservoir and particulate filter trap  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  61

5.3.2

PCU drop-out circuit check  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  61

5.3.3

Emergency stop test  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  61

5.3.4

Dovetail ways   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  61

5.3.5

Lubricate the RDU bearing  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  62

5.4

 

R

ESETTING

 

THE

 

CAM

 

ARM

-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  63

5.5 T

ROUBLESHOOTING

 -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  64

5.5.1

The machine isn’t turning -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  64

5.5.2

The machine bearing is overheating   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  65

5.5.3

The machine isn’t feeding-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  65

5.5.4

The machine is performing poorly -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  65

5.5.5

The machine isn’t cutting flat  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  66

6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

6.1 S

HORT

-

TERM

 

STORAGE

  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  67

6.2 L

ONG

-

TERM

 

STORAGE

 -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  67

6.3 S

HIPPING

-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  68

6.4 D

ECOMMISSIONING

  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  69

 APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
 APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
 APPENDIX C SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Summary of Contents for FF1200

Page 1: ...P N 95936 July 2019 Revision 0 FF1200 FF2400 FF3600 COMPACT FLANGE FACER OPERATING MANUAL ORIGINAL INSTRUCTIONS FF1200 FF2400 FF3600 ...

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 Telephone number Machine model Serial number if applicable Date of purchase CLIMAX World Headquarters 2712 East 2nd Street Newberg Oregon 97132 USA Telephone worldwide 1 503 538 2815 Toll free North America 1...

Page 4: ...Page B FF1200 FF2400 FF3600 Operating Manual CLIMAX GLOBAL LOCATIONS ...

Page 5: ...P N 95936 Rev 0 Page C CE DOCUMENTATION ...

Page 6: ... its factory 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 labor performed both at no charge and return the part or repaired machine shipping prepaid These warranties do not apply to the following Damage after the date of shipment not caused by defects in...

Page 7: ... AND RIGGING 25 3 3 MACHINE ASSEMBLY 28 3 3 1 FF1200 Determining the chucking range 28 3 3 2 FF2400 Determining the chucking range 29 3 3 3 FF3600 Determining the chucking range 30 3 3 4 Attaching the chucking feet 31 3 3 5 Mount the chuck to the workpiece 32 3 3 6 Install the slide assembly 41 3 3 7 Install or replace the cutting tool 42 3 3 8 Install the motor 43 3 3 9 Set up the PCU 44 3 4 MACH...

Page 8: ...er trap 61 5 3 2 PCU drop out circuit check 61 5 3 3 Emergency stop test 61 5 3 4 Dovetail ways 61 5 3 5 Lubricate the RDU bearing 62 5 4 RESETTING THE CAM ARM 63 5 5 TROUBLESHOOTING 64 5 5 1 The machine isn t turning 64 5 5 2 The machine bearing is overheating 65 5 5 3 The machine isn t feeding 65 5 5 4 The machine is performing poorly 65 5 5 5 The machine isn t cutting flat 66 6 STORAGE AND SHIP...

Page 9: ...point identification label 26 3 2 Lifting points on RDU for the FF2400 and FF3600 FF2400 shown 26 3 3 Lifting points on FF1200 27 3 4 FF1200 chucking foot components 28 3 5 FF2400 Chucking foot components 29 3 6 FF3600 Chucking foot components 30 3 7 RDU inverted FF1200 shown 31 3 8 RDU with all chucking feet attached FF1200 shown 31 3 9 Chucking foot assembly attached to RDU FF1200 shown 32 3 10 ...

Page 10: ...arm and key position 63 5 4 Adjusting cam arm screw to correct torque value 64 5 5 Cam arm and key operational alignment 64 6 1 FF1200 shipping container 68 6 2 FF2400 shipping container 68 6 3 FF3600 shipping container 68 A 1 FF1200 principal components 72 A 2 FF2400 principal components 73 A 3 FF3600 principal components 74 A 4 FF1200 rotational drive unit assembly P N 79752 75 A 5 FF1200 rotati...

Page 11: ...oot assembly P N 78979 93 A 23 FF3600 chucking foot assembly P N 80097 94 A 24 Pneumatic drive assembly P N 76027 95 A 25 Pneumatic conditioning unit PCU assembly P N 78264 96 A 26 PCU assembly parts list P N 78264 97 A 27 FF1200 1 07 hp straight air motor P N 80570 98 A 28 FF2400 and FF3600 2 2 hp straight air motor P N 80632 99 A 29 2 2 hp right angle air motor P N 80618 100 B 1 Pneumatic schema...

Page 12: ...Page 4 FF1200 FF2400 FF3600 Operating Manual This page intentionally left blank ...

Page 13: ... 3 5 Vertical tether identification 33 3 6 Vertical example with setup fingers identification 34 3 7 Upside down tether identification 35 3 8 Upside down example with setup fingers identification 36 3 9 Horizontal tether identification 37 3 10 Horizontal example with setup fingers identification 38 3 11 Feed control identification 48 3 12 FF1200 radial slide tilt angle conversion 51 3 13 FF2400 an...

Page 14: ...Page 2 FF1200 FF2400 FF3600 Operating Manual This page intentionally left blank ...

Page 15: ... to aid in setup operation and maintenance tasks Read this entire manual to familiarize yourself with the FF1200 FF2400 FF3600 before attempting to set it up or operate it 1 2 SAFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual Safety alerts will call your attention to specific hazardous situations that may be encoun tered when operating this machine Examples of...

Page 16: ...e for conducting 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 machine for any purpose other than its intended use as described in this manual Personal protective equipment Always wear appropriate personal pro tective gear when operating this or any ot...

Page 17: ...g the machine Sound level This machine produces potentially harmful sound levels Hearing protection is required when operating this machine or working around it During testing the machine produced the sound levels1 listed in Table 1 1 Hazardous environments Do not operate the machine in environments where potentially explosive materials toxic chemicals or radiation may be present Machine mounting ...

Page 18: ...ions They typ ically attach directly to the workpiece itself or to an adjacent structure and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and the structure to which it is attached become one complete machine during the material removal process To achieve the intended results and to promote safety the operator must under stand...

Page 19: ... identified the best placement for the controls cabling and the operator I have assessed for additional risks unique to this application of the Portable Machine tool TABLE 1 3 RISK ASSESSMENT CHECKLIST AFTER SET UP After Set up I checked that the machine is safely installed according to Section 3 and the potential fall path is clear If the machine is installed at an elevated position I checked tha...

Page 20: ...ct CLIMAX immediately for replacements TABLE 1 4 LABELS P N 29152 Mass plate P N 46902 Warning label hot surface P N 59035 Warning label wear eye pro tection P N 59037 Wear ear protection warning label P N 59039 Lift point warn ing label P N 59042 Warning label hand crunch mov ing parts P N 59044 Read opera tors manual warning label P N 81132 Warning label lock out tag out ...

Page 21: ... 7 P N 70226 CLIMAX logo P N 80569 Air direction and pressure label P N 80682 Serial year model mass plate CE Plate P N 84645 High temperature warning read manual P N 84856 Warning label tether machine before use TABLE 1 4 LABELS ...

Page 22: ...r further identification of location placement refer to the exploded views in Appendix A FIGURE 1 1 TOOL HEAD HOLDER LABEL LOCATION Label P N 46902 FIGURE 1 2 FF1200 RADIAL SLIDE ASSEMBLY LABEL LOCA TION Label P N 29152 80682 FIGURE 1 3 FF2400 AND FF3600 RADIAL SLIDE ASSEMBLY LABEL LOCATION Label P N 29152 80682 FIGURE 1 4 RDU TOP LABEL LOCATION Label P N 59035 59042 59044 70226 ...

Page 23: ...Labels P N 95936 Rev 0 Page 9 FIGURE 1 5 RDU SIDE LABEL LOCATIONS Label P N 84645 84856 59039 FIGURE 1 6 PNEUMATIC MOTOR LABEL LOCATIONS Label P N 59037 80569 ...

Page 24: ...Labels Page 10 FF1200 FF2400 FF3600 Operating Manual This page left intentionally blank ...

Page 25: ...2 2 on page 12 and Figure 2 3 on page 12 See Table 2 1 on page 12 for text identi fication within the figure Pneumatic motor The pneumatic motor is avail able in the straight option 1 07 hp for the FF1200 2 2 hp for the FF2400 and FF3600 as shown in Fig ure 2 1 Figure 2 2 on page 12 and Figure 2 3 A right angle 2 2 hp option is also available as shown in Figure A 29 on page 100 TABLE 2 1 OUTSIDE D...

Page 26: ...es the main bearing and the feed drive unit The rate of the feed is adjustable from the sta tionary portion of the FF1200 FF2400 FF3600 Chuck foot assembly The chuck foot assembly is designed for OD mount ing only Refer to Section 3 3 1 on page 28 through Section 3 3 3 on page 30 depending on the machine model for more mounting dimensional constraints TABLE 2 1 FF1200 FF2400 FF3600 COMPONENT IDENT...

Page 27: ...y shutdown To stop machine operation immediately press the EMERGENCY STOP button on the PCU Figure 2 6 Before restarting the FF1200 FF2400 FF3600 do the fol lowing 1 Close the speed adjustment valve 2 Pull the EMERGENCY STOP button up 3 Press the START button FIGURE 2 4 FEED ENGAGEMENT AND FEED RATE ADJUSTMENT CONTROLS FF1200 SHOWN FIGURE 2 5 FEED CONTROLS FF1200 SHOWN FEED ENGAGEMENT PIN FEED RAT...

Page 28: ...se manual feed A out feed out down Middle neutral B in feed in up 2 Clutch position legend 3 Feed axis shift 1 in radial feed 2 out axial feed TABLE 2 2 PCU CONTROL IDENTIFICATION Number Component 1 Air supply lock out 2 Regulator 3 Start button 4 Emergency stop button 5 Oil drip rate dial 6 Speed adjustment valve 7 Oil reservoir 8 Filter AIR SUPPLY LOCK OUT START BUTTON EMERGENCY STOP BUTTON SPEE...

Page 29: ...t supplied P N 95936 Rev 0 Page 15 2 3 ITEMS REQUIRED BUT NOT SUPPLIED Torque wrench Dial indicator Wood blocks 2 4 DIMENSIONS Machine and operating dimensions are shown in Figure 2 9 and Figure 2 12 on the subsequent pages ...

Page 30: ... FF2400 FF3600 Operating Manual FIGURE 2 7 FF1200 MACHINE DIMENSIONS 8 6 218 mm 11 2 285 mm 16 9 429 mm 5 7 144 mm 8 0 203 mm P17 2 437 mm P29 8 757 mm MAX WHEN CHUCKED TO MAX FLANGE P18 0 457 mm MIN WHEN CHUCKED TO MIN FLANGE ...

Page 31: ...95936 Rev 0 Page 17 FIGURE 2 8 FF2400 MACHINE DIMENSIONS 18 6 473 mm 6 5 165 mm 8 7 222 mm 15 5 393 mm 18 3 465 mm P31 0 786 mm P52 2 1326 mm MAX WHEN CHUCKED TO MAX FLANGE P34 5 876 mm MIN WHEN CHUCKED TO MIN FLANGE ...

Page 32: ...F2400 FF3600 Operating Manual FIGURE 2 9 FF3600 MACHINE DIMENSIONS 19 0 482 mm 6 8 172 mm 8 7 222 mm P44 5 1130 mm 22 3 565 mm 25 1 637 mm P64 2 1631 mm MAX WHEN CHUCKED TO MAX FLANGE P46 5 1181 mm MIN WHEN CHUCKED TO MIN FLANGE ...

Page 33: ... P N 95936 Rev 0 Page 19 FIGURE 2 10 FF1200 MACHINE DIMENSIONS 8 6 218 mm 11 2 285 mm 9 9 252 mm 5 8 147 mm 8 0 203 mm P29 8 757 mm WHEN CHUCKED TO MAX FLANGE P18 0 457 mm WHEN CHUCKED TO MIN FLANGE P17 2 437 mm ...

Page 34: ...1200 FF2400 FF3600 Operating Manual FIGURE 2 11 FF2400 MACHINE DIMENSIONS 8 6 218 mm 11 2 285 mm 9 9 252 mm 5 8 147 mm 8 0 203 mm P29 8 757 mm WHEN CHUCKED TO MAX FLANGE P18 0 457 mm WHEN CHUCKED TO MIN FLANGE P17 2 437 mm ...

Page 35: ...ge 21 FIGURE 2 12 FF3600 RIGHT ANGLE PNEUMATIC MOTOR MACHINE DIMENSIONS 10 6 270 mm 6 4 163 mm 8 7 222 mm P31 0 786 mm P34 5 876 mm MIN WHEN CHUCKED TO MIN FLANGE P52 2 1326 mm MAX WHEN CHUCKED TO MAX FLANGE 15 5 393 mm 18 3 465 mm ...

Page 36: ...ASSEMBLIES TABLE 2 3 FF1200 SUB COMPONENT MASS Sub assembly number Component Mass 1 Chuck Foot P N 78911 7 85 lbs 3 56 kg 2 Rotational Drive Unit P N 79752 85 lbs 38 5 kg 3 Radial Axial Slide P N 79192 21 8 lbs 9 89 kg 4 1 07 hp Straight Air Motor P N 80570 6 64 lbs 3 01 kg Total 143 lbs 64 9 kg 1 3 4 2 ...

Page 37: ... FF2400 SUB COMPONENT MASS Sub assembly number Component Mass 1 Chuck Foot P N 78979 20 2 lbs 9 16 kg 2 Rotational Drive Unit P N 79903 204 lbs 92 7 kg 3 2 2 hp Straight Air Motor P N 80632 8 84 lbs 4 01 kg 4 Radial Axial Slide P N 80683 49 2 lbs 22 3 kg Total 343 lbs 156 kg 4 2 1 3 ...

Page 38: ...ES TABLE 2 5 FF3600 SUB COMPONENT MASS Sub assembly number Component Mass 1 Rotational Drive Unit P N 80017 428 lbs 194 kg 2 Chuck Foot P N 78979 20 2 lbs 9 16 kg 3 2 2 hp Straight Air Motor P N 80632 8 84 lbs 4 01 kg 4 Radial Axial Slide P N 80702 68 2 lbs 30 9 kg Total 666 lbs 302 kg 2 1 3 4 ...

Page 39: ... 4 1 SET THE TOOL CUTTING DEPTH 45 3 4 2 TILT THE AXIAL SLIDE 45 3 4 3 TILT THE RADIAL SLIDE 47 3 1 RECEIPT AND INSPECTION Your CLIMAX product was inspected and tested prior to shipment and packaged for normal shipment conditions CLIMAX does not guarantee the condition of your machine upon delivery When you receive your CLIMAX product perform the following receipt checks 1 Inspect the shipping con...

Page 40: ... for heavy lifting Serious injury or fatalities can result from improper lifting methods CAUTION Falling or uncontrolled swinging of machinery can cause serious injury or be fatal to the operator and bystanders Only lift the machine by the hoist rings marked by Figure 3 1 Do not lift the FF1200 FF2400 FF3600 by the handles on the slide assembly For the FF2400 and FF3600 Attach separate hoist shack...

Page 41: ...the machine The FF1200 can weigh 143 lbs 64 9 kg Use cau tion if manually lifting by the han dles CAUTION Make sure the rigging is correctly attached before lifting the machine Lift the machine slowly making sure that no components will be crushed or bent if the machine is lifted in the vertical orientation If the rigging causes the FF1200 FF2400 FF3600 to swing or become unstable lower it and adj...

Page 42: ...s 12 Nm 4 Use the chart on the side of each chucking foot Table 3 2 to determine the cor rect chucking range for the workpiece TABLE 3 1 CHUCKING FOOT COMPONENT IDENTIFICATION Number Component 1 Chucking foot adjustment screw 2 Jam nut 3 Chucking range holes 4 Setup finger 5 Leveling screw FIGURE 3 4 FF1200 CHUCKING FOOT COMPONENTS CHUCKING FOOT SCREW JAM NUT RANGE HOLES CHUCKING FINGER SET LEVELI...

Page 43: ...e of each chucking foot Table 3 3 to determine the cor rect chucking range for the workpiece See Table 3 1 on page 28 for text identifi cation within the figure FIGURE 3 5 FF2400 CHUCKING FOOT COMPONENTS JAM NUT CHUCKING FOOT ADJUSTMENT SCREW CHUCKING RANGE HOLES SETUP FINGER LEVELING SCREW 1 2 3 4 5 TABLE 3 3 FF2400 CHUCKING RANGE CHART P N 79901 RANGE 1 2 3 4 5 6 7 MAX inch 10 0 11 6 13 2 14 8 1...

Page 44: ...on the side of each chucking foot Table 3 4 to determine the cor rect chucking range for the workpiece See Table 3 1 on page 28 for text identifi cation within the figure FIGURE 3 6 FF3600 CHUCKING FOOT COMPONENTS JAM NUT CHUCKING FOOT ADJUSTMENT SCREW CHUCKING RANGE HOLES SETUP FINGER LEVELING SCREW 1 2 3 4 5 TABLE 3 4 FF3600 CHUCKING RANGE CHART P N 80088 RANGE 1 2 3 4 5 6 7 MAX inch 22 0 23 6 2...

Page 45: ... holes Fig ure 3 8 and turn them into the RDU Tighten both screws to 36 ft lbs 49 Nm 4 Turn the jam nut away from the chucking foot body 5 Turn the chucking foot set screw to retract the chuck ing foot all the way open 6 Repeat steps 2 5 for each chucking foot 7 In small increments turn opposite pairs of chuck ing foot setscrews to adjust the distance between opposite pairs of chucking feet to sli...

Page 46: ...kpiece 2 In approximately 20 ft lb 27 Nm increments turn two opposing chucking foot setscrews to tighten the opposing chucking feet to the workpiece 3 Repeat step 2 for the other opposing pair of chucking feet 4 Attach an appropriate tether restraint See Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 and Figure 3 16 for example tether arrange ments for horizontal vertical and upside d...

Page 47: ... STRAP RATED FOR 5000 LBS 22 2KN SUITABLE ANCHOR POINT RATED FOR 5000 LBS 22 2 KN EXAMPLE WORKPIECE 80371 2 3 4 5 1 TABLE 3 5 VERTICAL TETHER IDENTIFICATION Number Component 1 Example tether arrangement for use in vertical machining applications 2 Tether e g chain cable strap rated for 5000 lbs 22 2 kN 3 Suitable anchor point rated for 5000 lbs 22 2 kN 4 Example workpiece 5 Note tether anchor poin...

Page 48: ... SETUP FINGERS P N 78916 SCREWS 78924 EXAMPLE RESTRAINT ARRANGEMENT FOR USE IN VERTICAL MACHINING APPLICATIONS 2 3 1 4 TABLE 3 6 VERTICAL EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component 1 Example restraint arrangement for use in vertical machining applications 2 Example workpiece 3 Restrain by means of additional back side setup fingers P N 78916 screws 78924 4 Detail A ...

Page 49: ... 22 2KN NOTE TETHER ANCHOR POINT PROVIDED BY CUSTOMER TETHER LENGTH MUST LIMIT ANY FALL TO NO MORE THAN 6 INCHES 152mm HOIST RING 80371 AVAILABLE FROM CLIMAX 2 3 3 4 4 5 1 TABLE 3 7 UPSIDE DOWN TETHER IDENTIFICATION Number Component 1 Example tether arrangement for use in upside down machining applications 2 Example workpiece 3 Suitable anchor point rated for 5 000 lbs 22 2 kN 4 Tether e g chain c...

Page 50: ...TRAINT ARRANGEMENT FOR USE IN UP SIDE DOWN MACHINING APPLICATIONS RESTRAIN BY MEANS OF BACK SIDE SETUP FINGERS 2 3 4 1 TABLE 3 8 UPSIDE DOWN EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component 1 Example restraint arrangement for use in upside down machining applica tions 2 Example workpiece 3 Restrain by means of back side setup fingers 4 Detail A ...

Page 51: ...OMER TETHER LENGTH MUST LIMIT ANY FALL TO NO MORE THAN 6 INCHES 152mm HOIST RING 80371 AVAILABLE FROM CLIMAX 2 3 4 5 1 TABLE 3 9 HORIZONTAL TETHER IDENTIFICATION Number Component 1 Example tether arrangement for use in horizontal machining applications 2 Suitable anchor point rated for 5000 lbs 22 2 kN 3 Tether e g chain cable strap rated for 5000 lbs 22 2kN 4 Example workpiece 5 Note tether ancho...

Page 52: ...EXAMPLE RESTRAINT ARRANGEMENT FOR USE IN HORIZONTAL MACHINING APPLICATIONS RESTRAIN BY MEANS OF SETUP FINGERS 2 3 4 1 TABLE 3 10 HORIZONTAL EXAMPLE WITH SETUP FINGERS IDENTIFICATION Number Component 1 Example restraint arrangement for use in horizontal machining applications 2 Example workpiece 3 Restraint by means of setup fingers 4 Detail A ...

Page 53: ...ert the supplied 5 16 rods into one of the slide assembly bushings Figure 3 18 Use the rods to rotate the RDU bearing 3 Measure level and adjust the setup finger leveling setscrews as necessary Figure 3 17 4 Alternate the centering pro cedure Section 3 3 5 2 and this procedure until the desired alignment is achieved FIGURE 3 17 LEVEL THE RDU FF3600 SHOWN FIGURE 3 18 5 16 RODS FOR MANUALLY ROTATING...

Page 54: ...is achieved 5 Tighten all four chucking foot setscrews to a minimum torque of the fol lowing depending on your machine For the FF1200 a minimum torque of 20 ft lbs 9 1 Nm For the FF2400 or FF3600 a minimum torque of 60 ft lbs 27 Nm CAUTION Do not tighten the chucking foot setscrews beyond 40 ft lbs 18 Nm for the FF1200 or 100 ft lbs 45 Nm for the FF2400 or FF3600 Exceeding the maximum torque value...

Page 55: ...installing the slide assembly 2 Set the feed direction shift knob in the neutral middle position Refer to Section 2 2 on page 13 for controls information 3 Turn and hold the cam release key clockwise Fig ure 3 20 4 With the feed body cam aligned over the cam slot place the slide body onto the RDU bearing Figure 3 21 FIGURE 3 20 ALIGN THE SLIDE BODY OVER THE CAM SLOT FF1200 SHOWN FIGURE 3 21 HOLDIN...

Page 56: ...ction Keep these characteristics in mind when installing a new tool in the machine Do the following to install or replace the cutting tool 1 With a 6 mm hex key loosen the tool clamp set screw 2 Insert a tool horizontally into the tool post Figure 3 23 and rotate it in the clamp to the desired posi tion 3 Tighten the tool clamp set screw WARNING Do not adjust the cutting tool unless the machine is...

Page 57: ... with the motor coupling keyway Figure 3 24 2 Mate the motor to the drive assembly Figure 3 25 3 Align the motor flange holes with the drive assem bly threaded holes 4 Insert the three M5x20 socket head cap screws tighten to 106 in lb 12 Nm FIGURE 3 24 ALIGN THE AIR MOTOR FF1200 SHOWN FIGURE 3 25 MOTOR INSTALLED FF1200 SHOWN ...

Page 58: ...or FF3600 connect to an air supply with minimum 90 psi 6 21 bar at 75 cfm 2 2 m3 min for both the straight and right angle pneumatic motor 4 Connect the PCU air supply hose to the motor CAUTION Make sure that air hoses are routed and secured to avoid tripping entanglement damage from hot chips or other damage should an air hose or connection fail Failure to do so may result in injury from uncontro...

Page 59: ...of the cut 4 Use the supplied 1 4 wrench to turn the axial feed drive shaft to adjust tool depth Figure 3 26 OR Shift the feed box to axial feed and use the manual feed knob to adjust tool depth 5 Finger tighten the axial gib lock screw Figure 3 27 3 4 2 Tilt the axial slide The axial slide can be tilted by swiveling the tool head to within 0 5 of any desired angle using its built in protractor Th...

Page 60: ...b screw side of the tool head Figure 3 28 two full turns 2 Using an 4 mm hex key tighten the two swivel release setscrews on the side of the tool head oppo site the gib screw Figure 3 29 until you feel the inter nal pins give way 3 Loosen both swivel release setscrews about two turns FIGURE 3 28 LOOSEN THE SWIVEL LOCK SETSCREWS FIGURE 3 29 TIGHTEN THE SWIVEL RELEASE SETSCREWS ...

Page 61: ... prevent the setscrews from vibrat ing out during operation 3 4 3 Tilt the radial slide The radial slide can be tilted to enable machining of tapered flanges Do the following to tilt the radial slide 1 Flip the slide body upside down 2 With a 13 mm socket loosen the recessed set screw jam nut Figure 3 31 3 With a 4 mm hex key loosen recessed setscrew out about two full turns 4 Flip the slide body ...

Page 62: ...ON Number Component 1 Direction shift manual feed crank Crank clockwise manual feed A out feed out down Middle neutral B in feed in up 2 Clutch position legend 3 Feed axis shift 1 in radial feed 2 out axial feed FIGURE 3 32 SUPPORT THE RADIAL SLIDE FF1200 SHOWN FIGURE 3 33 FEED CONTROLS FF1200 SHOWN DIRECTION SHIFT MANUAL FEED CRANK CRANK CLOCKWISE MANUAL FEED A OUT FEED OUT DOWN MIDDLE NEUTRAL B ...

Page 63: ...lide body Figure 3 34 8 Position a depth gauge with a flat contact head to mea sure from the top of the slide body to the dowel pin in the radial slide Figure 3 35 Either zero the dial indicator or record this value FIGURE 3 34 REMOVE THE PLUG SCREW FF1200 SHOWN FIGURE 3 35 POSITION THE DIAL INDICATOR FF1200 SHOWN ...

Page 64: ...l the dial indi cator reads the desired depth change Figure 3 37 14 If the tilt adjust setscrew tightens before reaching the desired depth repeat steps 1 4 15 Tighten the radial slide screws to 140 in lb 16 Nm 16 Flip the slide body upside down 17 Tighten the jam nut see Figure 3 27 on the recessed setscrew TIP If the radial slide tilt angle will be used frequently the recessed bottom setscrew can...

Page 65: ...m 0 90 0 1131 2 87 mm 0 20 0 0251 0 64 mm 0 95 0 1194 3 03 mm 0 25 0 0314 0 80 mm 1 00 0 1257 3 19 mm 0 30 0 0377 0 96 mm 1 05 0 1319 3 35 mm 0 35 0 0440 1 12 mm 1 10 0 1382 3 51 mm 0 40 0 0503 1 28 mm 1 15 0 1445 3 67 mm 0 45 0 0565 1 44 mm 1 20 0 1508 3 83 mm 0 50 0 0628 1 60 mm 1 25 0 1571 3 99 mm 0 55 0 0691 1 76 mm 1 30 0 1633 4 15 mm 0 60 0 0754 1 92 mm 1 35 0 1696 4 31 mm 0 65 0 0817 2 07 m...

Page 66: ...ADIAL SLIDE TILT ANGLE CONVERSION Slide angle Dowel pin depth Slide angle Dowel pin depth 0 10 0 0301 77 mm 0 85 0 2562 6 51 mm 0 15 0 0452 1 15 mm 0 90 0 2713 6 89 mm 0 20 0 0603 1 53 mm 0 95 0 2863 7 27 mm 0 25 0 0754 1 91 mm 1 00 0 3014 7 66 mm 0 30 0 0904 2 30 mm 1 05 0 3165 8 04 mm 0 35 0 1055 2 68 mm 1 10 0 3315 8 42 mm 0 40 0 1206 3 06 mm 1 15 0 3466 8 80 mm 0 45 0 1356 3 45 mm 1 20 0 3617 ...

Page 67: ...ing modes Refer to Section 2 2 on page 13 for controls information 4 1 1 Configure for machining on a flat flange Flat facing is the default operating mode of the FF1200 FF2400 FF3600 WARNING Do not configure or adjust the machining direction unless the machine is turned off the air hose has been disconnected and any required lockout tag out has been performed Do the following to configure the FF1...

Page 68: ...Section 3 4 3 on page 47 3 Complete all pre operation checks see Section 4 2 on page 55 4 Use the feed axis and direction knobs to move the cutting tool to the start ing point of the cut 5 Set the feed axis shift knob to position 1 radial for facing or position 2 axial for grooving or beveling 6 Set the feed direction shift knob to position A down TABLE 4 1 FEED CONTROL IDENTIFICATION Number Compo...

Page 69: ...al personnel and equipment 2 Check that the machine control observation area will not be in the path of hot flying chips during machine operation 3 Check that the machine is securely mounted to the work piece 4 Check that the air hoses are routed and secured to avoid tripping entangle ment damage from hot chips or other damage should an air hose or con nection fail 5 Check the tool condition and s...

Page 70: ...ate until you reach the desired feed rate Figure 4 4 6 Adjust the feed rate and rotary speed as necessary to maintain the desired cut 7 Adjust the oil drip rate as needed Figure 4 4 NOTICE For best machine performance and service life CLIMAX recommends that the PCU oil drip rate not be adjusted below 6 drips per minute WARNING Do not operate the machine if the bearing heats up significantly that i...

Page 71: ...TION Number Component 1 Air supply lock out 2 Regulator 3 Start button 4 Emergency stop button 5 Oil drip rate dial 6 Speed adjustment valve 7 Oil reservoir 8 Filter AIR SUPPLY LOCK OUT START BUTTON EMERGENCY STOP BUTTON SPEED ADJUSTMENT VALVE OIL DRIP RATE DIAL FILTER OIL RESERVOIR REGULATOR ...

Page 72: ...eed see Figure 4 5 2 Stop the and lock out the machine see Section 4 3 2 3 Manually adjust the cutting tool position or angle see Section 3 4 on page 44 WARNING Do not attempt to manually adjust the cutting tool angle or change the feed box settings during operation Attempting to operate the feed box controls by hand or with hand tools while the machine is running may result in severe injury TABLE...

Page 73: ...PERFORMING POORLY 65 5 5 5 THE MACHINE ISN T CUTTING FLAT 66 5 1 MAINTENANCE CHECKLIST Maintenance intervals and their associated tasks are listed in Table 5 1 TABLE 5 1 MAINTENANCE INTERVALS AND TASKS Interval Task Section ref Before each use Check the pneumatic conditioning unit PCU oil reservoir level and par ticulate filter trap Section 5 3 1 on page 61 Check air lines for damage and wear Chec...

Page 74: ...use Each use Pneumatic condi tioning unit Unax AW 32 N A 22 68 40 C 4 3 8 7 100 C Refill oil lubricator Each use Unpainted Sur faces LPS1 or LPS2 N A 38 25C As required Each use and before storage Weekly Lead screw on single point tool head NOOK E 100 spray lube NOOK PAG 1 grease CASTROLBioTac EP 2 96 40C 113 100C Light coat ing applied by hand or spray Weekly during machine use Chuck jacking scre...

Page 75: ...CU is connected to a shop air supply and the FF1200 FF2400 FF3600 2 Check that the air supply lock out is open pulled up Figure 2 6 on page 14 3 Press the START button 4 Slowly open the PCU speed adjustment valve until the rotary drive engages 5 Close press down the lock out valve 6 Check that the FF1200 FF2400 FF3600 stops 7 Open the lock out valve 8 Verify that the machine does not start 5 3 3 E...

Page 76: ...tool slide to one end of the axial feed track 2 Wipe down the exposed dovetail ways and lubricate them with Mobil VACTRA medium heavy way oil or equivalent 3 Move the tool slide to the other end of the axial feed track 4 Wipe down the remaining exposed dovetail ways and lubricate them with Mobil VACTRA medium heavy way oil or equivalent 5 3 5 Lubricate the RDU bearing On the outside surface of the...

Page 77: ...will eventually turn into the feed direction knob and stop advancing Once this happens the FF1200 FF2400 FF3600 will not be able to feed the tool regard less of the cutting resistance Do the following to readjust the feed box so that it is operational 1 Loosen the clamp screw on the cam arm using a 3mm Allen wrench shown in Figure 5 2 2 Adjust the key and cam arm so that they are positioned as sho...

Page 78: ...ligned with the cam key as shown in Figure 5 5 5 5 TROUBLESHOOTING This section is intended to help you solve basic machine performance problems For serious maintenance or if you have questions on the following procedures contact CLIMAX 5 5 1 The machine isn t turning If the machine is not rotating check the following 1 The power source is connected and energized 2 The emergency stop is reset Sect...

Page 79: ...ºF 10ºC above the ambient temperature as the bearing may expand thermally and fall off the workpiece 5 5 3 The machine isn t feeding If the machine isn t feeding properly check the following 1 The feed is engaged see Section 4 3 3 on page 58 2 The leadscrew and hex shaft are free to turn in the desired directions 5 5 4 The machine is performing poorly If the machine is performing poorly check the ...

Page 80: ...not cutting flat do the following 1 Before making a critical finish pass run the machine continuously for at least 15 minutes to make sure that the machine is warmed up to operating temperature 2 Check the machine for level see Section 3 3 5 1 on page 39 3 Tram the turning arm as necessary see Section 3 4 2 on page 45 ...

Page 81: ... and other debris before storage 6 Apply a moisture preventative material to unpainted surfaces LPS 2 for short term storage LPS 3 for long term storage to prevent corrosion 7 Store the machine in a stable position on a stand or in storage container a according to your company policies 8 Store the FF1200 FF2400 FF3600 in its original shipping box 6 2 LONG TERM STORAGE Do the following for long ter...

Page 82: ...g Manual 6 3 SHIPPING The FF1200 FF2400 FF3600 can be shipped in its original shipping container see Figure 6 1 Figure 6 2 and Figure 6 3 FIGURE 6 1 FF1200 SHIPPING CONTAINER FIGURE 6 2 FF2400 SHIPPING CONTAINER FIGURE 6 3 FF3600 SHIPPING CONTAINER ...

Page 83: ...OMMISSIONING To decommission the FF1200 FF2400 FF3600 before disposal remove the drive assembly from the RDU and dispose of the drive assembly separately from the rest of the machine components Refer to Appendix A for component assembly infor mation ...

Page 84: ...Decommissioning Page 70 FF1200 FF2400 FF3600 Operating Manual This page left intentionally blank ...

Page 85: ...00 RADIAL AND AXIAL SLIDE ASSEMBLY PARTS LIST P N 80683 85 FIGURE A 15 FF3600 RADIAL AND AXIAL SLIDE ASSEMBLY P N 80702 86 FIGURE A 16 FF3600 RADIAL AND AXIAL SLIDE ASSEMBLY PARTS LIST P N 80702 87 FIGURE A 17 FEED BOX ASSEMBLY P N 79194 88 FIGURE A 18 FEED BOX ASSEMBLY PARTS LIST P N 79194 89 FIGURE A 19 TOOL HEAD ASSEMBLY P N 80407 90 FIGURE A 20 TOOL HEAD ASSEMBLY PARTS LIST P N 80407 91 FIGURE...

Page 86: ...ing Manual FIGURE A 1 FF1200 PRINCIPAL COMPONENTS PARTS LIST DESCRIPTION P N QTY ITEM ASSY CHUCK FOOT 12 78911 4 1 ASSY RADIAL AND AXIAL SLIDE 79192 1 2 ASSY RDU 0 12 INCH OD FF 79752 1 3 ASSY MOTOR AIR 1 07HP STRAIGHT 80570 1 4 1 3 4 2 ...

Page 87: ...URE A 2 FF2400 PRINCIPAL COMPONENTS PARTS LIST DESCRIPTION P N QTY ITEM ASSY CHUCK FOOT 24 78979 4 1 ASSY RDU 0 24 INCH OD FF 79903 1 2 ASSY MOTOR AIR 2 2HP STRAIGHT 80632 1 3 ASSY AXIAL RADIAL AXIAL SLIDE 0 24 80683 1 4 4 2 1 3 ...

Page 88: ...ting Manual FIGURE A 3 FF3600 PRINCIPAL COMPONENTS PARTS LIST DESCRIPTION P N QTY ITEM ASSY RDU 0 36 INCH 80017 1 1 ASSY CHUCK FOOT 36 80097 8 2 ASSY MOTOR AIR 2 2HP STRAIGHT 80632 1 3 ASSY AXIAL RADIAL SLIDE 0 36 INCH 80702 1 4 2 1 3 4 ...

Page 89: ...P N 95936 Rev 0 Page 75 FIGURE A 4 FF1200 ROTATIONAL DRIVE UNIT ASSEMBLY P N 79752 4 19 13 15 11 14 8 17 3 1 9 7 10 16 12 18 5 2 6 23 24 ...

Page 90: ...YE PROTECTION 59035 1 7 LABEL WARNING LIFT POINT ROUND 1 5 59039 6 8 LABEL WARNING HAND CRUSH MOVING PARTS 59042 1 9 LABEL WARNING CONSULT OPERATOR S MANUAL 59044 1 10 SCREW M8 X 1 25 X 75 MM SHCS 59998 4 11 BELT POLYCHAIN 8MM PITCH X 12MM WIDE X 160 TEETH 74581 1 12 BRG SLEWING ASSY 0 12 IN 78999 1 13 HANDLE BAR 79746 2 14 HANDLE TUBE 79747 4 15 WELDMENT BELT GUARD 0 12 OD FF 79748 1 16 ASSY DRIV...

Page 91: ...P N 95936 Rev 0 Page 77 FIGURE A 6 FF2400 ROTATIONAL DRIVE UNIT ASSEMBLY P N 79903 4 9 7 11 10 15 12 1 3 14 13 17 8 16 5 6 2 18 19 20 21 21 ...

Page 92: ...BEL WARNING LIFT POINT ROUND 1 5 59039 4 8 LABEL WARNING HAND CRUSH MOVING PARTS 59042 1 9 LABEL WARNING CONSULT OPERATOR S MANUAL 59044 1 10 LABEL CLIMAX LOGO 1 5 X 5 5 70226 1 11 BELT POLYCHAIN 8mm PITCH X 12mm WIDE X 280 TEETH 75520 1 12 BRG SLEWING ASSY 0 24 IN 79647 1 13 ASSY DRIVE WITH FEED CONTROL 79749 1 14 WELDMENT BELT GUARD 0 24 79805 1 15 CAM GUARD 0 24 79902 1 16 HOIST RING M8 X 1 25 ...

Page 93: ...P N 95936 Rev 0 Page 79 FIGURE A 8 FF3600 ROTATIONAL DRIVE UNIT ASSEMBLY P N 80017 13 5 16 7 15 1 3 12 11 4 10 9 8 6 14 17 5 2 18 19 20 ...

Page 94: ...INT ROUND 1 5 59039 4 7 LABEL WARNING HAND CRUSH MOVING PARTS 59042 1 8 LABEL WARNING CONSULT OPERATOR S MANUAL 59044 1 9 LABEL CLIMAX LOGO 1 5 X 5 5 70226 1 10 BELT POLYCHAIN 8MM PITCH X 12MM WIDE X xxx TEETH 76006 1 11 ASSY DRIVE WITH FEED CONTROL 79749 1 12 BRG SLEWING ASSY 0 36 IN 79924 1 13 WELDMENT BELT GUARD 0 12 OD FF 80018 1 14 HOIST RING M8 X 1 25 X 12 5MM 38 1 ID 57 2 OD 102 3 OAL 880 L...

Page 95: ...X 20MM SSSDPPL 74296 1 7 BRG BALL 1 1811 ID X 1 8504 OD X 3543 2 SEALS 76242 2 8 SCREW M6 X 1 0 X 40MM KNURLED HEAD 76599 1 9 PIN LOCATING 6MM OD X 20MM X M5 X 8 THREAD 76601 1 10 PULLEY POLYCHAIN 8mm PITCH X 12mm WIDE X 28 TEETH 77277 1 11 BLOCK CAM ACTUATOR 79753 1 12 BLOCK CUP BEARING 79754 1 13 LATCH BOLT CAM ACTUATOR 79755 1 14 MOTOR MOUNT FOR PULLEY SUPPORT 79756 1 15 PLATE PULLEY 79757 1 16...

Page 96: ...ge 82 FF1200 FF2400 FF3600 Operating Manual FIGURE A 11 FF1200 RADIAL AND AXIAL SLIDE ASSEMBLY P N 79192 19 21 28 11 16 6 13 9 22 19 16 26 7 15 8 12 3 1 3 27 3 1 3 17 18 15 4 23 5 20 14 10 2 29 25 24 12 8 ...

Page 97: ... X 4 mm SSSFP 53365 4 12 HANDLE PULL 1 4 CBORE MTG 2 0 X 5 12 X 1 02W PLASTIC COATED 53462 1 13 BRG RETAINING NUT AXIAL FEED LEADSCREW 57214 2 14 RING O 1 16 X 13 16 ID X 15 16 OD 57320 4 15 NUT M8 X 1 25 STDN ZINC PLATED 67546 2 16 DRIVE SHAFT AXIAL FEED 0 12 INCHES 74228 1 17 LEADSCREW RADIAL FEED 0 12 INCH 74231 1 18 SCREW M8 X 1 25 X 35 SSSFP 74291 3 19 SCREW M8 X 1 25 X 30 OAL X 10 THD L STAI...

Page 98: ...ge 84 FF1200 FF2400 FF3600 Operating Manual FIGURE A 13 FF2400 RADIAL AND AXIAL SLIDE ASSEMBLY P N 80683 5 2 18 11 16 17 26 27 9 6 13 23 22 17 16 29 25 28 7 30 10 15 8 12 14 3 1 3 24 3 1 3 20 19 4 15 21 2 ...

Page 99: ...LL 1 4 CBORE MTG 2 0 X 5 12 X 1 02W PLASTIC COATED 53462 2 13 BRG RETAINING NUT AXIAL FEED LEADSCREW 57214 2 14 RING O 1 16 X 13 16 ID X 15 16 OD 57320 4 15 NUT M8 X 1 25 STDN ZINC PLATED 67546 2 16 SCREW M8 X 1 25 X 35 SSSFP 74291 3 17 SCREW M8 X 1 25 X 30 OAL X 10 THD L STAINLESS 74632 4 18 LEADSCREW RADIAL FEED 0 24 36 INCH 75302 1 19 DRIVE SHAFT 0 24 36 INCH 75303 1 20 ASSY FEED BOX 79194 1 21...

Page 100: ...F2400 FF3600 Operating Manual FIGURE A 15 FF3600 RADIAL AND AXIAL SLIDE ASSEMBLY P N 80702 26 25 15 8 12 31 9 30 2 7 28 20 18 21 32 29 12 37 33 17 16 14 4 27 1 4 4 1 4 23 22 17 5 11 3 35 5 3 11 24 6 6 34 2 10 36 13 19 ...

Page 101: ... 53462 2 15 BRG RETAINING NUT AXIAL FEED LEADSCREW 57214 2 16 RING O 1 16 X 13 16 ID X 15 16 OD 57320 4 17 NUT M8 X 1 25 STDN ZINC PLATED 67546 2 18 LABEL CLIMAX LOGO 2 X 8 70227 1 19 SCREW M8 X 1 25 X 35 SSSFP 74291 1 20 SCREW M8 X 1 25 X 30 OAL X 10 THD L STAINLESS 74632 4 21 LEADSCREW RADIAL FEED 0 24 36 INCH 75302 1 22 DRIVE SHAFT 0 24 36 INCH 75303 1 23 ASSY FEED BOX 79194 1 24 SHIM FEEDBOX M...

Page 102: ...g Manual FIGURE A 17 FEED BOX ASSEMBLY P N 79194 34 3 30 39 1 12 16 24 27 24 43 17 35 14 42 41 16 37 40 29 5 29 4 11 34 9 38 6 4 13 31 33 26 13 21 32 5 44 25 10 8 34 15 48 3 4 11 10 30 20 47 1 23 2 7 28 10 30 22 36 30 46 45 49 32 12 18 19 ...

Page 103: ...R BEVEL 16 DP 24T 1 1 20PA STL KEYWAY MODIFIED HEX BORE 74253 2 24 GEAR BEVEL 16DP 24T 1 1 20PA STL MODIFIED KEYWAY 74255 1 25 SPACER GEAR 85 IN HEX BORE 74262 1 26 GEAR SPUR 20DP 20T 20PA 1 2 FACE MODIFIED 75LG HEX ID 74266 1 27 GEAR SPUR 20DP 30T 20PA 625LG STEEL MODIFIED 74270 1 28 GEAR SPUR 20DP 25T 0 5 FACE MODIFIED 625LG 875ID 74275 2 29 BRG NEEDLE 1 2 ID X 11 16 OD X 562 ONE SEAL 74277 4 30...

Page 104: ... 90 FF1200 FF2400 FF3600 Operating Manual FIGURE A 19 TOOL HEAD ASSEMBLY P N 80407 34 16 26 30 14 12 2 28 5 19 20 25 18 25 24 29 28 3 27 7 23 8 13 32 3 15 29 3 15 9 13 22 4 17 11 33 19 5 10 21 24 1 31 14 6 ...

Page 105: ...5 X 10 SSSFP 51261 4 13 WASHER THRUST 8MM ID X 21MM OD X 1 00MM 57426 2 14 SCREW M6 X 1 0 X 16MM SSSFP 68514 3 15 SCREW M6 X 1 0 X 8MM BHSCS 73447 1 16 CLAMP TOOL BIT 74227 1 17 DRIVE WORM AXIAL FEED 74238 1 18 FELT SEAL 1 4 HEX SHAFT 79 OD 74239 2 19 NUT WORM RETAING 74241 1 20 BASE TOOL HEAD 74243 1 21 SLIDE SWIVELING TOOL HEAD 74245 1 22 SHAFT PINION DOWN FEED 74246 1 23 GIB 365 X 125 X 3 4 SS ...

Page 106: ...969 1 4 SCREW M10 X 1 5 X 50MM SHCS 66826 2 11 WASHER THRUST 8MM ID X 21MM OD X 2 75MM THICK 75359 1 3 HOUSING CHUCK FOOT 12 78913 1 7 SCREW ADJUSTING CHUCK FOOT 12 78914 1 6 JAW CHUCK FOOT 78915 1 5 FINGER SETUP FFOD 78916 1 8 NUT M22 X 1 5 JAMN ZINC PLATED 78917 1 2 SCREW M6 X 1 0 X 20MM SHCS CAPTIVE 8 THD STAINLESS 78924 2 10 LABEL 0 12 INCH CHUCK RANGES 80083 1 13 5 13 1 8 4 10 2 7 6 11 3 ...

Page 107: ...CREW M12 X 1 75 X 65mm SHCS 43182 2 3 JAW CHUCK FOOT 78915 1 4 FINGER SETUP FFOD 78916 1 5 SCREW M6 X 1 0 X 20MM SHCS CAPTIVE 8 THD STAINLESS 78924 2 6 HOUSING CHUCK FOOT 24 78980 1 7 SCREW ADJUSTING CHUCK FOOT 24 36 78981 1 8 NUT 1 3 8 12 JAMN 78984 1 9 WASHER THRUST 787 ID X 1 378 OD X 108 HOUSING PILOTED 79003 1 10 LABEL 0 24 INCH CHUCK RANGES 79901 1 11 5 2 6 1 10 3 7 8 9 4 11 ...

Page 108: ...42969 1 2 SCREW M12 X 1 75 X 65mm SHCS 43182 2 3 JAW CHUCK FOOT 78915 1 4 FINGER SETUP FFOD 78916 1 5 SCREW M6 X 1 0 X 20MM SHCS CAPTIVE 8 THD STAINLESS 78924 2 6 HOUSING CHUCK FOOT 24 78980 1 7 SCREW ADJUSTING CHUCK FOOT 24 36 78981 1 8 NUT 1 3 8 12 JAMN 78984 1 9 WASHER THRUST 787 ID X 1 378 OD X 108 HOUSING PILOTED 79003 1 10 LABEL 0 36 INCH CHUCK RANGES 80088 1 11 5 2 6 1 10 3 7 8 9 4 11 ...

Page 109: ...ION P N QTY ITEM FTG QD COUPLER 1 2B 1 2 NPTF PNEUMATIC 13208 1 1 VALVE BALL 1 2 NPTF X 1 2 NPTF OVAL HANDLE 36328 1 2 HOSE ASSY 801 1 2 X 1 2 NPTM X 1 2 NPTMS X 96 37008 1 3 FTG NIPPLE 1 2 NPTM X 2 INCH BRASS 76030 1 4 PNEUMATIC CONDITIONING UNIT 1 2 IN LOW PRES DROPOUT 78264 1 5 1 3 2 4 5 ...

Page 110: ...F3600 Operating Manual FIGURE A 25 PNEUMATIC CONDITIONING UNIT PCU ASSEMBLY P N 78264 ASSEMBLED SCALE 1 5 18 3 21 21 21 25 17 31 33 1 5 27 36 29 28 30 7 35 37 19 4 11 32 16 10 14 3 34 26 12 13 6 24 8 23 15 20 2 38 11 9 40 39 ...

Page 111: ...START 10250 SERIES 46797 1 19 1 63 X 1 63 X 3 375L MODU TEK EXTRUSION 46802 1 20 FTG ELBOW 1 8 NPTM X 1 4 TUBE PRESTOLOK 48648 3 21 TUBING 1 4 OD POLYURETHANE INCH NOT SHOWN 48650 60 22 SCREW M5 X 0 8 X 12MM BHCS BLACK FINISH 53617 6 23 SCREW 5 16 18 X 3 4 T BOLT 59436 6 24 1 63 X 1 63 X 7 00L MODU TEK EXTRUSION 59437 3 25 O RING 2mm X 23mm ID X 25mm OD 59442 3 26 PUSHBUTTON GREEN FLUSH 59458 1 27...

Page 112: ...80570 PARTS LIST DESCRIPTION P N QTY ITEM FTG QD NIPPLE 1 2B 1 2 NPTM PNEUMATIC 13209 1 1 FTG SWIVEL AIR 1 2 NPTM X 1 2 NPTF 35670 1 2 LABEL WARNING WEAR EAR PROTECTION 59037 1 3 MOTOR AIR 1 07HP 382 RPM FS 177 RPM MAX 54TQ STALL 74585 1 4 LABEL AIR MOTOR DIRECTION AND PRESSURE 80569 1 5 5 3 4 1 2 ...

Page 113: ... DESCRIPTION P N QTY ITEM FTG QUICK COUPLER 1 2B 1 2 NPTM MALE AIR 13209 1 1 FTG SWIVEL AIR 1 2 NPTM X 1 2 NPTF 35670 1 2 LABEL WARNING WEAR EAR PROTECTION 59037 1 3 LABEL AIR MOTOR DIRECTION AND PRESSURE 80569 1 4 MOTOR AIR 486 RPM FS 208 RPM MAX 160 NM TQ 3 BOLT FLANGE 3 4 SHAFT 80614 1 5 5 4 3 2 1 ...

Page 114: ... DESCRIPTION P N QTY ITEM FTG QD NIPPLE 1 2B 1 2 NPTM PNEUMATIC 13209 1 1 FTG SWIVEL AIR 1 2 NPTM X 1 2 NPTF 35670 1 2 LABEL AIR MOTOR DIRECTION AND PRESSURE 80569 1 4 LABEL WARNING WEAR EAR PROTECTION 59037 1 3 MOTOR AIR RIGHT ANGLE 448 RPM FS 219 RPM MAX 101 NM TQ 3 BOLT FLANGE 3 4 SHAFT 80617 1 5 4 3 2 5 1 ...

Page 115: ...W M5 X 0 8 X 8mm SSSFP 57214 BRG RETAINING NUT LEADSCREW AXIAL RADIAL FEED FF LINE KB 57320 RING O 1 16 X 13 16 ID X 15 16 OD 58672 SCREW M4 X 0 7 X 16MM SHCS BLACK OXIDE 67573 SCREW M8 X 1 25 X 50MM SSSHDP 68514 SCREW M6 X 1 0 X 16MM SSSFP 72222 SCREW M10 X 1 5 X 70MM SHCS 74227 CLAMP TOOL BIT METRIC 74228 DRIVE SHAFT AXIAL FEED 0 12 INCHES 74231 LEADSCREW RADIAL FEED 0 12 INCH 74245 SLIDE SWIVEL...

Page 116: ...TUP FINGER 80407 ASSY TOOL HEAD TABLE A 1 FF1200 SPARE PARTS KIT P N 78263 CONTINUED Part number Description TABLE A 2 FF2400 SPARE PARTS KIT P N 81453 Part number Description 74245 SLIDE SWIVELING TOOL HEAD 58672 SCREW M4 X 0 7 X 16MM SHCS BLACK OXIDE 78964 PIN TAPERED ROTATING TOOL HEAD BRONZE 68514 SCREW M6 X 1 0 X 16MM SSSFP 54724 SCREW M5 X 0 8 X 8mm SSSFP 74296 SCREW M6 X 1 0 X 20 SSSHDP 356...

Page 117: ...74227 CLAMP TOOL BIT METRIC 35651 SCREW M6 X 1 0 X 55MM SHCS 44519 SCREW M12 X 1 75 X 30MM SSSFP 80210 SP ASSY SETUP FINGER 76755 KNOB FEED KNURLED 2 5 OD X 1 2 13 ID THDS 74292 GIB 365 X 125 X 3 4 SS UNEVEN SP 79194 ASSY FEED BOX 14315 PIN DOWEL 3 32 DIA X 1 2 75303 DRIVE SHAFT 0 24 36 INCH 11736 WASHER THRUST 500 ID X 937 OD X 030 VMI 22402 WASHER THRUST 1 000 ID X 1 562 OD X 095 VMI 12895 PIN R...

Page 118: ... X 0781 VMI 76006 BELT POLYCHAIN 8mm PITCH X 12mm WIDE X 400 TEETH 72222 SCREW M10 X 1 5 X 70MM SHCS 20772 NUT M6 X 1 0 STDN ZINC PLATED 74248 ARM CAM FOLLOWER 74658 SCREW M6 X 1 X 25MM SSSDP 76480 KEY 8MM X 12MM X 30MM RADIUS BOTH ENDS W M5 THREAD 74634 BRG CAM FOLLOWER SHAFT MOUNT 8 mm ID X 24 mm OD X 10 mm 67573 SCREW M8 X 1 25 X 50MM SSSHDP 74632 SCREW M8 X 1 25 X 30MM SHCS CAPTIVE 10 THD STAI...

Page 119: ...P 74636 PIN CAM FOLLOWER 8 mm X 80 74836 SCREW 1 2 13 X 3 8 SSSFP 74295 NUT LEADSCREW ACME 3 8 6 BRONZE LH 80097 ASSY CHUCK FOOT 36 76601 PIN LOCATING 6MM OD X 20MM X M5 X 8 THREAD 57320 RING O 1 16 X 13 16 ID X 15 16 OD TABLE A 3 FF3600 SPARE PARTS KIT P N 81454 CONTINUED Part number Description TABLE A 4 TOOL KIT P N 78262 Part number Description 38678 WRENCH HEX SET 1 5 10MM BOUNDHUS BALL END K...

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Page 121: ...P N 95936 Rev 0 Page 107 APPENDIX B SCHEMATICS FIGURE B 1 PNEUMATIC SCHEMATIC P N 78264 1 2 3 4 5 1 2 3 4 5 XP SHUTOFF E STOP START 1 3 2 V1 ...

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Page 123: ...P N 95936 Rev 0 Page 109 APPENDIX C SDS Contact CLIMAX for the current safety data sheets ...

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