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FF4000 Operating Manual

Exploded Views and Parts

The following diagrams and parts lists are for your reference purposes only. The machine
Limited Warranty is void if the machine has been tampered with by anyone who has not
been authorized in writing by Climax Portable Machining & Welding Systems to perform
service on the machine.

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Summary of Contents for FF4000

Page 1: ...P N 35425 May 2019 Revision 2 FF4000 FLANGE FACER OPERATING MANUAL SERIAL NUMBER RANGE 11017900 15121870 ORIGINAL INSTRUCTIONS FF4000 Flange Facer shown ...

Page 2: ......

Page 3: ...ons 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 ...

Page 4: ...Page B FF4000 Operating Manual CLIMAX GLOBAL LOCATIONS ...

Page 5: ...ctory 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 materi...

Page 6: ...Page D FF4000 Operating Manual CE DOCUMENTATION LACEHOLDER FOR CE DECLARATION OF INCORPORATION ...

Page 7: ... Guidelines 1 Machine Specific Safety Practices 2 Labeling Guidelines 3 Introduction 6 About this manual 7 Receiving Inspection 8 Recommended tools 9 Setup 10 Operation 17 Disassembly 21 Maintenance 22 Storage 23 Exploded Views and Parts 24 ...

Page 8: ...Page F FF4000 Operating Manual This page is intentionally left blank ...

Page 9: ...ar of the machine during operation Never lean toward or reach into the machine to remove chips or to adjust the machine while it is running Keep bystanders away while operating this machinery ROTATING MACHINERY Rotating machinery can seriously injure an operator Lock out all power sources before you interact with the machine KEEP YOUR WORK AREA CLEAN AND TIDY Keep all cords and hoses away from mov...

Page 10: ...rols perform a one to one action The machine is not supplied with a power unit and therefore does not have an E stop MACHINE SETUP AND DISASSEMBLY With a modular design the machine can be broken down into components to ease setup MACHINE GUARDS There are no guards used on this machine ELECTRICAL EMISSIONS There are no electrical components used on this machine OPERATOR STATION Due to the nature of...

Page 11: ...ns to reduce the risk of hazards and serious injury DANGER Indicates a hazardous situation that could be fatal or cause serious injury WARNING Indicates a potentially hazardous situation that could be fatal or cause serious injury CAUTION Indicates a potentially hazardous situation that could result in minor to moderate injury damage to the machine or interruption of an important process IMPORTANT...

Page 12: ...ly 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 attached to it become one complete machine during the material removal process To achieve the intended results and to promote safety the operator must understand and follow the design inten...

Page 13: ...precautions to keep workers away from the identified fall path I considered how this machine operates and the best placement for the controls cabling and the operator I evaluated and mitigated any other potential risks specific to my work area TABLE 2 RISK ASSESSMENT CHECKLIST AFTER SET UP After Set up I checked that the machine is safely installed and the potential fall path is clear If the machi...

Page 14: ...g weld prep configurations on tube and pipe The basic machine configuration includes An air motor pneumatic conditioner and facing head Sets of 15 clamp blades 3 blades set for bores 3 65 12 7 93 323 mm diameter 3 0 3 65 without a chuck blade Tool kit with hexagon wrench set Operating Manual dead blow hammer and spanner wrench Facing bits for roughing and finishing operations Heavy duty plastic co...

Page 15: ... describes the most effective setup and operation of your Model FF4000 Flange Facer All parts meet Climax Portable Machining Welding Systems strict quality standards For maximum safety and performance read the entire manual before operating this machine ...

Page 16: ...nspection In accordance with normal practice be sure to inspect the machine for any damage that may have occurred in shipping Check parts received against the invoice or packing slip and promptly notify Climax should there be any discrepancies ...

Page 17: ...panner wrench Hex key wrench set Other tools you could have on hand Pliers for pulling chips away from the machine Chip brush Cutting oil File Honing stone Precision instruments In most cases this machine can be setup using basic measuring devices such as a steel rule or tape measure Should greater precision be required some or all of the following may be useful Dial or digital calipers ID caliper...

Page 18: ...be machined This measurement is important with regard to correct sizing and selection of the clamping blades Install a matched set of clamp blades on the ID clamping chuck being sure all blades are secure and properly seated Lightly oil the draw rod and ramps in the chuck Install the chuck on the mandrel Line up the hexagon in the chuck with the hexagon in the end of the draw rod Align the bayonet...

Page 19: ... 109 35525 4 25 4 90 108 124 35526 4 85 5 50 123 140 35527 5 45 6 10 138 155 35528 6 05 6 70 154 170 35529 6 65 7 30 169 185 35530 7 25 7 90 184 201 35531 7 85 8 50 199 216 35532 8 45 9 10 215 231 35533 9 05 9 70 230 246 35534 9 65 10 30 245 262 35535 10 25 10 90 260 277 35536 10 85 11 50 276 292 35537 11 45 12 10 265 307 35538 12 05 12 70 306 323 35539 CAUTION Dirt or burrs in the bore may preven...

Page 20: ...re set first facing or squaring bits next and outside diameter or j groove bits last With each tool bit correctly in place tighten the setscrews When a land is required on the work piece use a facing bit in combination with the beveling bit The FF4000 beveling head can plunge cut but does not feed in a radial direction The width of the land is controlled by the position of the beveling bit or by s...

Page 21: ...ll the machine in the pipe tube end and turn the draw rod knob clockwise to spread the clamp blades in the bore To center and secure the machine gently work the tool back and forth while tightening the draw rod knob clockwise For final tightening push the draw rod knob into the feed handle and use the added leverage to tighten the chuck CAUTION Machine is NOT securely clamped until draw rod knob i...

Page 22: ... air supply line to the motor Close and lock out the air supply Connect the air supply to the pneumatic conditioning unit Be sure the air supply line is at least 3 8 Make sure the ball valve is turned off The ball valve is closed when the handle is perpendicular with the air line Connect the air supply line from the pneumatic conditioning unit to the machine using quick disconnect fittings CAUTION...

Page 23: ...00 is equipped with a 1 45 hp 1 08 Kw air motor and a ball type shut off valve Motor speed is controlled by adjusting the ball valve CAUTION DO NOT attempt to control motor speed by adjusting the in line air pressure from 90 psi 620 kPa Slowly open the ball valve The valve is fully open when the handle aligns with the air supply line Adjust the ball valve to obtain an appropriate tool head speed S...

Page 24: ...000 Flange Facer includes a feed mechanism with both left hand and right hand screw threads While providing a more compact feed system this innovative design effectively doubles the length of travel for the tool head When feeding the tool head away from the work piece use caution to prevent the nut barrel from coming in contact with the main housing The barrel has left hand threads To move the bar...

Page 25: ...r to deliver oil at a rate of 15 20 drops per minute Drain all liquid and remove dirt from the air filter Close the ball valve Check that the in line air pressure is 90 psi 620 kPa Facing NOTE For precision facing operations it is good practice to lock the feed by tightening the set screws under the feed handle Be sure the air supply is disconnected and turned off Secure the tool bit in the facing...

Page 26: ...ing out To feed toward the chuck push the feed shaft on the side of the facing head with the arrow pointing in NOTE When both shaft pins are out of their detent slots the feed system is in NEUTRAL and can be fed by hand in either direction Feed rate Adjust the feed rate using the small round knob located near the trip mechanism Clockwise decreases the feed rate Counterclockwise increases the feed ...

Page 27: ...Push and turn to lock A good whack with a dead blow hammer in the opposite direction of the arrow ensures proper seating of the tool head Reinstall the chuck Change the chuck blades if required Mount the machine in the tube or pipe Turn the draw rod knob counterclockwise drawing the clamp blades back inward CAUTION To avoid damage to the clamp blades be sure the machine is mounted far enough insid...

Page 28: ...uring machining set screws on the mandrel gib can be tightened moderately to minimize backlash Do not over tighten The gib screws are preset at the factory Field adjustments may be required over time When adjusting the gib the screws should be snug but not too tight When adjusted properly the tool head moves smoothly along the slide but does not feel loose Check by manually feeding the tool head f...

Page 29: ...g machinery by turning off and disconnecting the air supply before disassembly Back off the tool bits 1 4 to 1 2 away from the work piece Loosen the draw rod knob by turning it counterclockwise and gently rock the tool to loosen the clamping chuck Remove the FF4000 from the work piece ...

Page 30: ...Page 22 FF4000 Operating Manual Maintenance Lubricants LUBRICANT WHERE USED Light oil Unpainted surfaces Cutting oil Tool bits work piece Air tool oil Air lubricator oil cup ...

Page 31: ...g clean the machine with solvent to remove grease metal chips and moisture To prevent corrosion spray unpainted surfaces using WD 40 for short term storage Cosmoline for long term storage Disassemble the Flange Facer and place it with any tools and accessories in the case provided Include desiccant or vapor wrap to absorb moisture ...

Page 32: ...ing diagrams and parts lists are for your reference purposes only The machine Limited Warranty is void if the machine has been tampered with by anyone who has not been authorized in writing by Climax Portable Machining Welding Systems to perform service on the machine ...

Page 33: ...425 Rev 2 Page 25 FF4000 MAIN ASSEMBLY BALLOON NO QTY PART DESCRIPTION 1 1 49593 FF4000 BASE UNIT 2 1 34936 ASSY FACING HEAD 19 DIA 3 1 35439 ASSY HEAD BEVELING 2 00 12 75 DIA 4 1 35427 ASSY CHUCK HEAD FF4000 ...

Page 34: ...Page 26 FF4000 Operating Manual FF4000 MAIN AS S EMBL Y ...

Page 35: ...P N 35425 Rev 2 Page 27 ...

Page 36: ...Page 28 FF4000 Operating Manual ...

Page 37: ... 120 RPM MAX HP 2 33691 MUFFLER FF4000 3 36825 VALVE BALL 1 2 OVAL HANDLE ASSY W LABEL 4 35670 FTG SWIVEL 1 2 NPTM X 1 2 NPTF 5 13209 FTG QUICK COUPLER 1 2B 1 2 NPTM MALE AIR NOT SHOWN 34866 AIRTOOL OIL COMPLETE NOT SHOWN 13208 FTG QUICK COUPLER 1 2B 1 2 NPTF FEMALE AIR NOT SHOWN 28826 PNEUMATIC CONDITIONING UNIT 1 2 IN ...

Page 38: ...Page 30 FF4000 Operating Manual ...

Page 39: ...K HEAD FF4000 BALLOON No PART DESCRIPTION 1 35916 SCREW M5 X 0 8 X 10 SHCS 2 33530 RETAINER CHUCK 3 33531 PLATE RETAINER 4 33529 JAW CHUCK 5 10850 PIN ROLL 3 16 DIA X 3 4 6 33528 CHUCK HEAD 7 15174 PIN DOWEL 3 8 DIA X 5 8 8 33532 BOLT CHUCK ...

Page 40: ...Page 32 FF4000 Operating Manual ...

Page 41: ... PINION AXIAL FEED 7 19562 BALL STEEL 5 32 DIA KB 8 39872 SPRING COMP 148 OD X 023 WIRE X 44 LONG KB 9 11763 PIN DOWEL 3 16 DIA X 3 4 10 16407 PIN DOWEL 3 8 DIA X 3 4 11 35036 ARM FLANGE FACER 19 DIA 12 34992 LEVER FEED KB 13 35595 KNOB KNURLED DOMED 1 1 2 OD 3 8 16 TAP STEEL KB 14 18689 PIN ROLL 3 32 DIA X 1 15 35599 PIN DOWEL 3 16 DIA X 2 16 33563 BUSHING OILITE 2 ID X 2 1 4 OD X 1 17 36152 SCRE...

Page 42: ...OLDER FF3000 FF4000 22 35911 SCREW M6 X 1 0 X 25MM SSSCP 23 45034 SCREW M6 X 1 0 X 12MM SSSDPPL 24 35005 GIB 47 X 15 X 2 0 1018 2 SS X 1 0 KB 25 35600 PIN DOWEL 3 16 DIA X 1 1 2 35 41290 SUPPORT RACK RADIAL FEED FACING HEAD KB 36 11846 SCREW 10 32 X 7 8 SHCS 1 35196 BALL TOOLING 1 2 DIA KB ...

Page 43: ...P N 35425 Rev 2 Page 35 34936 FACING HEAD ASSEMBLY ...

Page 44: ...39 ASSY HEAD BEVELING 2 00 12 75 DIA BALLOON No PART DESCRIPTION 1 33619 HEAD BEVELING 2 12 75 IN 2 33563 BUSHING OILITE 2 ID X 2 1 4 OD X 1 3 11027 PIN DOWEL 3 8 DIA X 1 4 35368 SCREW M10 X 1 5 X 12 SSSCP 5 35541 SET STARTER FORM TOOLS ...

Page 45: ...P N 35425 Rev 2 Page 37 ...

Page 46: ...Page 38 FF4000 Operating Manual ...

Page 47: ...2 Page 39 34980 ASSY HEAD BEVELING 1 25 6 63 DIA BALLOON No PART DESCRIPTION 1 35557 HEAD BEVELING 1 25 7 00 DIA 2 35368 SCREW M10 X 1 5 X 12 SSSCP 3 11027 PIN DOWEL 3 8 DIA X 1 NOT SHOWN 35541 SET STARTER FORM TOOLS ...

Page 48: ...Page 40 FF4000 Operating Manual 35424 KIT TOOL FF4000 PART DESCRIPTION 35516 HAMMER DEAD BLOW 1 3 4 DIA HEAD 34181 WRENCH HEX SET FOLD UP 5 64 TO 1 4 9 PIECES 34482 WRENCH SPANNER 3 FIXED HEAD PIN STYLE ...

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