Climax FF5300 Operating Manual Download Page 78

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FF5300 Operating Manual

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ASSEMBLY

(P/N 90252)

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Summary of Contents for FF5300

Page 1: ...FF5300 FLANGE FACER FF5300 OPERATING MANUAL ORIGINAL INSTRUCTIONS P N 91025 June 2019 Revision 4...

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 FF5300 Operating Manual CLIMAX GLOBAL LOCATIONS...

Page 5: ...P N 91025 Rev 4 Page C CE DOCUMENTATION...

Page 6: ...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...

Page 7: ...2 4 3 Rotational speed 17 2 4 4 Feed adjustments 17 2 4 5 Weights 20 2 5 ITEMS REQUIRED BUT NOT SUPPLIED 20 3 SETUP 21 3 1 RECEIPT AND INSPECTION 21 3 2 PREPARING THE MACHINE FOR USE 22 3 2 1 Pre set...

Page 8: ...PCU oil reservoir levels 49 5 4 2 Empty the air filter water trap 49 5 4 3 PCU emergency stop check 49 5 4 4 PCU drop out circuit check 49 5 4 5 Dovetail ways maintenance 50 5 4 6 Leadscrew maintenanc...

Page 9: ...ing and counterweight arm installed 31 3 13 Location of locking screws 31 3 14 FF5300 with short machining arm 32 3 15 FF5300 40 1 016 mm arm maximum swing diameter 33 3 16 FF5300 40 1 016 mm arm mini...

Page 10: ...Page iv FF5300 Operating Manual LIST OF FIGURES CONTINUED FIGURE PAGE A 11 Counterweight assembly P N 90252 66 A 12 Pneumatic motor assembly P N 90060 67...

Page 11: ...s 20 3 1 ID chuck setup table for standard ID chuck hub 25 3 2 Standard ID chuck leg identification 27 3 3 Optional adjustable leveling foot identification 27 3 4 Optional machining arms 29 3 5 ID chu...

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Page 13: ...ental product information to aid in setup operation and maintenance tasks Read this entire manual to familiarize yourself with the FF5300 before attempting to set it up or operate it 1 2 SAFETY ALERTS...

Page 14: ...e end user are responsible 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 precaut...

Page 15: ...machine produces metal chips during operation Always wear eye protection when operating the machine Sound level This machine produces potentially harmful sound levels Hearing protection is required wh...

Page 16: ...ttach directly to the workpiece itself or to an adjacent struc ture and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and the st...

Page 17: ...s to keep workers away from the identified fall path I considered how this machine operates and identified the best placement for the controls cabling and the operator I evaluated and mitigated any ot...

Page 18: ...ntact CLIMAX immediately for replacements TABLE 1 4 FF5300 LABELS P N 29152 Mass plate P N 35740 Serial plate P N 46902 Warning label hot surface P N 59035 Warning label wear eye protection P N 59042...

Page 19: ...of the components of the FF5300 For further identification of location placement refer to the exploded views in Appendix A P N 91585 Climax logo TABLE 1 4 FF5300 LABELS CONTINUED FIGURE 1 1 TOP LABEL...

Page 20: ...Page 8 FF5300 Operating Manual This page intentionally left blank...

Page 21: ...eeds and has an adjustable feed rate control on a non rotating part of the machine Feed rate is cam controlled to match machine RPM Manual feeding for rapid positioning is also possible Face to swing...

Page 22: ...CHUCK ASSEMBLY Axial Radial Feed Selector Pneumatic Drive Motor wiveling Tool Holder Axial Radial Feed Rate Control Chuck Mount nect et Counterweight Assembly ections 2 6 1 7 5 8 9 3 4 TABLE 2 1 FF530...

Page 23: ...ergency shutdown To stop machine operation immediately press the emergency stop button on the PCU Before restarting the FF5300 do the following 1 Check that the area around the machine swing area is f...

Page 24: ...dropout 5 Emergency STOP Isolates the supply air and vents the downstream air Press down to stop the machine pull up to reset 6 Oil drip rate dial Controls the air lubricator drip rate For more inform...

Page 25: ...at it con trols the exhaust from the air motor WARNING Always stop the machine using the e stop button on the PCU This removes all pressure from the FF5300 drive motor The air plumbing includes an exh...

Page 26: ...4 DIMENSIONS FOR 32 813 MM MACHINING ARM MAX MACHINING 32 INCH ARM 32 INCHES 813 MM MAX SWING 32 INCH ARM 31 4 INCHES 798 MM MAX CHUCKING 35 8 INCHES 909 MM MIN SWING 32 INCH ARM 22 75 INCHES 578 MM...

Page 27: ...ENSIONS FOR 40 1 016 MM MACHINING ARM MAX MACHINING 40 INCH ARM 40 INCHES 1016 MM MAX SWING 40 INCH ARM 38 2 INCHES 970 MM MAX CHUCKING 35 8 INCHES 909 MM MIN SWING 40 INCH ARM 26 25 INCHES 667 MM MIN...

Page 28: ...l FIGURE 2 6 DIMENSIONS SIDE VIEW 3 23 INCHES 82 MM MAXIMUM AXIAL RETRACT 4 INCHES 100 MM AXIAL TOOL HEAD TRAVEL 2 INCHES 51 MM MAX CLEARANCE WITH TOOL HEAD FULLY RETRACTED 3 INCHES 76 MM 2 6 INCHES 6...

Page 29: ...ion when changing inserts and handling or adjusting the cutting tool after use 2 4 2 Pressure The recommended air pressure is 90 psi 6 2 bar at 71 cubic feet per minute 2 0 cubic meters per minute 2 4...

Page 30: ...a free spinning RPM of more than 40 Different RPMs cubic feet per minute of supply air flange material cutting tool geometry depth of cut or other heavier cutting forces will reduce these feed rate va...

Page 31: ...art the machine 4 Move the feed speed adjustment arm to the desired feed rate position The feed rate can be increased decreased or set to zero at any time during machine operation WARNING To protect y...

Page 32: ...huck1 and 40 1 016 mm machining arm 1 Machine weights are operating weights 196 7 89 Total machine weight ID chuck2 and 32 813 mm machining arm 2 Machine weights are operating weights 192 87 ID chuck...

Page 33: ...ion describes the setup and assembly procedures for the FF5300 flange facer 3 1 RECEIPT AND INSPECTION Your CLIMAX product was inspected and tested prior to shipment and packaged for normal shipment c...

Page 34: ...6 on page 7 for each job before starting work The FF5300 machine has remote operation features that enable you to choose the optimum location to operate the machine Section 2 3 on page 21 WARNING Alw...

Page 35: ...ll machine parts are tightened properly to prevent hazards The machine can be broken down quickly into smaller sections if needed The maximum weight of the heaviest individual module is 65 lbs 29 5 kg...

Page 36: ...y blocks and clamps not included with the machine WARNING Do not remove the crane until at least one of the securing methods is in place and the jacking screws are tightened to 30 ft lb 40 Nm NOTICE I...

Page 37: ...ge chuck Short jacking Standard jacking Short tube Long tube 5 68 7 68 144 195 mm 1 0 1 0 0 0 7 32 9 32 186 237 mm 1 0 0 1 0 0 9 18 12 68 233 322 mm 1 0 0 1 1 0 12 54 16 04 319 407 mm 1 0 0 1 0 1 15 9...

Page 38: ...screws HHCS 4 Assemble the ID chuck Figure 3 4 5 Adjust the four HHCS to approximately level the interface plate to the chuck 6 Apply the anti seize com pound provided in the tool kit to the threads...

Page 39: ...TABLE 3 2 STANDARD ID CHUCK LEG IDENTI FICATION Number Component 1 Captive screw 2 Setup finger 3 Swivel gripper 4 Chuck foot 5 Jacking screw 6 Full extension groove not shown TABLE 3 3 OPTIONAL ADJU...

Page 40: ...retain the chuck WARNING Failure to check that the chuck is secure could result in the machine falling out of or into the workpiece causing personnel injury or damage 3 7 INSTALLING THE MACHINE TO THE...

Page 41: ...awbolt to the chuck interface plate to 16 ft lbs 22 Nm and torque to 100 ft lbs 135 Nm NOTICE Check that the machine is securely mounted for best machining results 3 8 INSTALLING THE MACHINING ARM TIP...

Page 42: ...engage Loosely secure the top dovetail clamp plates so that the arm is retained against the body 3 Slide the arm to the desired location and tighten the M8 clamp screws on the top dovetail clamp plate...

Page 43: ...lure to secure the counterweight arm could result in the arm coming loose from the machine and swinging or falling causing personnel injury or damage TABLE 3 5 ID CHUCK LEG IDENTIFICATION Number Compo...

Page 44: ...for the minimum swing diameter the counterweight block should be removed and moved to an intermediate position on the counterweight arm See Figure 3 14 and Table 3 6 TIP There is a longer M12 screw w...

Page 45: ...G DIAMETER FIGURE 3 16 FF5300 40 1 016 MM ARM MINIMUM SWING DIAMETER 26 25 667 MM 3 10 CENTERING AND LEVELING THE MACHINE TO THE WORKPIECE Do the following to center and level the machine to the workp...

Page 46: ...ing personnel injury or damage TIP Use the supplied 3 4 19 mm end wrench to hold the setup fingers vertical while tightening the jacking screws 6 Remove the setup fingers if necessary NOTICE M6 screws...

Page 47: ...ead angle TIP There are detents located at 0 23 and 45 to assist in setting the desired angle TIP Note that when the tool slide is on the outboard side of the feed pinion as shown in Figure 3 19 on pa...

Page 48: ...Take this into consideration when orienting the cutting tip 2 Adjust the tool position by turning the hex shafts upper for radial or lower for axial at the control end of the machining arm TIP See Sec...

Page 49: ...e 3 22 on page 38 When the symbol is exposed the feed will be out for radial or down for axial When the lever is in the neutral that is vertical position it is the most convenient position for adjusti...

Page 50: ...ction selector is in the neutral position or the feed speed adjustment lever is at zero Do not manually rotate the machining arm counterclockwise when the feed direction selector is engaged and or wit...

Page 51: ...nd that the drive key is in place and aligned with the keyway in the worm 2 Connect the air hose from the PCU to the air motor 3 Connect the PCU to a air source with 90 psi 6 bar pressure using a mini...

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Page 53: ...chine has remote operation features that enable you to choose the optimum location to work from WARNING Always follow safe work practices including site specific safety requirements It is your respons...

Page 54: ...re secure and cannot be hit by moving parts 10 Check the tool condition and sharpness 11 Check that the tool head is set at the desired angle and is tight 12 Check all hand tools are removed from insi...

Page 55: ...machine to complete facing the flange 6 Repeat step 1 through step 5 as necessary WARNING Rotating machinery can cause serious injury Turn off the air control valve and disconnect the air line before...

Page 56: ...se supplemental rigging as a precaution Do the following to remove the machine from the workpiece 1 De energize the machine 2 De pressurize the air system by disconnecting the air supply to the PCU 3...

Page 57: ...NG POORLY 51 5 5 4 THE MACHINE IS NOT CUTTING FLAT 52 5 6 DECOMMISSIONING 52 5 1 MAINTENANCE CHECKLIST This chapter explains periodic maintenance intervals and tasks and provides trou bleshooting guid...

Page 58: ...nterval Task See section Before each use Check the pneumatic conditioning unit PCU oil reservoir levels 5 4 1 Check the pneumatic lines for damage and wear Perform a PCU emergency stop check 5 4 3 Per...

Page 59: ...mber Component Function 1 Thrust bearings The thrust bearings are lubricated at the factory and should not need further lubrication 2 Dovetail ways Lubricate the rectangle and dovetail ways daily duri...

Page 60: ...glass level Replace oil every two years a AWS 32 hydraulic oil winter CONOCO Ecoterra 32 or Castrol BioBar 32 32 40 C 6 100 C Weekly PCU AW 32 hydraulic oil N A 32 40 C 6 100 C Refill oil lubricator L...

Page 61: ...the machine doesn t restart 5 4 4 PCU drop out circuit check The PCU drop out circuit prevents the machine from restarting unexpectedly after air supply to the PCU is lost and restored Do the followi...

Page 62: ...during operation to ensure smooth travel For leadscrew loca tions see Figure A 5 on page 60 and Figure A 7 on page 62 2 During operation clean ball screws and ACME leadscrews frequently to prevent thr...

Page 63: ...power to the machine drive is isolated and locked out then manually rotate the pneu matic machine clockwise by pushing on the end of the machining arm 5 5 2 The machine isn t feeding If the machine i...

Page 64: ...chatter 5 5 4 The machine is not cutting flat Do the following if the machine is not cutting flat 1 Before making a critical finish pass run the machine continuously for at least 15 minutes to check t...

Page 65: ...ort term storage Do the following for short term storage three months or less 1 Retract the tool head from the workpiece 2 Remove the tooling 3 Remove hoses 4 Remove the machine from the workpiece 5 C...

Page 66: ...ts original shipping container 6 3 DECOMMISSIONING To decommission the flange facer prior to disposal remove the drive assembly from the RDU and dispose of the drive assembly separately from the rest...

Page 67: ...ASSEMBLY P N 90337 60 FIGURE A 6 MACHINING ARM ASSEMBLY PARTS LIST P N 90337 61 FIGURE A 7 TOOL HOLDER ASSEMBLY P N 89940 62 FIGURE A 8 TOOL HOLDER ASSEMBLY P N 89940 63 FIGURE A 9 ID CHUCK ASSEMBLY P...

Page 68: ...Page 56 FF5300 Operating Manual FIGURE A 1 FF5300 ASSEMBLY P N 89900...

Page 69: ...P N 91025 Rev 4 Page 57 FIGURE A 2 FF5300 ASSEMBLY DETAIL P N 89900 7 7...

Page 70: ...0 7 5 87 5 2 6 6 6 5 0 PP 3 1 2 3 1 2 5 1 6 5 7 5867 2 5 1 61 3 17 00 64 27 1 6 5 2 6 6 3 81 5 386 7 3 7 0 66 187 1 5 187 6 5 666 3 6 5 0 6 6 3 7 6 5 5 02 6 5 0 PP 6 6 6 5 0 PP 666 3 5 1 61 3 2 63 5 9...

Page 71: ...5 6 5 0 00 6 6 66 6322 0 287 5 03 5 7851 1 50 723 03 5 7851 1 50 27720 6 7 9 5 5 7 21 6 5 5229 6 7 0 5 50 0 2 2 5 29 5 3 7 21752 6 7 5 7 21 6 7 5 9 5 6 7 5 286 1 29 5 9 5 867 3 1 21 867 3 7 5 1 2 2 63...

Page 72: ...Page 60 FF5300 Operating Manual FIGURE A 5 MACHINING ARM ASSEMBLY P N 90337...

Page 73: ...3 5 5 7 1 1 187 6 5 5 1 2 2 51 1 5 3527 7 21 51 1 1 586 029 1 3 576 51 1 2168 7 23 5 725 6 0 18 51 1 1 17 1 0 17 527 7 1 56 7 75 1 2 2 7 5867 5 1 3 7 5 2 5 5 6385 3 7 3 5 9 5 6 5 0 00 6 6 6 57 286 1...

Page 74: ...Page 62 FF5300 Operating Manual FIGURE A 7 TOOL HOLDER ASSEMBLY P N 89940...

Page 75: ...5 1 61 3 3 81 5 386 7 250 5 3 3 6 1 5 187 250 64 64 27 1 6 6 5 0 666 3 6 5 0 6 6 3 1 2 6 5 0 PP 666 3 6 5 0 666 3 51 1 27 685 5 3 7 6 5 0 00 666 3 6 5 0 00 6 6 03 722 7 6 5 0 00 666 3 187 0 1 6 5 0 00...

Page 76: ...Page 64 FF5300 Operating Manual FIGURE A 9 ID CHUCK ASSEMBLY P N 89990 1 5 6 8 17 3 4 2 13 15 14 11 10 9 12 16 7...

Page 77: ...52 4 4 BALL SWIVEL CONTACT 89943 4 5 CHUCK HUB 5 7 TO 19 90213 1 6 CHUCK HUB 16 TO 32 90214 1 7 PLATE INTERFACE CHUCK SPINDLE FF5300 90215 1 8 SCREW JACKING SHORT 90216 4 9 SCREW JACKING LONG 90217 4...

Page 78: ...1 COUNTERWEIGHT ASSEMBLY P N 90252 3 576 67 6 5 37 21 3 1 47 7 0 635 1 3 81 5 1 5 75 7 6 5 0 PP 6 6 6 5 0 00 6 6 127 6 2 1 6 5 0 00 6 6 1 2 7 2817 5 7 2817 5 7 50 2817 5 7 6 57 9 21 85 7 216 3 57 12 6...

Page 79: ...m SHCS 50458 2 6 FTG ADPTER 3 8 BSPP MALE X 3 8 NPTF 52734 1 7 FTG QUICK COUPLER 3 8B 1 2 NPTM FEMALE AIR 55126 1 8 FTG QUICK COUPLER 3 8B 3 8 NPTF MALE AIR 71910 2 9 FTG BARB 1 2 NPTM X 1 2 HOSE SWIV...

Page 80: ...CKING FOOT SETUP FINGER 2 90380 NUT LEADSCREW ACME 3 8 8 BRONZE LH 1 91042 O RING 1 25MM X 16MM ID X 18 5MM OD BUNA N 8 91050 WASHER SPHERICAL LEVELING 1 2 MALE HALF BLK OXIDE 8 91596 SP REPAIR KIT AT...

Page 81: ...ABLE 3MM PIN 1 91885 WRENCH SPANNER SIDE ADJUSTABLE 1 4 PIN 1 94904 PIN DOWEL 1 16 DIA X 7 16 SS 2 TABLE A 2 TOOL KIT P N 90350 CONTINUED Part number Description Quantity TABLE A 3 ACCESSORIES Part nu...

Page 82: ...mm 80 Diamond 3 8 9 5 mm IC 52862 Insert Holder RH 1 2 X 3 1 2 12 7 x 88 9 mm 80 Diamond 3 8 9 5 mm IC 52863 Insert Holder LH 1 2 X 3 1 2 12 7 x 88 9 mm 80 Diamond 3 8 9 5 mm IC 91588 Carbide Insert...

Page 83: ...P N 91025 Rev 4 Page 71 APPENDIX B SDS Safety Data Sheets are available upon request...

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