Climax FF7200 Operating Manual Download Page 68

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Page 60

FF7200 Operating Manual

Maintenance

Recommended Lubricants

CAUTION

Avoid damage to the machine and protect your warranty by using only
approved lubricants.

LUBRICANT

BRAND

WHERE USED

Light lubricant

LPS1™ or LPS2™

Unpainted surfaces

Cutting oil

KOOLKUT ™

UNOCAL

Tool bits, work piece

Pneumatic
lubricant

10W30 weight motor oil

Air motors

Way oil

10W30 weight motor oil

Square Ways

–

Acme

Screws , Dovetail and
Linear Rails

Gear Grease

CONOCO PolyTac EP 2 Gearboxes

Leadscrew Maintenance

During operation, clean ball screws and ACME leadscrews frequently to prevent
thread damage to nut and leadscrew.

Lightly oil the lead screws periodically to ensure smooth travel.

NOTE

Do not grease the ball screws.

Milling Head Gearbox

Change the gearbox grease after the first 10 hours of use, then every 50 hours of use.

Summary of Contents for FF7200

Page 1: ...PN 59129 March 2019 Revision 9 FF7200 Flange Facer Machine OPERATING MANUAL This manual is available in electronic format as P N 59129 Original Instructions Serial Number Range 11017900 15121870...

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 FF7200 Operating Manual CLIMAX WORLDWIDE LOCATIONS...

Page 5: ...P N 59129 Rev 9 Page C CE...

Page 6: ...Page D FF7200 Operating Manual This page left intentionally blank...

Page 7: ...l Information 8 Standard Components 9 Dimensions and Clearance 12 Setup 13 Surface mount optional equipment 28 Back face attachment setup optional equipment 31 OD mount optional equipment 36 Grinding...

Page 8: ...Page F FF7200 Operating Manual This page left intentionally blank...

Page 9: ...working around the machine Training Before operating this or any machine tool you should receive instruction from a qualified trainer Contact CLIMAX for machine specific training information Risk asse...

Page 10: ...in moving parts Sharp edges Cutting tools and workpieces have sharp edges that can easily cut skin Wear protective gloves and exercise caution when handling a cutting tool or workpiece Hot surfaces Du...

Page 11: ...s 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...

Page 12: ...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...

Page 13: ...hine 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...

Page 14: ...2 Mass Tag displays the weight of a group of components or the assembly Part Number 59039 Designated Lift Point Part Number 39546 Chemical Designator Part Number 35772 Ball Valve Handle Part Number 27...

Page 15: ...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 16: ...ther angular surfaces as needed Oversized ring gear provides steady rotation for difficult machining challenges Unique chucking system minimizes parts and greatly simplifies machine set up and tear do...

Page 17: ...le 3 Components figure identification Number Description 1 Lifting eyes 2 Tool arm assembly 30 72 762 1 829 mm range 3 Rotary union 4 Tool arm clamps 5 Drag brake 6 Counterweight assembly 7 Leveling f...

Page 18: ...ter weight and turning arm assembly 8 57701 Chuck Leg 2 5 Inch Long 8 57702 Chuck Leg 5 0 Inch Long 8 57703 Chuck Leg 8 0 Inch Long 8 57704 End Cap 4 5 Diameter 4 57637 Leveling Foot with 57556 M30 x...

Page 19: ...x Socket 10mm x Drive 1 46249 Hex Socket 14mm x Drive 1 46252 Hex Socket 17mm x Drive 1 58354 Socket Wrench Extension Drive x 5 Long 1 34866 Air Tool Oil 4 oz Bottle 1 33999 Hex Wrench Set 050 3 8 Inc...

Page 20: ...Page 12 FF7200 Operating Manual Dimensions and Clearance...

Page 21: ...ely to report damaged or missing components Preparing the Machine for Use Pre setup Check The FF7200 can be set up and mounted in many ways Before setting up the flange facer check the following 1 The...

Page 22: ...2 Inside flange 3 Support legs The sub assemblies may be disassembled and individually lifted by the labeled hoist rings on each sub assembly The counterweight lifting eyes can be positioned in many...

Page 23: ...ble Depending on the application orientation secure the supplied hoist rings in the necessary locations When lifting the machine pay special attention to the location of the center of gravity when lif...

Page 24: ...pper jaws or by using clamps bolted to the underside of the leveling feet safety blocks and clamps not included with the machine WARNING Do not remove the crane until the jacking bolts are tightened t...

Page 25: ...P N 59129 Rev 9 Page 17 Eight Step Installation Instructions The FF6200 is shown in the above illustration...

Page 26: ...he OD mounting legs are set to a diameter larger than the flange diameter Refer to the Chuck mounting section on page 23 for the complete procedure for chuck leg setup IMPORTANT If mounting the FF7200...

Page 27: ...ions Adjusting the tool head gib screws The tool head gib is adjusted using the six M6 screws Adjustment should only be necessary after many hours of use and if the machine is no longer producing a go...

Page 28: ...tioning the machining arm The machining arm is adjustable for versatile positioning and to clear obstructions Do the following to reposition the arm 1 Loosen the screws holding the four clamps 2 Hold...

Page 29: ...ing and to avoid damage to the machine the counterweight and machining arm should always be equally spaced from the center of the machine Figure 8 Machining arm and counterweight equally spaced The ma...

Page 30: ...ou always use the counterweight as it improves the performance of the machine and produces a flatter surface The counterweight arm can be positioned at various distances from center to balance the mac...

Page 31: ...ng the machine into place before leveling or centering the machine Recommended ID mounting setup Chucking leg chart Diameters 10 762 mm leg 5 127 mm leg 2 5 63 5 mm leg 30 35 762 889 mm 0 0 0 35 40 88...

Page 32: ...r tool to the bore if the exact center is required 8 After securely attaching the machine to the flange mount a dial indicator on the turning arm and indicate the surface of the flange by manually rot...

Page 33: ...5 Figure 13 Tool kit Feed system The feed system includes a flow control at the 3 way control valve that is set at the factory at 5 scfm Figure 14 Flow control IMPORTANT CLIMAX recommends that you do...

Page 34: ...p change To reverse the direction it is not necessary to disconnect the hoses Do the following 1 Remove the feed shaft and the two bolts connecting it to the arm 2 Rotate the feedbox until the arrow p...

Page 35: ...x in this configuration P N 48854 3 8 7 16 CAUTION When single point turning with the milling arm use the supplied ratchet box wrench for the feedbox not the hand wheel This will prevent the creation...

Page 36: ...tions for easier lifting Do not lift the machine by the drive motors pneumatic lines controls machining arm back face attachment turning arm or counterweight lifting points WARNING Falling or uncontro...

Page 37: ...in Figure 16 3 Attach the tack weld blocks to the plate extensions using the supplied bolts as seen in Figure 17 and Figure 18 4 Attach the tack weld plates to the workpiece by either tack welding the...

Page 38: ...and one centering set screw per plate extension tack weld block combination as seen in Figure 19 1 Center the machine using a tape measure to get a rough centering 2 Use the set screws to make the fin...

Page 39: ...sts of the back face attachment and screws to mount the attachment to the turning arm Figure 20 Backfacing attachment CAUTION Always use the counterweight arm with the back face attachment The heavy b...

Page 40: ...sition back face attachment based on the flange thickness Table 5 Backfacing attachment detail figure identification Number Description 1 Back face attachment 2 Milling arm 3 M10 socket head cap screw...

Page 41: ...ol head to the radial arm see Figure 23 Tighten the cap screw to 135 ft lbs 185 Nm 2 Place the cutting tool into the tool head Counterweight assembly The counterweight should be moved out the same dis...

Page 42: ...Page 34 FF7200 Operating Manual...

Page 43: ...P N 59129 Rev 9 Page 35...

Page 44: ...hining then the main body or chuck of the flange facer must be rotated upside down in order to use the OD mount Before rotating the legs must be removed and the rotary union must be attached in the pr...

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Page 46: ...Page 38 FF7200 Operating Manual...

Page 47: ...108 mm 30 70 762 1 778 mm 2 1 1 Top plate outside 4 88 2 235 mm 30 72 762 1 828 8 mm 2 2 0 Top plate outside 2 The tool head may be tilted to cut at a 3 76 mm larger diameter than what is listed at ea...

Page 48: ...ts in the arm Figure 26 OD mount rotary table and arm assembly Reference Figure 27 for the following procedure 1 Invert rotary table and arm and set onto wooden blocks or some other fixture to protect...

Page 49: ...tall lifting eyes in holes on top plate Figure 28 Block Riser and Leg Assembly 9 Weld on tack weld plates to quadrants of the fixture on the underside 1 5x5x10 minimum dimensions 10 Match drill and ta...

Page 50: ...to the threads and contacting faces of each leg section before screwing them together see Figure 27 on page 40 CAUTION Do not remove support rigging until machine is completely secured by all fixed an...

Page 51: ...set of legs and then rotate 180 While monitoring the indicators you may adjust the machine using the leveling legs Make sure they are both moving in the appropriate direction evenly Move to the leg th...

Page 52: ...Page 44 FF7200 Operating Manual Grinding attachment optional equipment...

Page 53: ...een ring while pulling out the tubing 2 Remove the fitting from the rotary union Install the elbow fitting shown in the next photo 3 Cap or plug the end of the blue tubing to prevent contamination fro...

Page 54: ...Page 46 FF7200 Operating Manual Milling attachment optional equipment...

Page 55: ...you have the standard flange facer you must replace that turning arm with the milling turning arm and counterweight for vertical applications arm assembly with the milling arm assembly and standard dr...

Page 56: ...allows the milling head to be jacked away from the adapter plate to tram the vertical orientation of the spindle Two additional screws are on top of the plate to adjust the tilt of the milling head S...

Page 57: ...hole 2 If the spindle drive motor is installed remove it from the spindle gearbox to enable easy hand rotation of the spindle CAUTION Be careful not to remove the RDU drive motor when the machine is v...

Page 58: ...ge 42 2 Check that the milling cutter is securely mounted see the Milling head cutter section on page 44 3 Extend the spindle to touch the surface 4 Take a skim cut to test the settings 5 Check the fi...

Page 59: ...the feed to minimum 12 Engage the feed and adjust the feed speed for the desired cut Adjusting the machine when the cut is complete IMPORTANT During milling operations keep chips clear of moving part...

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Page 61: ...eled or aligned to the job s requirements see Chuck mounting section on page 23 and Centering and leveling the machine section on page 30 The machining arm and counterweight arm are secured to the tur...

Page 62: ...resulting peak force at the cutter could damage the machine It is acceptable to run a tool at less than 150 sfpm as long as at 20 gpm it is greater than 150 sfpm If the operator chooses to run the mac...

Page 63: ...ns depending on machine type Controls The PCU controls include the following see the figures to the right and the nest page 1 START button system reset resets the low pressure drop out 2 Emergency STO...

Page 64: ...e 33 PCU components Table 11 PCU components figure identification Number Description 1 Connections Conn A Shop Air and Conn B 2 Pneumatic conditioning unit 3 Feed on off valve 4 Feed rate adjustment 5...

Page 65: ...7 When the cut is complete first stop the feed and then stop the machine rotation Hydraulic power unit Controls The hydraulic power unit HPU controls include Table 12 HPU control figure identification...

Page 66: ...the minimum 5 Press the HYDRAULIC ON button 6 Press the SPEED CONTROL FASTER button to reach the desired speed 7 Turn the feed rate adjustment dial to the minimum feed or to the desired setting if kn...

Page 67: ...ured this machine can fall and cause fatal injuries to personnel Pay special attention to vertical flange installations The machine must be properly rigged and attached to a crane or other suitable li...

Page 68: ...cant 10W30 weight motor oil Air motors Way oil 10W30 weight motor oil Square Ways Acme Screws Dovetail and Linear Rails Gear Grease CONOCO PolyTac EP 2 Gearboxes Leadscrew Maintenance During operation...

Page 69: ...the machine will extend its usefulness and prevent undue damage Before storing clean the machine with solvent to remove grease metal chips and moisture Prevent corrosion by spraying with LPS for short...

Page 70: ...ETAL THK SHS 1 57794 KNOB ASSY MODIFIED 1 58133 HANDLE ADJUSTABLE M6 X 1 X 9 42969 SCREW M10 X 1 5 X 12 SSSFP 4 41772 SCREW M16 X 2 0 X 95 SHCS 2 59626 BOLT EYE M12 X 1 75 X 20 5MM FF7200 FEED SYSTEM...

Page 71: ...M12 X 1 75 X 40MM 2 11238 WASHER 1 2 LOCW 4 18215 SCREW M8 X 1 25 X 35MM 4 59329 PNEUMATIC CONDITIONING 1 67730 MOTOR HYD 11 9 CU IN 1 1 4 INCH KEYED SHAFT SAE O RING 2000 1 69216 MOTOR HYD 14 9 CU I...

Page 72: ...Page 64 FF7200 Operating Manual Specifications...

Page 73: ...B 1 Piece 46249 WRENCH HEX BIT SOCKET 14MM X 1 2 1 Piece 46250 WRENCH HEX BIT SOCKET 10MM X 1 2 1 Piece 46252 WRENCH HEX BIT SOCKET 17MM X 1 2 1 Piece 48854 WRENCH RATCHET BOX 3 8 X 7 16 1 Piece 50985...

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Page 105: ...P N 59129 Rev 9 Page 97 SDS 10W30 weight motor oil 98 Koolkut 107 LPS1 113 LPS2 121 PolyTac EP 2 130...

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