Climax KM4000 Operating Manual Download Page 1

Page: 1 / 78

P/N 16328
June 2019
Revision 7

KM4000

KEY MILL MACHINE

OPERATING MANUAL

SERIAL NUMBER RANGE

BEGINNING WITH 14001731

ORIGINAL INSTRUCTIONS

KM4000 Key Mill Machine

Summary of Contents for KM4000

Page 1: ...P N 16328 June 2019 Revision 7 KM4000 KEY MILL MACHINE OPERATING MANUAL SERIAL NUMBER RANGE BEGINNING WITH 14001731 ORIGINAL INSTRUCTIONS KM4000 Key Mill Machine...

Page 2: ......

Page 3: ...NTS GENERAL SAFETY II SAFETY PRACTICES III LABELING GUIDELINES IV CE DATA VII WARNING LABELS 1 WARRANTY 3 INTRODUCTION 3 SETUP 10 OPERATION 15 MAINTENANCE 20 STORAGE 23 SPARE PARTS 24 SPECIFICATIONS 2...

Page 4: ...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...

Page 5: ...ensure there are no other persons in danger from the machine METAL FRAGMENT HAZARD The machine produces metallic fragments during normal operation You should wear eye protection at all times when wor...

Page 6: ...utions 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 coul...

Page 7: ...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 8: ...d 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 placement for the contro...

Page 9: ...Page vii CE Data Hearing protection is required The Declared Sound Power Level is LWA 88 8 dBA The Declared Operator Sound Pressure Level is LpA 89 4 dBA The Declared Bystander Sound Pressure Level i...

Page 10: ...Page viii KM4000 Operating Manual...

Page 11: ...on your machine If any are defaced or missing contact Climax immediately for replacements Machine labels are listed in Table 1 Machine label locations are shown in Figure 1 Table 1 KM4000 labels P N...

Page 12: ...Page 2 KM4000 Operating Manual Figure 1 KM4000 label locations...

Page 13: ...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 14: ...onal extra chain and may be used anywhere along the shaft With the optional shim kit the machine can be used on shafts as small as 4 inches 100 mm in diameter Compact rugged portable milling machine f...

Page 15: ...age The motor operates on either 50 or 60 cycle AC or on DC current Spindle speed can be controlled by an in line speed control The no load spindle speed is fully adjustable from 350 to 675 rpm CAUTIO...

Page 16: ...d with the machine must be used or the machine warranty is void The lubricator should be set to deliver oil at a rate of 20 30 drops per minute at full throttle Figure 4 KM4000 Pneumatic Power Schemat...

Page 17: ...t is not filtered and lubricated can damage the air motor Avoid damage by routing incoming air through the air filter and lubricator Hydraulic Power A wide variety of hydraulic power options are avail...

Page 18: ...t HPU is an electrically driven piston pump with horizontally mounted high torque motor Separate documentation detailing the HPU is available with the HPU CAUTION To avoid damaging the power unit pump...

Page 19: ...P N 16328 Rev 7 Page 9 Figure 7 KM4000 Hydraulic Power Schematic Diagram...

Page 20: ...er to OFF before plugging in the unit 3 Plug the machine into a properly grounded outlet WARNING The electric motor is not rated to run motor in a damp or explosive environment Keep liquids away from...

Page 21: ...Clean all hydraulic fittings before connecting them Tooling setup CAUTION Tools are very sharp Handle with extreme care and follow all safety procedures for dealing with sharp objects 1 Loosen the qu...

Page 22: ...NG Support the machine with rigging while securing it to the workpiece Failure to do so sill allow the machine to fall causing death or serious crushing injury 1 Use a hoist to set the key mill on the...

Page 23: ...e on the shaft and can be tightened 3 Set up the machine as described in Steps 2 through 7 in Standard shaft mounting Large shaft mounting Using the optional chain clamp assembly shafts up to 24 609 m...

Page 24: ...ne 2 Attach a variable speed drill to the traverse drive shaft protruding from the feed lever housing Feed the machine by running the drill Lateral Feed Hand crank the cross slide leadscrew One comple...

Page 25: ...NING To avoid serious bodily injury from moving machinery turn speed control power switch to OFF before connecting it to the power source 4 Connect speed controller to the power source Set motor on of...

Page 26: ...is pushed all the way 2 Turn the needle valve clockwise all the way You will not be able to see any of the colored bands when the valve is completely closed 3 Connect the air supply line through the...

Page 27: ...power unit by pressing the ON button on the pendant Keyway Cutting 1 Position the end mill at the end of the shaft where the keyway will be cut 2 Turn on the motor and adjust the motor speed For elect...

Page 28: ...the machine WARNING The vertical feed has no built in top position stop Do not Do not allow the vertical feed to feed all the way out of the frame Doing so may result in death or severe crushing inju...

Page 29: ...e setup Be sure the machine is level Cut the first keyway 2 Reposition the machine on the side of the shaft Place a level on the side of the base to verify that the machine is 90 degrees to the first...

Page 30: ...oid damage to the machine and protect your warranty by using only approved lubricants IMPORTANT Before servicing the machine with any of the lubricants above consult the manufacturer s MSDS Top Slide...

Page 31: ...re each job lubricate the quill housing with lubricant on the section of quill that slides inside the quill clamp Ball and roller bearings are sealed and lubricated for life Hydraulic hoses and fittin...

Page 32: ...life of the air motor do the following Route the air supply through a lubricator and air filter Use nonrestrictive 1 2 air lines and fittings supplied by Climax Periodically check the air system to b...

Page 33: ...e Before storing clean the machine with solvent to remove grease metal chips and moisture Drain the air filter on pneumatic models Spray the machine with a moisture protective material to prevent rust...

Page 34: ...st screw inch 1 Vertical adjustment leadscrew assembly 19634 Vertical adjust screw metric 1 10449 Brass nut inch 1 10450 Brass nut metric 1 16253 Cross slide leadscrew inch 1 16254 Cross slide leadscr...

Page 35: ...mm Max opt chain 24 0 609 mm Minimum stub shaft clamping Length 8 0 200 mm Spindle shank required Weldon 3 4 20 mm No load spindle speed 675 rpm 675 rpm Min 350 rpm Max 675 rpm Vertical cutter depth a...

Page 36: ...y 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 Systemsl to perform service on the ma...

Page 37: ...P N 16328 Rev 7 Page 27...

Page 38: ...X 750 OPEN 10 10466 RING O 1 8 X 1 3 16 ID X 1 7 16 OD 11 16202 HOUSING CAM 12 10439 STUD 5 16 24 X 5 16 18 X 1 1 2 13 10440 BALL 1 DIA BLACK PLASTIC 14 16220 COLLAR SET 1 2 ID 15 10464 SCREW 1 4 20 X...

Page 39: ...ev 7 Page 29 13736 SLIDE CROSS ASSY KM4000 BALLOON PART DESCRIPTION 1 10454 BASE KM4000 2 10444 GIB KM4000 3 10189 SCREW 1 4 20 X 5 8 SSSHDPNI 4 10139 OILER BALL VALVE DRIVE IN 5 10474 SCREW 3 8 16 X...

Page 40: ...Page 30 KM4000 Operating Manual...

Page 41: ...P N 16328 Rev 7 Page 31...

Page 42: ...38117 LEADSCREW TOP SLIDE KM4000 PM2000 PM3000 4 13175 WASHER THRUST 875 ID X 1 437 OD X 060 4 10144 WASHER THRUST 1 000 ID X 1 562 OD X 060 5 13174 BRG THRUST 875 ID X 1 437 OD X 0781 5 10145 BRG TH...

Page 43: ...P N 16328 Rev 7 Page 33...

Page 44: ...X 1 7 8 OD X 625 OPN GR 5 19493 HOUSING QUILL 3rd KM4000 CPM 7 10150 BRG BALL 7874 ID X 1 8504 OD X 5512 2 SHLDS 19650 SPINDLE QUILL ASSY METRIC 3rd KM4000 CPM BALLOON PART DESCRIPTION 1 19635 SPINDL...

Page 45: ...P N 16328 Rev 7 Page 35...

Page 46: ...PRING FINGER 688 ID X 1 164 OD 7 15666 WASHER THRUST 669 ID X 1 181 OD X 030 8 15668 RING SNAP 43 64 OD INVERTED 19649 LEADSCREW VERT ADJ ASSY METRIC 3rd KM4000 CPM BALLOON PART DESCRIPTION 1 19634 LE...

Page 47: ...P N 16328 Rev 7 Page 37...

Page 48: ...Page 38 KM4000 Operating Manual This page intentionally left blnak...

Page 49: ...P N 16328 Rev 7 Page 39...

Page 50: ...Page 40 KM4000 Operating Manual...

Page 51: ...P N 16328 Rev 7 Page 41...

Page 52: ...Page 42 KM4000 Operating Manual...

Page 53: ...P N 16328 Rev 7 Page 43...

Page 54: ...Page 44 KM4000 Operating Manual...

Page 55: ...0313 CONNECTOR PLUG MALE SNAP BULLET 16 14 GA NOT SHOWN 29435 TUBE SHRINK 375 DIA BLACK 35973 CAP MOTOR END ASSY W 3 POLE CONNECTOR 230V BALLOON PART DESCRIPTION 1 12574 CONDUIT NUT 1 2 NPT 2 31734 PL...

Page 56: ...Page 46 KM4000 Operating Manual This page intentionally left blank...

Page 57: ...P N 16328 Rev 7 Page 47...

Page 58: ...SP SCREW 2nd 3rd 14 12552 SP HOUSING MOTOR 3rd 15 12551 SP BRG BALL MILWAUKEE 5455 ARMATURE LOWER 16 12550 SP FIELD 120 VOLT 3rd 17 10355 SP NUT HEX LOCKING 2nd 3rd 18 12549 SP ARMATURE 3rd 120V 19 1...

Page 59: ...rd 14 12552 SP HOUSING MOTOR 3rd 15 12551 SP BRG BALL MILWAUKEE 5455 ARMATURE LOWER 16 12550 SP FIELD 120 VOLT 3rd SP FIELD 120 VOLT 3rd 17 10355 SP NUT HEX LOCKING 2nd 3rd 18 12549 SP ARMATURE 3rd 12...

Page 60: ...Page 50 KM4000 Operating Manual...

Page 61: ...P N 16328 Rev 7 Page 51...

Page 62: ...Page 52 KM4000 Operating Manual...

Page 63: ...P N 16328 Rev 7 Page 53...

Page 64: ...Page 54 KM4000 Operating Manual...

Page 65: ...P N 16328 Rev 7 Page 55...

Page 66: ...Page 56 KM4000 Operating Manual...

Page 67: ...ED HYD MOTOR 23 12850 HOSE ASSY 560 3 8 X 9 16 JICM X 3 8 NPTM X 24 24 12849 FTG ELBOW 9 16 SAEM ORING X 9 16 JICM 90 DEG 25 12873 FTG NIPPLE 1 2 NPTM X 8 27 12872 FTG ELBOW 3 4 NPTM X 3 4 NPTF STREET...

Page 68: ...Page 58 KM4000 Operating Manual...

Page 69: ...1 9 16253 LEADSCREW CROSS SLIDE INCH 2nd KM4000 10 10449 NUT BRASS INCH 11 10453 SCREW 3 8 16 X 1 1 4 SHCS 16264 LEADSCREW ASSY CROSS SLIDE METRIC KM4000 BALLOON PART DESCRIPTION 1 15668 RING SNAP 43...

Page 70: ...Page 60 KM4000 Operating Manual...

Page 71: ...P N 16328 Rev 7 Page 61...

Page 72: ...Page 62 KM4000 Operating Manual...

Page 73: ...P N 16328 Rev 7 Page 63...

Page 74: ...Page 64 KM4000 Operating Manual This page intentionally left blank...

Page 75: ...P N 16328 Rev 7 Page 65 SDS Contact CLIMAX for the current Safety Data Sheets...

Page 76: ...Page 66 KM4000 Operating Manual...

Page 77: ......

Page 78: ......

Search results

Summary of Contents for KM4000

Reviews:

Related manuals for KM4000

Brands by name

Popular brands

Climax KM4000, Operating Manual

Search results

Summary of Contents for KM4000

Reviews:

Related manuals for KM4000

Brands by name

Popular brands