Climax LM5200 Operating Manual Download Page 1

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P/N 66188

July 2019

Revision 5

LM5200

LINEAR MILLING MACHINE

OPERATING MANUAL

SERIAL NUMBER RANGE: 11017900 – 15121870

ORIGINAL INSTRUCTIONS

LM5200 Milling Machine

Summary of Contents for LM5200

Page 1: ...P N 66188 July 2019 Revision 5 LM5200 LINEAR MILLING MACHINE OPERATING MANUAL SERIAL NUMBER RANGE 11017900 15121870 ORIGINAL INSTRUCTIONS LM5200 Milling Machine...

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Page 3: ...ving the Machine 31 Datum Surfaces 32 Bed Assembly 33 Machine Setup 40 Operation 53 Maintenance 57 Disassembly and Storage 59 Specifications 60 Exploded Views and Parts Lists 61 WARNING For maximum sa...

Page 4: ...erating 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 al...

Page 5: ...of the machine The operator must 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...

Page 6: ...y precautions 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 th...

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Page 8: ...y 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...

Page 9: ...ntified 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 T...

Page 10: ...ht of a group of components or the assembly in Kilos Part Number 59039 Designated Lift Point Part Number 65487 Mass Tag Part Number 35772 Ball Valve Handle Part Number 27307 Warning Label Part Number...

Page 11: ...Page 9 Part Number 37576 Electrical Warning Part Number 36094 Speed Controller Nameplate Part Number 41949 Speed Controller Nameplate CE Part Number 30081 230V Part Number 32585 120V Part Number 3473...

Page 12: ...nd return the part or repaired machine shipping prepaid For quick and accurate service please provide your factory representative with your name shipping address and telephone number the machine model...

Page 13: ...cific machine application requires additional options or accessories please contact Climax for assistance in obtaining the needed components This manual describes the operation and maintenance of your...

Page 14: ...re of this machine Risks and hazards associated with the use of this equipment are clearly marked on the machine or referenced in the operating manual in accordance with International Standards If you...

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Page 16: ...n when bed is extended by 2 or 3 times the original length Flexible Configuration Operation The innovative new design of these milling machines allow them to be configured for traditional linear milli...

Page 17: ...Weights and Dimensions Machine Weights Bed Travel 48 36 1219mm 914mm 358 lb 163 kg 72 60 1829mm 1524mm 506 lb 230 kg 96 84 2438mm 2134mm 654 lb 298 kg Ram Travel 26 16 660mm 406mm 176 lb 80 kg 44 34 1...

Page 18: ...Page 16 LM5200 Operating Manual Lifting Eyes Ram ONLY Lift Points Bed Lifting Eye Example of Vertical Lifting Lifting Points...

Page 19: ...4 ONLY lift the entire assembled machine from the bed lifting eyes DO NOT lift the entire machine from the machining arm ram lift points 5 Use a sling to install the milling head when the complete ma...

Page 20: ...Page 18 LM5200 Operating Manual Operational Dimensions...

Page 21: ...P N 66188 Rev 5 Page 19 Conventional Machining Area Ram at Maximum Recommended Offset...

Page 22: ...Page 20 LM5200 Operating Manual Gantry Machining Area...

Page 23: ...P N 66188 Rev 5 Page 21 Overhead View...

Page 24: ...Page 22 LM5200 Operating Manual Overhead View Ram at Maximum Recommended Offset...

Page 25: ...P N 66188 Rev 5 Page 23 End View Side Milling...

Page 26: ...Page 24 LM5200 Operating Manual Overhead Milling Ram at Maximum Recommended Offset Spindle Travel...

Page 27: ...P N 66188 Rev 5 Page 25 Standard Mounting Pattern Gantry Mounting Pattern...

Page 28: ...Page 26 LM5200 Operating Manual Components Control cables are available in 10 20 or 30 meter lengths...

Page 29: ...66665 KIT BED LENGTHEN BY 24 LM5200 66667 KIT BED LENGTHEN BY 24 FOR 48 BED ONLY LM5200 Gantry Kits for Bed Lengthening 66687 KIT GANTRY PLATE LENGTHEN BY 24 LM5200 66688 KIT GANTRY PLATES LENGTHEN B...

Page 30: ...e lengthened shortened or go gantry to satisfy a future need you may not have yet You are now ready for anything that comes your way What is the accuracy of the ballscrew LM5200 ram bed spindle Pitch...

Page 31: ...f the spindle What is the maximum metal removal rate and how does this compare to the LM6000 Metal removable rates of 10 in3 min 163 9 cm3 min and potentially greater are possible with the LM5200 6200...

Page 32: ...ill the machine clear the bed while overhead milling The LM5200 will clear the machine in overhead milling right out of the box The LM6200 will clear with limited travel in the Z axis over the bed Pur...

Page 33: ...immediately concerning damaged or missing components Unpacking instructions When unpacking the machine take care not to drop or damage the components Use lifting eyes or slings to lift the components...

Page 34: ...nment and setup purposes The inside edge of the ram mounting brackets are ground surfaces This allows precise alignment by pushing the front edge of the ram against the inside edge of the bracket duri...

Page 35: ...depict a 72 inch long LM6200 bed assembly the process is the same for the LM5200 Actual bed length may vary Standard Bed Assembly 1 Set up one 24 inch and one 48 inch bed section as shown in Figure 1...

Page 36: ...the other sections as shown in Figure 2 Install 6 M16 fasteners Item 3 and tighten them to 10 ft lb Then loosen them completely and retighten until they are just touching 6 Place the second bed align...

Page 37: ...osition and push it against the other sections as shown in Figure 4 Install 6 M16 fasteners Item 3 and tighten them to 10 ft lb Then loosen them completely and retighten until they are just touching 1...

Page 38: ...8 inch gantry connect plate and one 24 inch gantry connect plate as shown in Figure 5 2 Install 3 M16 fasteners Item 3 and 3 M16 fasteners item 7 into the 24 inch bed section and 48 inch gantry plate...

Page 39: ...nts as shown in Figure 6 The A points should be within 0 001 inch of each other and the B points should also be within 0 001 inch of each other If they are not repeat steps 2 through 7 Figure 6 Second...

Page 40: ...together 15 Install a bed connection plate Item 4 as shown in Figure 7 and tighten the fasteners to 40 ft lbs 16 Attach a dial indicator with a magnetic base to one of the linear rails and check the...

Page 41: ...emove the setscrew to gain access to the bearing preload nut locking screw 3 Loosen the locking screw and remove the bearing preload nut 4 Install the ballscrew into the bearing block assembly 5 Hand...

Page 42: ...he Datum Surfaces section for more information Take into consideration the vertical travel of the milling assembly the horizontal travel of the ram and the bed travel when positioning the machine See...

Page 43: ...e bed and in turn aligns the ram to the bed 2 Check for free movement of the saddle up and down the entire length of the bed If the saddle shows resistance at any point stop and check the bed and rail...

Page 44: ...tallation of the linear mill ram tether kit on the LM5200 6200 linear mill The ram tether kit should be installed on the Linear Mill whenever the machine is configured with the ram oriented vertically...

Page 45: ...am tether kit cannot be completed on your machine for any reason contact Climax before operating the machine with the ram in a vertical orientation Ram Hazard Warning Label Check that the two ram haza...

Page 46: ...ew and washer so that the setscrew will point up when the ram of the linear mill is oriented vertically Figure 15 Leave the M16 hex head screw loose in the clamp block hole 6 Install the swivel base l...

Page 47: ...NG When connecting the chain to the swivel base lifting eye thread the shoulder screws completely into the hoist ring shackle Failure to do so may cause the shackle chain connection to fail and allow...

Page 48: ...n death or serious crushing injury 14 Torque the slide block hex head screw to 150 ft lb 200 Nm Removing the Ram Tether Kit WARNING If the ram of the linear mill is oriented vertically do not remove t...

Page 49: ...ther kit is reinstalled on the machine Attempting to do so may cause the ram to slip or fall causing death or serious crushing injury Attaching the Milling Assembly 1 Attach the milling head to the tr...

Page 50: ...eeded the milling head mounting plate has been supplied with tramming screws This allows the mounting plate to be jacked away from the tramming plate to adjust X axis orientation and rotated on the tr...

Page 51: ...screws on the milling head mounting plate as shown in Figure 12 The mounting screws will have to be loosened slightly to make these adjustments Figure 19 6 Tram the direction along the Y axis by adjus...

Page 52: ...so work for a vertical work piece with the machine mounted horizontal and the milling assembly turned 90 Setting up the machine on a vertical work piece with the bed mounted vertically can be done but...

Page 53: ...surface of the ram to adjust the gantry side of the bed until it is coplanar with the drive side The beds must be within 0 004 inch for every 12 inches the rails are separated The following diagrams...

Page 54: ...ntry side IMPORTANT When changing direction there may be significant movement of the indicator as the machine loads to move in the opposite direction Option 2 1 Remove the feed motor from the drive si...

Page 55: ...he control panel cover Read the manual included with your HPU and follow the instructions before operating Pre Start Checks Before starting the machine always check for the following items All energy...

Page 56: ...at indicated on the feed speed selector knob Feed Speed Control Knob 7 Increases and decreases feed speed Feed Stop 9 Feed Start Reverse 10 Feed Start Forward 11 WARNING Rotating machinery can cause s...

Page 57: ...ction turn off the spindle Press the E Stop button Lock out the HPU Switch the hydraulic hoses at either the motor end or at the HPU to correct the rotation Move the machine axes to the desired starti...

Page 58: ...n alternating pattern while checking the leadscrew resistance between each adjustment Continue to tighten the drag brakes until the torque resistance is 25 in lb Figure 22 After Machining When the mil...

Page 59: ...cant Viscosity cSt Quantity Frequency Rectangular Dovetail Ways1 ExxonMobil Vactra No 2S N A 67 78 40C 8 6 100C Light coating applied by hand Daily during machine use Gearboxes and mechanisms lubricat...

Page 60: ...reservoir to mid sight glass level Refill every use Replace oil every 2 years5 AWS 32 winter 32 40C 5 44 100C Electric motors See vendor literature N A N A See vendor literature See vendor literature...

Page 61: ...er Remove the feed motor and install brakes on the ends of the ballscrews Attach lifting equipment to the beds using the supplied hoist rings Remove the machine from the work piece Clean the machine t...

Page 62: ...Milling Head Gearbox Ratio 1 1 1 1 Tool Head Position 90 increments infinite 360 position w optional swivel plate Gearbox Position Adjustment 180 in 90 increments 3 positions Electric Feed Drive Power...

Page 63: ...STRUCTION LM5200 1 Piece Drawing List 64203 Bed Saddle Assembly 81673 Saddle Assembly 84313 Saddle assembly with zimmer brakes 64405 Ballscrew Lock Assembly 66494 Ballscrew Assembly 64513 Bearing Bloc...

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