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7229-S1BB7200 SURFACE MOUNT

OPERATING MANUALORIGINAL INSTRUCTIONS

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©2014 Climax Portable Machining and Welding Systems or its subsidiaries.All rights reserved.

Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-inated, downloaded, or stored in any storage medium, without the express prior written consent of Climax. Climax hereby grants permission to download a single copy of this manual and of any revision hereto onto an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, provided that such electronic or printed copy of this manual or revision must contain the complete text of this copy-right notice and provided further that any unauthorized commercial distribution of this manual or any revi-sion hereto is prohibited.

At Climax Portable Machining and Welding Systems, we value your opinion.

For comments or questions about this manual or other Climax documentation, please [email protected].

For comments or questions about Climax products or services, please call Climax or e-mail [email protected]. For quick and accurate service, please provide your factory representative with the following:

• Your name• Shipping address• Telephone number• Machine model• Serial number (if applicable)• Date of purchase

Climax World Headquarters

Climax Portable Machining and Welding Systems2712 South Second Street Newberg, Oregon 97132 USATelephone (worldwide): (503) 538-2185Toll-free (North America):1-800-333-8311Fax: 503.538.7600E-mail: [email protected]

Climax European Headquarters

Climax GmbHAm Langen Graben 852353 Düren, GermanyTelephone: +49 (0) 2421-9177-0E-mail: [email protected]

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CLIMAX GLOBAL LOCATIONS

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REVISION HISTORY

Rev. no. Rev. Date Revision Description Revised Approved

1 Initial release -- GH

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CE DOCUMENTATION

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LIMITED WARRANTY

Climax Portable Machine Tools, Inc. (hereafter referred to as “Climax”) warrants that all new machines are free from defects in materials and workmanship. This warranty is available to the original purchaser for a period of one year after delivery. If the original purchaser finds any defect in materials or workmanship within the warranty period, the original purchaser should contact its factory representative and return the entire machine, shipping prepaid, to the factory. Climax will, at its option, either repair or replace the defec-tive machine at no charge and will return the machine with shipping prepaid.

Climax warrants that all parts are free from defects in materials and workmanship, and that all labor has been performed properly. This warranty is available to the customer purchasing parts or labor for a period of 90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the cus-tomer purchasing parts or labor finds any defect in materials or workmanship within the warranty period, the purchaser should contact its factory representative and return the part or repaired machine, shipping prepaid, 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 materials or workmanship• Damage caused by improper or inadequate machine maintenance• Damage caused by unauthorized machine modification or repair• Damage caused by machine abuse• Damage caused by using the machine beyond its rated capacity

All other warranties, express or implied, including without limitation the warranties of merchantability and fitness for a particular purpose are disclaimed and excluded.

Terms of Sale

Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and limit your rights with respect to the goods purchased from Climax.

About This Manual

Climax provides the contents of this manual in good faith as a guideline to the operator. Climax cannot guar-antee that the information contained in this manual is correct for applications other than the application described in this manual. Product specifications are subject to change without notice.

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TABLE OF CONTENTS

CHAPTER/SECTION PAGE

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 SAFETY ALERTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 GENERAL SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.5 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1 FEATURES AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2 CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1 MACHINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1.1 Assembling the surface mount kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1.2 Centering and leveling the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.1 OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114.3 SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.1 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156.1 SHORT-TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156.2 LONG-TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156.3 SHIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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LIST OF FIGURES

FIGURE PAGE

3-1. Remove the chuck, seen here highlighted in red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-2. Plate extensions attached to the bottom plate.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-3. Detail of surface mount kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83-4. Tack weld blocks attached to the plate extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-5. Location of leveling and centering setscrews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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IN THIS CHAPTER:HOW TO USE THIS MANUAL - - - - - - - 1SAFETY ALERTS - - - - - - - - - - - - - 1GENERAL SAFETY PRECAUTIONS - - - - - 2MACHINE-SPECIFIC SAFETY PRECAUTIONS 3RECEIPT AND INSPECTION - - - - - - - - 3

1 INTRODUCTION

1.1 HOW TO USE THIS MANUAL

This manual describes information necessary for the setup, operation, mainte-nance, storage, shipping, and decommissioning of the 7229-S1 surface mounting kit available for the FF7200 and FF8200 flange facing machines.

The first page of each chapter includes a summary of the chapter contents to help you locate specific information. The appendices contain supplemental product information to aid in setup, operation, and maintenance tasks.

Read this entire manual to familiarize yourself with the 7229-S1 before attempting to set it up or operate it.

1.2 SAFETY ALERTS

Pay careful attention to the safety alerts printed throughout this manual. Safety alerts will call your attention to specific hazardous situations that may be encoun-tered when operating this machine. Examples of safety alerts used in this manual are defined here:1

DANGERindicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

WARNINGindicates a hazardous situation which, if not avoided, COULD result in death or serious injury.

1. For more information on safety alerts, refer to ANSI/NEMA Z535.6-2011, Product safety Information in Product Manuals, Instructions, and Other Collateral Materials.

General Safety Precautions

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CAUTIONindicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICEindicates a hazardous situation which, if not avoided, could result in property damage, equipment failure, or undesired work results.

1.3 GENERAL SAFETY PRECAUTIONS

Climax Portable Machining and Welding Systems, Inc. leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. You, the end user, must do your part by being aware of your work environment and closely following the operating procedures and safety precautions contained in this manual, as well as your employer’s safety guidelines.

This machine may be used in elevated positions, near other operating equipment, overhead, etc. Climax cannot foresee all the possible applications of this machine. It is the responsibility of the end user to perform a risk assessment prior to the operation of the machine before use every time the machine is set up.

Observe the following safety precautions when operating or 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 Assessment – Working with and around this machine poses risks to your safety. You, the 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 precautions in this manual. Do not use this machine for any purpose other than its intended use as described in this manual.

Personal Protective Equipment – Always wear appropriate personal pro-tective gear when operating this or any other machine tool. Flame-resistant clothing with long sleeves and legs is recommended when operating the machine, as hot flying chips from the workpiece may burn or cut bare skin.

Work Area – Keep the work area around the machine clear of clutter. Restrain cords and hoses connected to the machine. Keep other cords and hoses away from the work area.

Lifting – Many Climax machine components are very heavy. Whenever pos-sible, lift the machine or its components using proper hoisting equipment and rigging. Always use designated lifting points on the machine. Follow and lifting instructions in the setup procedures of this manual.

Machine-Specific Safety Precautions

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Lock Out/Tag Out – Lock out and tag out the machine before performing maintenance.

Moving Parts – Climax machines have numerous exposed moving parts and interfaces that can cause severe impact, pinching, cutting, and other inju-ries. Except for stationary operating controls, avoid contact with moving parts by hands or tools during machine operation. remove gloves and secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts.

Sharp Edges – Cutting tools and workpieces have sharp edges that can eas-ily cut skin. Wear protective gloves and exercise caution when handling a cutting tool or workpiece.

Hot Surfaces – During operation, motors, pumps, HPUs, and cutting tools can generate enough heat to cause severe burns. Pay attention to hot sur-face labels, and avoid contact with bare skin until the machine has cooled.The maximum temperature data (taken after 35 minutes of operat-ing the machine in a continuous cut) is 54°C

1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS

Eye Hazard – This 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 when operating this machine or working around it.

Hazardous environments – Do not operate the machine in environments where explosive materials, toxic chemicals, or radiation may be present.

1.5 RECEIPT AND INSPECTION

Your Climax product was inspected and tested prior to shipment, and packaged for normal shipment conditions. Climax does not guarantee the condition of your machine upon delivery. When you receive your Climax product, perform the fol-lowing receipt checks.

1. Inspect the shipping container(s) for damage.

2. Check the contents of the shipping container(s) against the included invoice to ensure that all components have been shipped.

3. Inspect all components for damage.

4. Contact Climax immediately to report damaged or missing components.

Receipt and Inspection



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2 OVERVIEW

2.1 FEATURES AND COMPONENTS

The 7229-S1 provides the ability to use the FF7200 in situations where the regular inside diameter mount cannot be used, or where the outside diameter chuck would be cumbersome and not as rigid as a surface mount. The surface mount can also be used in backfacing applications, or where there is a need to machine up to or past the outside dimension and there is no way to mount the FF7200.

2.2 CONTROLS

For information on how to control the FF7200 refer to the main FF7200 operating manual. The addition of the 7229-S1 does not change controls or operation of the FF7200.

IN THIS CHAPTER:FEATURES AND COMPONENTS - - - - - - - - - - - - - - - 5CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - 5

Controls


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IN THIS CHAPTER:MACHINE ASSEMBLY- - - - - - - - - - - - - - - - - - - - - - - 9

Assembling the surface mount kit- - - - - - - - - - - - - - - 9

Centering and leveling the machine- - - - - - - - - - - - - - 12

3 SETUP

3.1 MACHINE ASSEMBLY

This machine is very heavy. Use the appropriate lifting equipment when lifting the machine. Only lift the machine by all the lifting points for stability. The machine can be broken down into smaller sections for easier lifting. Do not lift the machine by the drive motors, pneumatic lines, controls, machining arm or counterweight.

CAUTIONFalling or uncontrolled swinging of machinery can cause serious injury or be fatal to the operator and bystanders. Lift the machine by the lifting eyes.

3.1.1 Assembling the surface mount kit

Do the following to assemble the machine for surface mounted facing.

1. Remove the chuck from the bottom of the FF7200 as seen in Figure 3-1.

FIGURE 3-1. REMOVE THE CHUCK, SEEN HERE HIGHLIGHTED IN RED.

REMOVE THE CHUCK

Machine Assembly


2. Attach the plate extensions to the bottom plate as seen in Figure 3-2.

3. Attach the tack weld blocks to the plate extensions using the supplied bolts as seen in Figure 3-3 and Figure 3-4.

FIGURE 3-2. PLATE EXTENSIONS ATTACHED TO THE BOTTOM PLATE.

FIGURE 3-3. DETAIL OF SURFACE MOUNT KIT.

Machine Assembly

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4. Attach the tack weld plates to the workpiece by either tack welding them or other desired method.

3.1.2 Centering and leveling the machine

The 7229-S1 has two leveling set-screws and one centering setscrew per plate extension/tack weld block combination as seen in Figure 3-5.

1. Center the machine using a tape measure to get a rough centering.

2. Use the set-screws to make the final adjustments.

3. Level the machine using the eight leveling setscrews.

FIGURE 3-4. TACK WELD BLOCKS ATTACHED TO THE PLATE EXTENSIONS.

FIGURE 3-5. LOCATION OF LEVELING AND CENTERING SET-SCREWS.

LEVELING SETSCREWS

CENTERING SETSCREW

Machine Assembly


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4 OPERATION

4.1 OPERATION MODES

The 7229-S1 can machine on such applications as heat exchanger tube sheets where a inner dimension mount is impossible. The surface mount kit will also allow for backfacing operations.

4.2 OPERATION

The 7229-S1 surface mount kit does not change the operation of the FF7200. Refer to the main FF7200 manual for controls and operations of the machine.

4.3 SHUTDOWN

Refer to the main FF7200 manual for shutdown operations for the machine.

IN THIS CHAPTER:OPERATION MODES - - - - - - - - - - 35OPERATION - - - - - - - - - - - - - - 35SHUTDOWN - - - - - - - - - - - - - - 35

Shutdown



5 MAINTENANCE AND TROUBLESHOOTING

This section contains information on periodic maintenance intervals and tasks, as well as troubleshooting guidance.

5.1 MAINTENANCE

Keep the 7229-S1 surface mount kit clean and free of debris. Refer to the main FF7200 operating manual for details on maintenance of the machine.

IN THIS CHAPTER:MAINTENANCE- - - - - - - - - - - - - 39

Maintenance



6 STORAGE AND SHIPPING

6.1 SHORT-TERM STORAGE

Store the 7229-S1 in its original shipping container.

6.2 LONG-TERM STORAGE

1. Spray all unpainted machine surfaces with a layer of light oil.

2. Add a desiccant pouch to the shipping container. Replace according to manufacturer instructions.

3. Store the 7229-S1 in its shipping container.

4. Store the shipping container in an environment out of direct sunlight with temperature < 70ºF and humidity < 50%.

6.3 SHIPPING

The 7229-S1 can be shipped in its original shipping container.

IN THIS CHAPTER:SHORT-TERM STORAGE45LONG-TERM STORAGE45SHIPPING45

Shipping



APPENDIX A ASSEMBLY DRAWINGS APPENDIX A ASSEMBLY DRAWINGS

AC5000 Operating Manual

PARTS LISTDESCRIPTIONPART No.QTYITEM

SCREW DRIVE #2 x 1/4 HOLE SIZE .0891058881SCREW 1/2-13 X 1 SHCS15307152SEAL 3.500 ID FORSHEDA V-RING1813613PLATE MASS CE2915214PLATE SERIAL YEAR MODEL CE 2.0 X 3.02915415SCREW M6 X 1.0 X 35mm SHCS3550446SCREW M12 X 1.75 X 30mm SHCS4069787LABEL LIFT POINT 2 X 3 4142528SCREW M16 X 2.0 X 30MM SHCS41738109HOIST SWIVEL RING M12 X 1.75 1050 KG43001410TOP PLATE FF720057786111CLAMP ARM PINNED57815312SHAFT CENTER FF7200 AND FF820058050113ASSY BRG AND RING GEAR 25.5 OD58053114CLAMP SAFETY STOP ASSY58128115LABEL FLANGE FACERS IMPACT HAZARD62884116PLATE BOTTOM SURFACE MOUNT FF720079544117

58060 -

ASSY TABLE ROTARY FF7200

7

7

15

12

3

1016

1 4

5

11

13

9

14

17 6

2

8


PARTS LISTDESCRIPTIONP/N:QTYITEM

SCREW M10 X 1.5 X 35mm SHCS3607921SCREW M12 X 1.75 X 20mm SSSFP4318632BLOCK TACK WELD7954513PLATE EXTENSION7954614SCREW M12 X 1.75 X 20mm SHCS7955225WASHER 3/8 FLTW HARDENED 1 OD X .2 THK BLACK OXIDE FINISH7992726

79550 - ASSY SURFACE MOUNT FF7200

2

3

5

4

2

1

6


FF7200 SURFACE MOUNT SINGLE POINT -

Clearance with tool head fully retracted1.2" with turning arm, single point only1.2" with milling arm with milling head or single point head1.1" with milling arm or turning arm and grinder

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