Climax FF6300 Operating Manual

FF6300

FLANGE FACER

FF6300 OPERATING MANUAL

SERIAL NUMBER RANGE: 15000834–

ORIGINAL INSTRUCTIONS

P/N 80679
July 2019
Revision 10

©2019 CLIMAX or its subsidiaries.

All rights reserved.

Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem­inated, 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
copyright notice and provided further that any unauthorized commercial distribution of this manual or any
revision hereto is prohibited.

At CLIMAX, we value your opinion.

For comments or questions about this manual or other CLIMAX documentation, please e-mail

[e-mail].

For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail

[e-mail]. For quick and accurate service, please provide your representative with the following:

• Your name

• Shipping address

• Telephone number

• Machine model

• Serial number (if applicable)

• Date of purchase

CLIMAX World Headquarters

2712 East 2nd Street
Newberg, Oregon 97132 USA

Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]

CLIMAX | H&S Tool (UK Headquarters)

Unit 7 Castlehill Industrial Estate
Bredbury Industrial Park
Horsfield Way
Stockport SK6 2SU, UK

Telephone: [phone]

CLIMAX | H&S Tool (Asia Pacific Head­quarters)

316 Tanglin Road #02-01
Singapore 247978

Telephone: [phone]
Fax: [phone]

H&S Tool World Headquarters

715 Weber Dr.
Wadsworth, OH 44281 USA

Telephone: [phone]
Fax: [phone]

hstool.com

CLIMAX | H&S Tool (European Headquarters)

Am Langen Graben 8
52353 Düren, Germany

Telephone: [phone]
E-mail: [e-mail]

CLIMAX | H&S Tool (Middle East Headquarters)

Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE

Telephone: [phone]

P/N 80679, Rev. 10 Page A

CLIMAX GLOBAL LOCATIONS

Page B FF6300 Operating Manual

CE DOCUMENTATION

P/N 80679, Rev. 10 Page C

LIMITED WARRANTY

Climax Portable Machining & Welding Systems, 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 defective 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
customer 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
guarantee 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.

Page D FF6300 Operating Manual

TABLE OF CONTENTS

CHAPTER/SECTION PAGE

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 S

1.3 G

1.4 M

1.5 R

1.6 R

1.7 L

1.8 L

1.9 I

2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 FEATURES AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 R

2.3 C

2.4 M

AFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ENERAL SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ACHINE-SPECIFIC SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ISK ASSESSMENT AND HAZARD MITIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ISK ASSESSMENT CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

ABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TEMS REQUIRED BUT NOT SUPPLIED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1.1 ID chuck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.1.2 ID chuck assembly dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.1.3 OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1.4 OD mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.1.5 Surface mount assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.1.6 Surface mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

IGGING AND LIFTING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

ONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.3.1 Pneumatic conditioning unit controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.3.2 Hydraulic power unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

ACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.4.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.4.2 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4.3 Rotational speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.4.4 Feed rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.1 RECEIPT AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2 P

3.3 L

3.4 S

3.5 I

3.6 I

P/N 80679, Rev. 10 Page i

REPARING THE MACHINE FOR USE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2.1 Pre-setup check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.2.2 Assessing the work area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

IFTING AND RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

ETUP OVERVIEW FOR THE ID CHUCK MACHINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

NSTALLATION HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

NSTALLING THE ID CHUCK IN THE WORKPIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

3.7 OD MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7.1 Setup overview for the OD mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.7.2 Assembling the OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.7.3 OD mounting arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.7.4 Attaching the OD mount assembly to the workpiece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.7.5 Centering and leveling the OD mount assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.8 S

3.9 P

3.10 P

3.11 R

3.12 A

3.13 B

URFACE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.8.1 Setup overview for the surface mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.8.2 Assembling the surface mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.8.3 Centering and leveling the surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

OSITIONING THE MACHINING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

OSITIONING THE COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

OTATING THE TOOL HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

DJUSTING THE FEED BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3.12.1 Adjusting the feed rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.12.2 Conducting feed actuation measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.12.3 Reversing the feed direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.12.4 Disconnecting feed hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

ACKFACING ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.1 PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.2 P

4.3 M

RE-START CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.3.1 Pneumatic-powered machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.3.2 Hydraulic-powered machining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4.3.3 Adjusting the machine when the cut is completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.4 D

ISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.2 M

5.3 M

Page ii FF6300 Operating Manual

AINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

AINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.3.1 Check the pneumatic conditioning unit oil reservoir levels . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.3.2 Empty the air filter water trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.3.3 Pneumatic conditioning unit emergency stop check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.3.4 Pneumatic conditioning unit drop-out circuit check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.3.5 Hydraulic power unit maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

5.3.6 Dovetail and square ways maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.3.7 Leadscrew maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.3.8 Adjust the dovetail and square ways gib screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.3.9 Adjust the radial slide lead nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.3.10 Tram the turning arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.4 L

5.5 T

5.6 D

6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.1 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.2 S

UBRICATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

ROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.5.1 The machine isn’t turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.5.2 The machine isn’t feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.5.3 The feed is slow or unresponsive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

5.5.4 The machine is performing poorly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

5.5.5 The machine is not cutting flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

ECOMMISSIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.1.1 Short-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.1.2 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

HIPPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

APPENDIX A EXPLODED VIEWS AND PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

APPENDIX C SDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

P/N 80679, Rev. 10 Page iii

This page intentionally left blank

Page iv FF6300 Operating Manual

LIST OF FIGURES

FIGURE PAGE

1-1. Warning label placement FF6300 ID chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1-2. Warning label placement FF6300 ID chuck (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1-3. Warning label placement FF6300 OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1-4. Warning label placement FF6300 pneumatic conditioning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2-1. ID chuck assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2-2. ID chuck assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2-3. OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-4. OD mount assembly dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2-5. Surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2-6. Surface mount assembly dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2-7. Detail of pneumatic conditioning unit controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2-8. Detail of hydraulic power unit controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3-1. M10 lifting eye (P/N 70483) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3-2. Measure the flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3-3. Assemble the ID chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3-4. Adjust the turning arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3-5. Place the ID chuck in the flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3-6. Level and center the ID chuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3-7. Install a tool bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3-8. Connect the hoses (hydraulic version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3-9. Vertical hazard warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3-10. Attaching the ID chuck to the main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3-11. Vertical installation fall danger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3-12. Applying anti-seize compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3-13. Detail of ID chuck legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3-14. Adjusting the setup fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3-15. Location of the 10-mm hex for manual rotation of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3-16. OD mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3-17. Centering plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3-18. Attaching the OD mount assembly to the main body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3-19. OD mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3-20. Distance for OD mount measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3-21. Measurement points for each arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-22. Attaching the OD mount with a tack-weld nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-23. Attaching the OD mount using the CLIMAX chain clamp kit .

3-24. OD mount adjustment points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3-25. Surface mount assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3-26. Location of securing clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3-27. Detail of machining arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3-28. Location of clamping screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3-29. Location of locking screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3-30. Detail of tool holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3-31. Location of swivel clamping screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3-32. Feed box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

P/N 80679, Rev. 10 Page v

LIST OF FIGURES (CONTINUED)

FIGURE PAGE

3-33. Detail of feed box positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

3-34. Knob revolutions marked on the machined flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3-35. Feed rate adjustment knob and feed box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3-36. Pneumatic valve location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3-37. Dial indicator used for precise adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3-38. Location of feed box bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3-39. Location of feed box direction arrow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3-40. Feed adjustment knob positioned down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3-41. Location of feed hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3-42. Backfacing attachment on surface mount machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3-43. Installing the backfacing attachment to the turning arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3-44. Backfacing attachment dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4-1. Detail of hose guide bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4-2. Pneumatic powered machining valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4-3. Location of hydraulic powered rotation controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5-1. Location of lead nut adjustment screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5-2. Lubrication locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5-3. Location of feed box filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6-1. FF6300 in containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6-2. Packing the FF6300 with ID chuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6-3. Packing the FF6300 with OD mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

A-1. Feed box pneumatic manual feed adjust (P/N 87326). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

A-2. Air control assembly for pneumatic feed (P/N 87941) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

A-3. Pneumatic filter and valve with stand assembly (P/N 59329) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

A-4. Pneumatic conditioning unit 1/2" (13 mm) low-pressure drop-out (P/N 78264) . . . . . . . . . . . . . . . . . . 84

A-5. Pneumatic conditioning unit 1/2" (13 mm) low-pressure drop-out parts list (P/N 78264). . . . . . . . . . . 85

A-6. Slide tool holder assembly (P/N 79790). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

A-7. Slide tool holder assembly parts list (P/N 79790) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

A-8. Main body assembly (P/N 87913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

A-9. Main body assembly parts list (P/N 87913) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

A-10. Turning arm assembly 38" (965 mm) (P/N 80304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

A-11. Turning arm assembly 38" (965 mm) parts list (P/N 80304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

A-12. Counterweight arm assembly (P/N 80324) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

A-13. Backface attachment assembly (P/N 80362). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

A-14. OD mount assembly 38–63” (965–1,600 mm) (P/N 80477). . .

A-15. OD mount assembly 38–63" (965–1,600 mm) parts list (P/N 80477) . . . . . . . . . . . . . . . . . . . . . . . . 95

A-16. OD mount clamp kit (P/N 80622) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

A-17. FF6300 pneumatic kit (P/N 80969) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

A-18. FF6300 hydraulic kit (6.2 cu.in. motor with QD FTG) (P/N 80970) . . . . . . . . . . . . . . . . . . . . . . . . . . 98

A-19. Air valve assembly (P/N 87916). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

A-20. ID chuck assembly 4 leg 12–57" (305–1,448 mm) (P/N 81971) . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

A-21. Leveling foot 4" (102 mm) assembly (P/N 81977) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

A-22. Surface mount assembly (P/N 82309) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

A-23. Air control assembly for pneumatic feed and 1/2" (13 mm) drive supply (P/N 87917). . . . . . . . . . . 103

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Page vi FF6300 Operating Manual

LIST OF FIGURES (CONTINUED)

FIGURE PAGE

A-24. Hydraulic kit 6.2 cubic motor (P/N 82555) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

A-25. Bypass assembly for set up of hydraulic machine (P/N 83154). . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

A-26. Bypass assembly for set up of hydraulic machine (P/N 83166). . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

B-1. Pneumatic schematic (P/N 87917). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

B-2. Assembly schematic for pneumatic feed only (used with hydraulic machines) (P/N 87941) . . . . . . . 111

B-3. Hydraulic kit 6.2 cubic in motor with QD FTG FF6300 (P/N 80970) . . . . . . . . . . . . . . . . . . . . . . . . . 112

P/N 80679, Rev. 10 Page vii

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Page viii FF6300 Operating Manual

LIST OF TABLES

TABLE PAGE

1-1. Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

1-1. Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-2. Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-3. Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-4. Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2-1. Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2-2. Shipping weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2-3. Shipping dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3-1. ID chuck setup table for standard ID chuck hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3-2. Feed rate adjustment knob. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5-1. Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5-2. Recommended lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

A-1. Tool kit (P/N 80327) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

A-2. Recommended spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

P/N 80679, Rev. 10 Page ix

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Page x FF6300 Operating Manual

NOTICE

DANGER

1 INTRODUCTION

IN THIS CHAPTER:

1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

AFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

1.2 S

ENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2

1.3 G

1.4 M

ACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

ISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

1.5 R

ISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

1.6 R

1.7 L

ABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
ABEL LOCATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.8 L

TEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -11

1.9 I

1.1 HOW TO USE THIS MANUAL

This manual describes the setup, operation, maintenance, storage, shipping, and
decommissioning of the FF6300 Flange Facer Machine.

For maximum safety and performance, read this entire manual before
attempting to set up or operate the machine.

The first page of each chapter includes a list of the chapter contents to help you locate
specific information.

The appendices contain supplemental product information to aid in setup, operation,
and maintenance tasks.

1.2 SAFETY ALERTS

Pay careful attention to the safety alerts in this manual. Safety alerts call your attention
to dangerous situations that you may encounter when operating this machine. This
manual uses the following types of safety alerts:

indicates a dangerous situation that, if not avoided, WILL result in death or
serious injury.

1

P/N 80679, Rev. 10 Page 1

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

WARNING

indicates a dangerous situation that, if not avoided, COULD result in

CAUTION

NOTICE

death or serious injury.

indicates a dangerous situation that, if not avoided, could result in minor
or moderate injury.

indicates a dangerous situation that, if not avoided, could result in
property damage, equipment failure, or undesirable work results.

1.3 GENERAL SAFETY PRECAUTIONS

CLIMAX leads the way in promoting the safe use of portable machine tools.
Safety is a joint effort. You must do your part by:

• Being aware of your work environment

• Closely following the operating procedures and safety precautions con­tained in this manual

• Closely following your employer’s safety guidelines

When operating or working around the machine, observe the safety precautions
below.

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. Conduct a risk assessment (Section 1.5 and Section 1.5 on
page 6) 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. Wear
flame-resistant clothing with long sleeves and legs 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.

Danger zone – The danger zone of this machine is defined as being inside

the turning radius of the machine, or as being outside the diameter of the

Page 2 FF6300 Operating Manual

machine when using the OD mount assembly.

Lifting – Many CLIMAX machine components are very heavy. Whenever

possible, use proper hoisting equipment and rigging to lift the machine or
its components. Always use the lifting points designated on the machine.
Follow the lifting instructions in Section 3.3 on page 27. Be cautious;
never drop electrical equipment as this will damage the components.

Lock out/tag out – Lock out and tag out the machine before performing

maintenance or entering the danger zone to adjust this machine.

Moving parts – CLIMAX machines have numerous exposed moving parts

and interfaces that can cause severe impact, pinching, cutting, and other
injuries.

During machine operation:

• Keep hands and tools away from moving parts.

• 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-sur­face warning labels and avoid contact with bare skin until the machine has
cooled.

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.

Always wear hearing protection when operating the machine or working
around it. During testing, the machine produced the following sound lev-

1

els.

TABLE 1-1. SOUND LEVELS

Pneumatic Hydraulic

Sound power 87.3dBA 78.9dBA

Operator sound pressure 76dBA 65dBA

Bystander sound pressure 74dBA 68dBA

1. Machine sound testing was conducted in accordance with European Harmonized
Standards EN ISO 3744:2010 and EN 11201:2010.

P/N 80679, Rev. 10 Page 3

Hazardous environments – Do not operate the machine in environments

where explosive materials, toxic chemicals, or radiation may be present.
Do not expose the machine to rain or wet conditions.

Rotating machinery – Rotating machinery can cause serious injuries. Lock

out all power sources before performing any adjustment, lubrication, or
maintenance.

Secure loose clothing and long hair – Rotating machinery can cause

serious injuries. Do not wear loose fitting clothing or jewelry. Tie back
long hair or wear a hat.

Hoses, pendants, and electrical cables

• Do not abuse the pendant cable as this can damage the cable and pen­dant.

• Never use the cord for carrying, pulling, or unplugging.

• Remove any and all kinks before straightening the cable.

• Keep cords and hoses away from heat, oil, sharp edges, and moving
parts.

• Plugs must match the outlet. Never modify the plugs in any way. Do
not use an adapter plug with grounded power tools.

• Always examine hoses and cables for damage before use.

Adjustments and maintenance – Stop the machine and lock out all power

sources before performing any adjustment, lubrication, or maintenance.

Controls – The machine controls are designed to withstand the rigors of nor-

mal use. The on/off switches are clearly visible and identifiable. When you
leave the machine, disconnect all power sources to the machine:

• For the pneumatic machine (or portion of the machine), either discon­nect the air hose or move the lock-out/tag-out valve to the lock posi­tion.

• For the hydraulic machine, turn off the power at the HPU.

Page 4 FF6300 Operating Manual

This page intentionally left blank

P/N 80679, Rev. 10 Page 5

1.5 RISK ASSESSMENT AND HAZARD MITIGATION

Machine Tools are specifically designed to perform precise material-removal oper­ations.

Stationary Machine Tools include lathes and milling machines and are typically
found in a machine shop. They are mounted in a fixed location during operation
and are considered to be a complete, self-contained machine. Stationary Machine
Tools achieve the rigidity needed to accomplish material-removal operations from
the structure that is an integral part of the machine tool.

Portable Machine Tools are designed for on-site machining applications. They typ­ically 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 structure to which it is attached become
one complete machine during the material-removal process.

To achieve the intended results and to promote safety, the operator must under­stand and follow the design intent, set-up, and operation practices that are unique
to Portable Machine Tools.

The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of portable machining applications,
identifying one or more hazards that must be addressed is typical.

When performing the on-site risk assessment, it is important to consider the Porta­ble Machine Tool and the workpiece as a whole.

Page 6 FF6300 Operating Manual

1.6 RISK ASSESSMENT CHECKLIST

The following checklist is not intended to be an all inclusive list of things to watch
out for when setting up and operating this Portable Machine Tool. However these
checklists are typical of the types of risks the assembler and operator should be
considering. Use these checklists as part of your risk assessment:

TABLE 1-2. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

Before Set-up

I took note of all the warning labels on the machine.



I removed or mitigated all identified risks (such as tripping, cutting, crushing,



entanglement, shearing, or falling objects).

I considered the need for personnel safety guarding and installed any necessary



guards.

I read the Machine Assembly instructions (Section 3) and took inventory of all the



items required but not supplied (Section 1.9)..

I created a lift plan, including identifying the proper rigging, for each of the setup



lifts required during the setup of the support structure and machine.

I located the fall paths involved 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



controls, cabling, and the operator.

I evaluated and mitigated any other potential risks specific to my work area.



TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP

After Set-up

I checked that the machine is safely installed (according to Section 3) and the



potential fall path is clear. If the machine is installed at an elevated position, I
checked that the machine is safeguarded against falling.

I identified all possible pinch points, such as those caused by rotating parts, and



informed the affected personnel.



I planned for containment of any chips or swarf produced by the machine.

I followed the required Maintenance Intervals (Section 5.2) with the recommended



lubricants (Section 5.4).

I checked that all affected personnel have the recommended personal protective



equipment, as well as any site-required or regulatory equipment.

I checked that all affected personnel understand the danger zone and are clear of



it.



I evaluated and mitigated any other potential risks specific to my work area.

P/N 80679, Rev. 10 Page 7

1.7 LABELS

TABLE 1-4. LABELS

Table 1-4 shows the labels that should be on your machine. If any are defaced or
missing, contact CLIMAX immediately for replacements.

P/N 29154, 35828

CLIMAX serial num­ber, year, and model
number plate

P/N 29152

Label mass tag

PN 84019

CLIMAX logo

P/N 35772

Label ball valve
operation direction

P/N 39546

Label oil bottle 76
Unax AW 32

P/N 59035

Label warning wear
eye protection

PN 84535

Plate OD alignment

P/N 80569

Label OD mount cen­tering hardware direc­tion

P/N 80569

Label air motor
direction and pressure

P/N 59037

Label warning hear­ing protection required

Page 8 FF6300 Operating Manual

TABLE 1-4. LABELS

P/N 59044

Label warning consult
operator’s manual

P/N 59042

Label warning hand
crush/moving parts

1.8 LABEL LOCATIONS

P/N 46902

Label warning hot sur­face

P/N 79324

Label warning hand
entanglement/rotating
gears

FIGURE 1-1. WARNING LABEL PLACEMENT FF6300 ID CHUCK

P/N 80679, Rev. 10 Page 9

FIGURE 1-2. WARNING LABEL PLACEMENT FF6300 ID CHUCK (CONT.)

81003

82344

29152

70228

F

IGURE 1-3. WARNING LABEL PLACEMENT FF6300 OD MOUNT

Page 10 FF6300 Operating Manual

FIGURE 1-4. WARNING LABEL PLACEMENT FF6300 PNEUMATIC CONDITIONING UNIT

1.9 ITEMS REQUIRED BUT NOT SUPPLIED

During setup, you will need the following items that are not included with the
product:

• Dial indicator

• Tape measure

• Rigging and lifting equipment as needed for machine setup

• Fittings required to connect to the pneumatic conditioning unit (PCU),

or the plug for the hydraulic power unit (HPU)

CLIMAX offers a dial indicator kit for purchase; contact CLIMAX for more
information.

P/N 80679, Rev. 10 Page 11

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Page 12 FF6300 Operating Manual

2 OVERVIEW

IN THIS CHAPTER:

2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -13

2.1.1 ID

2.1.2 ID

2.1.3 OD

2.1.4 OD

2.1.5 S

2.1.6 S

IGGING AND LIFTING INFORMATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -20

2.2 R

ONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -21

2.3 C

2.3.1 P

2.3.2 H

2.4 M

2.4.1 T

2.4.2 P

2.4.3 R

2.4.4 F

CHUCK ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -15
CHUCK ASSEMBLY DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -16

MOUNT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -17

MOUNT ASSEMBLY DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -18
URFACE MOUNT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19
URFACE MOUNT ASSEMBLY DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

NEUMATIC CONDITIONING UNIT CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - -21
YDRAULIC POWER UNIT CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -21

ACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22

EMPERATURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -22
RESSURE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
OTATIONAL SPEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23
EED RATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -23

The FF6300 flange facing machine is designed for facing, beveling, and grooving
operations. All parts meet CLIMAX’s strict quality standards.

The FF6300 is highly configurable with a variety of options and accessories. The
machine you purchased may not have all of these. If you require additional accesso­ries, please contact CLIMAX for assistance.

2.1 FEATURES AND COMPONENTS

High precision in a compact design – The FF6300’s precision rotating

assembly incorporates two large tapered roller bearings on a spindle. All fluid
rotary passages are located between these bearings to provide the maximum
machine rigidity in a compact package.

Operator safety – Do not touch moving parts during machine operation. A

pneumatic-powered reversible feed box controls both the radial and axial
feeds. The feed box is not remotely adjustable and should only be adjusted at
the feed box when the machine is not rotating. The feed rate is cam-controlled
to match the machine RPM. Manual feeding for rapid positioning is also possi­ble.

Face to swing diameter – Because the feed box mounts to the inboard end of

the turning arm for facing, the machining diameter can exceed the swing diam­eter.

Simple rigging – An abundance of lifting points are provided to simplify bal-

anced rigging for flanges in all orientations.

P/N 80679, Rev. 10 Page 13

Easy setup – The turning and counterweight arms are adjustable for the desired

swing clearance and machining range. The counterweight can be adjusted eas­ily to achieve near-perfect rotational balance.

Ability to machine grooves and bevels – The swivel tool head rotates 360o

and has a tool holder that rotates 360o independently. It accepts up to .75"
(19mm) square shank tools.

Smooth high-torque machining – The low-backlash cone worm gear drive

allows smooth high-torque machining even during interrupted cuts.

Rigid chucking – The tubular chucking system with level-in-place adjusting

feet allows for quick setup.

Modular design – Many of the machine components can be removed to make

setup and storage easier. For example, you can set up the chuck independently
and then add the main rotary housing.

Mounting options – With the optional CLIMAX OD mount kit, the machine

can be mounted to the outside diameter of the flange, without welding. With
the CLIMAX surface mounting kit, the machine can be face mounted.

Multiple drive choices – Hydraulic and pneumatic drives are available.

Machining accessories available – CLIMAX offers a backfacing attachment

for tube sheet flanges. The main body has an extra rotary union port where you
can add your own pneumatic-powered live tooling for grinding or other opera­tions.

Page 14 FF6300 Operating Manual

2.1.1 ID chuck assembly

FIGURE 2-1. ID CHUCK ASSEMBLY

P/N 80679, Rev. 10 Page 15

2.1.2 ID chuck assembly dimensions

FIGURE 2-2. ID CHUCK ASSEMBLY DIMENSIONS

Page 16 FF6300 Operating Manual

2.1.3 OD mount assembly

FIGURE 2-3. OD MOUNT ASSEMBLY

P/N 80679, Rev. 10 Page 17

2.1.4 OD mount assembly dimensions

FIGURE 2-4. OD MOUNT ASSEMBLY DIMENSIONS

Page 18 FF6300 Operating Manual

2.1.5 Surface mount assembly

FIGURE 2-5. SURFACE MOUNT ASSEMBLY

2.1.6 Surface mount assembly dimensions

FIGURE 2-6. SURFACE MOUNT ASSEMBLY DIMENSIONS

P/N 80679, Rev. 10 Page 19

2.2 RIGGING AND LIFTING INFORMATION

TABLE 2-1. WEIGHTS

lbs kg

Total machine weight ID chuck

Total machine weight OD mount

ID chuck 187 85

Main body assembly 103 47

Turning arm with feed box 101 46

Counterweight assembly 77 35

Pneumatic motor 10 5

Hydraulic motor 10 4.5

Wooden shipping crate 177 80

Metal shipping container 220 100

Accessories

Backfacing attachment 37 17

*

†

473 215

773 353

OD mount 493 224

OD mount chain clamp 36 16

OD mount wooden shipping crate

(no metal shipping container)

* Machine weights are operating weights.
† OD mount weights are for the complete machine.

123 56

TABLE 2-2. SHIPPING WEIGHTS

lbs kg

ID chuck in wooden crate 650 294

ID chuck in metal container 693 314

OD mount in wooden crate 616 280

TABLE 2-3. SHIPPING DIMENSIONS

*

Width

Wooden crate 63.5" (1613 mm) 26" (660 mm) 25.75" (654 mm)

Metal container 60.16" (1528 mm) 24.16" (614 mm) 26.86" (682 mm)

OD mount wooden crate 47.25" (1200 mm) 42.25" (1073 mm) 19.75" (502 mm)

Depth Height

* All dimensions include handles and latches if applicable.

Page 20 FF6300 Operating Manual

1 2

4

5

6

7

3

2.3 CONTROLS

This section explains control locations and functions.

2.3.1 Pneumatic conditioning unit controls

Figure 2-7 shows the controls on the pneumatic-powered version of the FF6300.

FIGURE 2-7. DETAIL OF PNEUMATIC CONDITIONING UNIT CONTROLS

1. START (system reset)—Resets the low-pressure drop-out.

2. Emergency STOP—Isolates the supply air and vents the downstream air. Press
down to stop the machine; pull up to reset.

3. Lock-out/Tag-out valve—Isolates air pressure from the machine and provides
the ability to lock the valve closed so that you can perform maintenance.

4. Air regulator—Controls the air pressure supplied to the machine. The regulator
is preset at the factory, and does not require adjustment.

5. Oiler adjustment—Controls the air lubricator drip rate. For more information,
see Section 5.3.1 on page 64.

6. Feed on/off valve—Turns the feed on or off. This valve has a vent port that
stops the feed immediately when the valve is closed.

7. Speed adjustment valve—Controls the machine’s rate of rotation.

2.3.2 Hydraulic power unit controls

Figure 2-8 on page 22 shows the controls on the hydraulic version of the FF6300.

P/N 80679, Rev. 10 Page 21

FIGURE 2-8. DETAIL OF HYDRAULIC POWER UNIT CONTROLLER

MAIN

O

BAR

(-) (+)

RPM

I

I

PENDANT 65028
20' CABLE 53432
30' CABLE 62729
50' CABLE 53433

100' CABLE 53434

SPEED CONTROL

FASTER

SPEED CONTROL

SLOWER

HYDRAULIC ON

(Turns on hydraulic
flow to flange facer)

HYDRAULIC OFF

(Turns off hydraulic
flow to flange facer)

START (System reset)
(Starts main electric
drive motor on HPU)

EMERGENCY STOP
(Rotate clockwise to
reset)
(Stops electric drive
motor and oil flow)

• Speed Control buttons—Control the machine’s rate of rotation. Press to
speed up or slow down machine rotation.

• Hydraulic On and Off buttons—Control the hydraulic flow to the flange
facer. Press to start or stop machine rotation.

• Start button—Turns on the electric drive motor on the HPU. Press to start
the HPU.

• Emergency Stop button—Press to stop the machine. Rotate clockwise to
reset.

2.4 MACHINE SPECIFICATIONS

2.4.1 Temperature

The suggested machine operating temperature is -4–140 oF (-20–60 oC).

Page 22 FF6300 Operating Manual

NOTICE

CAUTION

During operation, individual machine components will exceed these
temperatures.

During normal use, the temperature of the machine housing normally increases to
about 25 oF (14 oC) above the ambient temperature. It is good practice to make critical
final machining cuts after the machine has been running continuously for at least 15
minutes.

Machining metal raises the temperature of machine components and can
generate hot chips that burn. Use caution when changing inserts and
handling or adjusting the cutting tool after use.

The suggested HPU oil temperature for AW32 is 27–155oF (-3–68oC).

The suggested HPU oil temperature for AW46 is 39–172oF (4–78oC).

2.4.2 Pressure

For the pneumatic machine, the recommended air pressure is 90 psi (6.2 bar) at
65 CFM.

For the hydraulic machine:

• The flow rate should not exceed 10gal/min (38l/min).

• The pressure should not exceed 2,200psi (152 bar).

2.4.3 Rotational speed

For the pneumatic machine, the operational rotating speed is 1–35 RPM.

For the hydraulic machine, the operational rotating speed is 3.5–37 RPM.

2.4.4 Feed rate

The feed is pneumatically powered and is controlled by the rotation of the machine.
The feed rate is not remotely adjustable and should be adjusted at the feed box as
described in Section 3.12.1 on page 49.

1

P/N 80679, Rev. 10 Page 23

The allowable air pressure for the feed mechanism is 30–100 psi (2–6.9 bar).

1. For HPU oils not mentioned in this manual, refer to the lubricant manufacturer's recom­mendation for oil temperature.

This page intentionally left blank

Page 24 FF6300 Operating Manual

3 SETUP

1IN THIS CHAPTER:

3.1 RECEIPT AND INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -25

REPARING THE MACHINE FOR USE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26

3.2 P

RE-SETUP CHECK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26

3.2.1 P

3.2.2 A

SSESSING THE WORK AREA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -26

IFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -27

3.3 L

ETUP OVERVIEW FOR THE ID CHUCK MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -28

3.4 S

3.5 I

NSTALLATION HAZARDS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -30

NSTALLING THE ID CHUCK IN THE WORKPIECE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -32

3.6 I

3.7 OD

3.8 S

3.9 P

3.10 P

3.11 R

3.12 A

3.13 B

MOUNTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -36

3.7.1 S

ETUP OVERVIEW FOR THE OD MOUNT MACHINE - - - - - - - - - - - - - - - - - - - - - - - - -37
SSEMBLING THE OD MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -37

3.7.2 A

3.7.3 OD

3.7.4 A

3.7.5 C

URFACE MOUNTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -42

3.8.1 S

3.8.2 A

3.8.3 C

OSITIONING THE MACHINING ARM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -44

OSITIONING THE COUNTERWEIGHT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -45
OTATING THE TOOL HEAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47
DJUSTING THE FEED BOX - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -48

3.12.1 A

3.12.2 C

3.12.3 R

3.12.4 D

MOUNTING ARRANGEMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -38
TTACHING THE OD MOUNT ASSEMBLY TO THE WORKPIECE - - - - - - - - - - - - - - - - - - - -40
ENTERING AND LEVELING THE OD MOUNT ASSEMBLY - - - - - - - - - - - - - - - - - - - - - -41

ETUP OVERVIEW FOR THE SURFACE MOUNT MACHINE - - - - - - - - - - - - - - - - - - - - - -42
SSEMBLING THE SURFACE MOUNT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -42
ENTERING AND LEVELING THE SURFACE MOUNT ASSEMBLY - - - - - - - - - - - - - - - - - - -43

DJUSTING THE FEED RATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -49
ONDUCTING FEED ACTUATION MEASUREMENT - - - - - - - - - - - - - - - - - - - - - - - - -50
EVERSING THE FEED DIRECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51
ISCONNECTING FEED HOSES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52

ACKFACING ATTACHMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -53

The FF6300 can machine a face, groove, or bevel on a flat flange. This chapter
explains how to set up the machine for these operating modes. and rigging.

3.1 RECEIPT AND INSPECTION

Your CLIMAX product was inspected and tested before shipment and packaged for
normal shipment conditions. CLIMAX does not guarantee the condition of your
machine upon delivery.

When you receive your CLIMAX product:

1. Inspect the shipping container for damage.

2. Check the contents of the shipping container against the included invoice to
check that all components have been shipped.

3. Inspect all components for damage.

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

P/N 80679, Rev. 10 Page 25

NOTICE

Keep the shipping container and all packing materials for future storage

WARNING

and shipping of the machine.

The machine ships from CLIMAX with a heavy coating of LPS 3. The recommended
cleaner is LPS PreSolve Orange Degreaser.

3.2 PREPARING THE MACHINE FOR USE

3.2.1 Pre-setup check

The FF6300 can be set up and mounted in many ways. Before setting up the flange
facer, check the following:

• The machine assemblies are positioned correctly.

• There is enough room to position the entire machine on or near the work
piece.

• All connections are correctly attached.

3.2.2 Assessing the work area

The FF6300 often is used in dangerous locations (in elevated positions, near other
operating equipment, overhead, etc.). CLIMAX cannot foresee where this machine
will be used; therefore, you must perform a site-specific risk assessment (Section 1.5
on page 6 and Section 1.6 on page 7) for each job before starting work.

The FF6300 machine has remote operation features that enable you to choose the
optimum location to work (Section 2.3 on page 21).

Always follow safe work practices, including site-specific safety
requirements. It is your responsibility to perform a risk assessment before
you set up the machine and each time before you operate the machine.

Page 26 FF6300 Operating Manual

3.3 LIFTING AND RIGGING

DANGER

CAUTION

DANGER

FIGURE 3-1. M10 LIFTING EYE (P/N 70483)

The FF6300 can weigh 473 lbs (215 kg) when fully assembled in the ID
configuration, and 773 lbs (353 kg) in the outside diameter (OD)
configuration.

Use caution and follow all site rigging procedures such as a lift plan and
never allowing anyone under the load. Falling or uncontrolled swinging
of machinery can cause serious injury or death.

The FF6300 has two M10 lifting eyes rated for 8,81lbs (400 kg). All M10 tapped
holes on the exterior of the machine are suitable for lifting with these lifting eyes.

Lift the machine only by the hoist rings marked by Figure 3-1.

Connect the appropriate lifting
equipment to the lifting eyes
located on top of the main body, on
the chuck assembly, or on the
machining arm when lifting the
entire assembly. Never lift the
machine by the drive motors, pneu­matic lines, or hoses.

Do not lift the assembled
machine by the lifting eyes
or hoist rings on the
counterweight or the
machining arm. Only lift the
assembled machine by the
four hoist rings shown in
Figure 3-1.

Lifting the assembled machine by other lifting points can cause the
machine to fall from the rigging.

P/N 80679, Rev. 10 Page 27

When lifting the machine, pay special attention to the location of the center of
gravity when lifting. Always check that all machine parts are tightened properly to
prevent hazards.

The machine can be broken down quickly into more manageable sections if needed.

FIGURE 3-2. MEASURE THE FLANGE

FIGURE 3-3. ASSEMBLE THE ID CHUCK

3.4 SETUP OVERVIEW FOR THE ID CHUCK MACHINE

Inspect and perform necessary maintenance on the machine before mounting on a
workpiece. The following steps are an overview of the processes involved with setting
up the FF6300 in the ID mounting configuration. The OD mount setup is listed in
Section 3.7 on page 36

To set up the FF6300 ID chuck, follow the process below. For details on these steps,
see Section 3.6 on page 32 through Section 3.12 on page 48.

To mount the machine to the workpiece:

1. Check that power sources are disconnected.

2. Measure the bore diameter. Use
the setup chart in Table 3-1 on
page 33 to select leg sections of
the correct length.

3. Assemble the ID chuck (Figure
3-3).

Page 28 FF6300 Operating Manual

FIGURE 3-4. ADJUST THE TURNING ARM

FIGURE 3-5. PLACE THE ID CHUCK IN THE FLANGE

FIGURE 3-6. LEVEL AND CENTER THE ID CHUCK

4. Adjust the turning arm and

counterweight arm to the cor­rect diameter (Figure 3-4). See
Section 3.9 on page 44
and Section 3.10 on page 45
for information on adjusting
the turning and counterweight
arms.

5. Install the machine in the

flange resting on the setup fin­gers (Figure 3-5).

P/N 80679, Rev. 10 Page 29

6. Tighten the jacking feet, and

adjust to level and center the
machine (Figure 3-6). See Sec­tion 3.6 on page 32 for infor­mation on centering and
leveling the ID chuck.

7. Install a tool bit (Figure 3-7).

NOTICE

FIGURE 3-7. INSTALL A TOOL BIT

FIGURE 3-8. CONNECT THE HOSES (HYDRAULIC VERSION)

The FF6300 cutting tool is
designed to trail behind the
turning arm as it rotates around
the workpiece surface. The
turning arm moves in a
clockwise direction. Keep these
characteristics in mind when
installing a new tool in the
machine.

8. Connect the power and feed
control hoses (Figure 3-8).

You are ready to begin machining.

3.5 INSTALLATION HAZARDS

The installation stage can be dangerous, as it relies on the operator and other personnel
following the recommended safety precautions. Consider the following warnings care­fully before undertaking the assembly process.

Page 30 FF6300 Operating Manual

WARNING

WARNING

WARNING

NOTICE

WARNING

FIGURE 3-9. VERTICAL HAZARD WARNING

Swinging or falling machinery could seriously injure or be fatal to personnel
who are near the machine. Secure all components to the machine before
lifting.

If not properly secured, this machine can
fall and cause fatal injuries to personnel.
Pay special attention to vertical flange
installations.

• Chucking feet must be secured to the
workpiece.

• Setup fingers and safety weld plates
should be utilized when possible.

• If not possible, contact CLIMAX to
determine a custom solution.

To avoid the risk of a falling machine, secure the
machine by tack-welding safety blocks over the
upper jaws or by using clamps bolted to the
underside of the leveling feet (safety blocks and clamps not included with the
machine).

Do not remove the crane until at least one of the securing methods is in
place and the jacking bolts are tightened to 60 ft-lb [149 Nm].

If the torque value cannot be achieved without acceptable workpiece
deformation, the operator must apply their own secondary support and
restraint devices.

The jacking bolt must be inserted so that the full extension groove is inside
the end cap.
Do not extend the jacking feet past the full-extension groove in the
threaded screw (Figure 3-12), as that may cause the jacking screw to be
overloaded and result in damage to the screw. If needed, add additional leg
sections to minimize the length of the threaded jacking screw that is
exposed.

P/N 80679, Rev. 10 Page 31

3.6 INSTALLING THE ID CHUCK IN THE WORKPIECE

WARNING

DANGER

FIGURE 3-10. ATTACHING THE ID CHUCK TO THE MAIN BODY

See Section Section 3.5 on page 30 for a full list of installation hazard warnings.

The machine ships with the main body mounted to the ID chuck. See Section 3.7 on
page 36 for OD mounting or Section 3.8 on page 42 for surface mounting.

The FF6300 ID chuck can be removed from the main body rotating assembly. The
chuck can be installed independently as a subassembly when there are access or
rigging constraints. It can also remain attached to the main body during the machine
installation.

Use supplemental rigging when mounting the machine, in case it falls out
or through the chucking diameter.

The ID chuck hub is attached to the
main body by three M12 through-bolts
that pass through the main machine
spindle (Figure 3-10).

Because the ID chuck secures the
machine to the workpiece, it is very
important that the chuck be securely
clamped into position. Common appli­cations include both flange faces that
are horizontal (on the same plane as
the floor or overhead) or vertical.

Whenever there is a possibility
of the machine falling out of or
through the chucking diameter,
take special care to check that
the ID chuck is secure before releasing the rigging.

Page 32 FF6300 Operating Manual

To install and align the ID chuck

DANGER

FIGURE 3-11. VERTICAL INSTALLATION FALL DANGER

When installed vertically, if not
secured properly, this machine
can fall and cause serious injury
or death to the operator and
bystanders. To avoid this
danger, secure the machine by
tack-welding safety blocks over
the upper jaws or by using
clamps bolted to the underside
of the leveling feet (safety
blocks and clamps not included
with the machine). Check that
all chucks and clamps are
tightened to a torque value of at
least 60 ft-lbs (~27 Nm).

1. Measure the bore diameter of

the work piece.

2. Use Table 3-1 on page 33 to select the correct leg extensions to fit the bore

diameter.

TABLE 3-1. ID CHUCK SETUP TABLE FOR STANDARD ID CHUCK HUB

Diameter Range Diameter Range Number of leg segments needed

Min in Max in Min mm Max mm short leg med leg long leg

11.8 16.8 300 427 0 0 0

16.3 21.3 414 541 1 0 0

20.8 25.8 528 655 0 1 0

25.3 30.3 642 769 1 1 0

29.8 34.8 756 883 0 0 1

34.3 39.3 871 998 1 0 1

38.8 43.8 985 1112 0 1 1

43.3 48.3 1099 1226 1 1 1

*

47.8

52.3

*

52.8 1213 1340 0 2 1

57.3 1328 1455 1 2 1

* Extended range--light duty machining only.

P/N 80679, Rev. 10 Page 33

3. Apply the anti-seize com-

FIGURE 3-12. APPLYING ANTI-SEIZE COMPOUND

SETUP

FINGER

CAPTIVE M8

SCREWS

LOCKING
SCREWS

LEVELING

JAW

FULL EXTENSION
GROOVE

JACKING
SCREW

PP:5(1&+

pound (provided in the tool kit)
to the threads and contacting
faces of each leg section.

4. Screw the leg sections together.
Adjust the leveling jaws even
with the base and check that the
setup fingers are installed on
the leveling jaw.

FIGURE 3-13. DETAIL OF ID CHUCK LEGS

Page 34 FF6300 Operating Manual

5. Use a simple scale to roughly center the jacking screws. About 0.1" (2.5 mm)
clearance will allow insertion of the chuck while maintaining sufficient contact
between the setup finger and the flange face.

6. Install the ID chuck into the bore of the flange.

7. Using the short-handled 46mm wrench provided in the tool kit, tighten the
jacking screws evenly.

NOTICE

WARNING

Leveling screw

(10mm

Hex wrench)

FIGURE 3-14. ADJUSTING THE SETUP FINGERS

FIGURE 3-15. LOCATION OF THE 10-MM HEX FOR MANUAL

ROTATION OF THE MACHINE

Do not over tighten, as this
could bind the leveling feet
during leveling. Check that the
setup fingers are seated evenly.

Do not extend the jacking feet
past the full-extension groove in
the threaded screw (Figure 3­13 on page 34). If needed, add
additional leg sections to
minimize the length of the threaded jacking screw that is exposed.

8. After securely attaching the machine to the flange, attach a dial indicator to the

turning arm.

9. Check that power to the machine drive is isolated and locked out.

10. Using the dial indicator, indicate the workpiece surface for level while

manually rotating the machine.

• To manually rotate the pneumatic machine, insert a 10-mm hex wrench in
the hex opposite the motor or push on the end of the turning arm.

• To manually rotate the
hydraulic machine, use the
cross-connection hose
supplied with the machine
to connect the #1 and #2
port hoses. Insert a 10 mm
hex wrench in the hex
opposite the motor or push
on the end of the turning
arm.

11. Level the machine by turning
the leveling screws in each of
the leveling feet with the dial
indicator close to leveling
adjustment (Figure 3-6 on
page 29).

12. Reposition the dial indicator
to check machine centering.

13. Center the machine by adjust­ing opposing pairs of jacking
feet.

P/N 80679, Rev. 10 Page 35

14. Check the machine for level and center again.

CAUTION

15. Repeat step 10 to step 14 until the machine is aligned.

16. Secure the chuck:

a) Use a dead blow hammer on the short handled wrench to tighten the lev-

b) Use a 6mm hex wrench to tighten the recessed M8 locking nuts. You

17. Repeat step 10 to check for level, and step 11 to step 14 as needed to finalize
leveling.

If you used the 10mm hex wrench, remove it from the hex opposite the
motor. Otherwise, damage to the machine may occur.

3.7 OD MOUNTING

See Section 3.5 on page 30 for a full list of installation hazard warnings.

eling feet to a torque value of 20 ft-lbs (27 Nm).

need to tighten only two of these screws to lock the jacking screw.

FIGURE 3-16. OD MOUNT

Page 36 FF6300 Operating Manual

CENTERING

PLATE

CENTERING
SCREW 4X

EQUAL SPACE HERE

FIGURE 3-17. CENTERING PLATE

3.7.1 Setup overview for the OD mount machine

To set up the FF6300 OD mount, follow the process below. For details on these steps,
see Section 3.7.2 on page 37 through Section 3.7.5 on page 41.

1. Remove the OD mount from its shipping/storage crate.

2. Position the turning and counterweight arms for the FF6300.

3. Set the OD mount on top of the FF6300 main body and secure it.

4. Set the legs of the OD mount to the approximate mounting dimension.

5. Attach the vertical legs and leveling feet.

6. Secure the OD mount to the workpiece.

7. Center and level the OD mount.

3.7.2 Assembling the OD mount

The FF6300 OD mount ships in a wooden crate separate from the base machine.

1. Using the three lifting eyes on the OD mount, remove the OD mount from the

shipping crate.

2. Check that the centering plate

is roughly centered to maxi­mize the centering adjustment.
To center the centering plate,
adjust the centering screws
until the gap marked in red in
Figure 3-17 is equal for all four
screws.

3. Apply any anti-seize com-

pound (provided in the tool kit)
to the threads and contacting
faces of each leg section
(Figure 3-12 on page 34).

4. Assemble the OD mount legs,

end cap, and leveling foot.

5. Adjust the turning arm and

counterweight arm on the main
machine before installing the
OD mount. See Section 3.9 on page 44 and Section 3.10 on page 45.

6. Remove the ID chuck.

P/N 80679, Rev. 10 Page 37

7. Install three M12 nuts on the

NOTICE

FIGURE 3-18. ATTACHING THE OD MOUNT ASSEMBLY TO THE

MAIN BODY

FIGURE 3-19. OD MOUNT ASSEMBLY

captive chuck mounting bolts
and tighten to 50 ft-lbs
(68 N m).

Failure to install and torque
these nuts may lead to poor
machine performance.

8. Set the FF6300 machine on the
ground on wooden blocks.

9. Remove any lifting eyes from
the top of the main body
assembly.

10. Using the three lifting eyes on
the OD mount, lift the OD
mount into place on top of the
machine. Use care when
threading the hoses through the
hole in the center of the OD
mount so that the hoses are not
ped or damaged.

11. Install the six M12 fasteners
and tighten to approximately
50 ft-lbs (68 N m).

12. Screw the leg sections into the radial extension legs.

13. The radial legs are adjustable. Adjust the legs to the desired mounting diame­ter. See Section 3.7.3 on page 38 for available mounting arrangements.

14. Tighten the 12 leg clamping bolts to 35 ft-lbs (47 N m).

3.7.3 OD mounting arrangements

There are two mounting arrangements (described further in Section 3.7.4 on page 40):

• Arrangement A attaches the OD mount to the workpiece using the M16

threaded rod to either a tack-welded nut, holes in the workpiece, or other
available feature. The key dimension is the diameter to the centerline of
where the M16 rod will attach.

• Arrangement B attaches the OD mount to the OD chain clamps and clamps

them to the OD of the workpiece. The key dimension is the outside dimen­sion to which the clamps will attach.

Page 38 FF6300 Operating Manual

Arrangement A

DISTANCE FOR

MEASUREMENT

FIGURE 3-20. DISTANCE FOR OD MOUNT MEASUREMENT

Do the following for arrangement A:

1. Subtract 15" (381 mm) from the key dimension. Divide the difference by two.

2. Hook the tape measure to the

interior 9" (228 mm) diameter
hole on the top plate of the OD
mount (see Figure 3-20).

3. Adjust the leg until the dimen-

sion to the top of the end leg
label equals the calculated
result.

Example for arrangement A: In order
to mount the OD mount to the three
existing M16 holes on the workpiece
that are on a 60.5" (1,537 mm) bolting
circle, calculate the following:

1. 60.5" – 15" = 45.5"

2. 45.5" / 2 = 22.75”

3. Adjust each leg so that the tape measure reads 22.75".

Arrangement B

Do the following for arrangement B:

1. Subtract 9" (228 mm) from the key dimension. Divide the difference by two.

2. Hook the tape measure to the interior 9" (228 mm) diameter hole on the top

plate of the OD mount (see Figure 3-20).

3. Adjust two of the legs until the dimension to the top of the end leg label equals

the calculated result.

4. Adjust the third leg so that it is .25" (6 mm) greater than the calculated dimen-

sion. This allows the OD mount to be installed with the chain clamp in place,
and then for the clamp to be tightened up as the leg is moved back to the same
position as the other two legs.

P/N 80679, Rev. 10 Page 39

NOTICE

Referring to Figure 3-21:

POINT FOR

ARRANGEMENT A

POINTS FOR

ARRANGEMENT B

FIGURE 3-21. MEASUREMENT POINTS FOR EACH ARRANGE-

MENT

FIGURE 3-22. ATTACHING THE OD MOUNT WITH A TACK-WELD

NUT

measure to the top point for the
dimension to the center of the
16-mm rod.

Swing the tape measure to the
appropriate bottom point to
align with the actual OD for the
chain clamp.

Example for arrangement B: In order
to chain clamp to a flange that is 55"
(1,397 mm), calculate the following:

1. 55" – 9" = 46"

2. 46" / 2 = 23"

3. Adjust two of the legs to 23".

4. Adjust the third leg to 23.25".

3.7.4 Attaching the OD mount assembly to the workpiece

The OD mount vertical legs attach to the workpiece with a single M16 x 2.0 all-thread
rod at each leg. There are numerous ways to mount the machine to the workpiece.
Three possible ways to attach the OD mount assembly to the workpiece are:

• Attach the vertical legs by

tack-welding an M16 nut to
the workpiece. Use a mini­mum of a 3/16" (4.76 mm)
weld x 1" (25 mm) long
(Figure 3-22).

• Attach the vertical legs by

clamping a plate with an
M16 threaded hole to the
workpiece at each mount­ing point.

Page 40 FF6300 Operating Manual

FIGURE 3-23. ATTACHING THE OD MOUNT USING THE CLIMAX

CHAIN CLAMP KIT

CENTERING
SCREW 4X

CENTERING

PLATE

LEVELING
SCREWS 3X

FIGURE 3-24. OD MOUNT ADJUSTMENT POINTS

• Attach the vertical legs by
using the CLIMAX OD
Chain Clamp Kit (P/N

80622) (Figure 3-23).
Tighten the chain evenly to
50 ft-lbs (68 N m).The
chain clamp kit is an
optional accessory; contact
your CLIMAX representa­tive for more information.

3.7.5 Centering and leveling the OD mount assembly

1. Check that the centering plate spacer is approximately centered on the OD
mount.

2. Mount a dial indicator on the turning arm.

3. Check that power to the machine drive is isolated and locked out.

4. Using the dial indicator, indicate the workpiece surface for level while
manually rotating the machine.

• To manually rotate the pneumatic machine, insert a 10-mm hex wrench in

the hex opposite the motor or push on the end of the turning arm.

• To manually rotate the hydraulic machine, use the cross-connection hose

supplied with the machine to connect the #1 and #2 port hoses. Insert a 10­mm hex wrench in the hex opposite the motor or push on the end of the
turning arm.

5. Level the machine by turning two of the three leveling screws at the end of the
vertical legs, with the dial indicator close to leveling adjustment (Figure 3-6 on
page 29, ID chuck shown).

6. Reposition the dial indicator to check machine centering.

7. Loosen the centering plate
clamp screws and adjust the
machine center using the four
jacking screws as necessary
(Figure 3-24).

8. Tighten the three centering
plate clamp screws (Figure 3-

24).

9. Check the machine for level
and center again.

10. Repeat step 5 to step 9 until the
machine is aligned.

P/N 80679, Rev. 10 Page 41

11. Tighten the twelve M12 screws on top of the OD mount that clamp the radial

CAUTION

leg section.

12. Repeat step 4 to check for level; repeat step 5 to step 9 as needed to finalize
leveling.

If you used the 10-mm hex wrench, remove it from the hex opposite the
motor. Otherwise, damage to the machine may occur.

3.8 SURFACE MOUNTING

See Section 3.5 on page 30 for a full list of installation hazard warnings.

3.8.1 Setup overview for the surface mount machine

To set up the FF6300 surface mount, follow the process below. For details on these
steps, see Section 3.8.2 on page 42 and Section 3.8.3 on page 43.

1. Remove the ID chuck from the FF6300 main body.

2. Secure the surface mount plate to the workpiece by either tack-welding, bolt­ing, or clamping.

3. Secure the FF6300 main body to the surface mount plate.

4. Center and level the machine.

3.8.2 Assembling the surface mount

The surface mount attaches to the main body with the same M12 fasteners as the ID
chuck. The surface mount can be secured to the work piece first and then the machine
bolted to the mount, or the machine can be mounted as a complete unit.

The surface mount consists of two primary parts:

• The circular mounting plate to which the machine is attached

• The four blocks secured to the workpiece, from which the mounting plate

is centered and leveled

The four blocks can be drilled for mounting holes and clamped or tack-welded to the
workpiece or other custom fixture determined by the operator.

• When the blocks are bolted, use a minimum of two M8 (5/16") bolts per

block.

• When the blocks are tack-welded, use a minimum of 1" (25mm) of 1/4"

(6mm) weld per block.

Page 42 FF6300 Operating Manual

TIP:

CAUTION

The surface mount circular mounting plate can be used as a template to
hold the four blocks in the correct orientation while attaching the blocks to
the workpiece.

Check that the blocks are secured to the mounting plate with approximately 0.2"
(5 mm) of adjustment range. Secure the blocks to the workpiece with the circular
mounting plate centered to the area to be machined, within the same true position [0.2"
(5mm)].

3.8.3 Centering and leveling the surface mount assembly

Do the following to center and level the surface mount assembly:

1. After securely attaching the machine to the flange, mount a dial indicator on

the turning arm.

2. Check that power to the machine drive is isolated and locked out.

3. Using the dial indicator, indicate the workpiece surface for level while

manually rotating the machine.

• To manually rotate the pneumatic machine, insert a 10-mm hex wrench in
the hex opposite the motor or push on the end of the turning arm.

• To manually rotate the hydraulic machine, use the cross-connection hose
supplied with the machine to connect the #1 and #2 port hoses. Insert a 10­mm hex wrench in the hex opposite the motor or push on the end of the
turning arm.

If you used the 10-mm hex wrench, remove it from the hex opposite the
motor. Otherwise, damage to the machine may occur.

4. Adjust the level of the machine using the two M16 adjustment screws in each
quadrant of the mounting plate (Figure 3-25).

5. Reposition the dial indicator to check machine centering.

6. Center the machine using the M16 set screw in the edge of each block.

7. Repeat step 3 to step 6 until the machine is aligned.

8. Secure the M10 screws to lock the position of the surface mount.

P/N 80679, Rev. 10 Page 43

9. Repeat step 3 to check for level; repeat step 4 to step 6 as needed to finalize

FIGURE 3-26. LOCATION OF SECURING CLAMPS

leveling.

FIGURE 3-25. SURFACE MOUNT ASSEMBLY

3.9 POSITIONING THE MACHINING ARM

The machining arm is adjustable for
versatile positioning and to clear
obstructions.Loosen the four clamps
that secure the arm to the main body
(Figure 3-26).

1. Pull and hold the safety stop
pin.

Page 44 FF6300 Operating Manual

WARNING

NOTICE

CAUTION

FIGURE 3-27. DETAIL OF MACHINING ARM

SPRING
LOADED PIN

MEASUREMENTS

RELATIVE TO THIS EDGE

MACHINING

DIAMETER IN CM

MACHINING DIAMETER

IN INCHES

152

60

142

56

132

52

2. Slide the arm to the desired

position.

The machining arm is engraved
with and centimeter markings
on the face of the slide to help
you set the position. Because
the arm is moved radially from
center, the scale shows es and
centimeters in half increments,
measured from the edge of the
main housing (Figure 3-27).

3. Release the safety stop pin.

Position the machining arm so that the safety stop pin engages the
retention notch in the machining arm.

Do not disable the safety stop pin. The safety stop pin is intended to
prevent unwanted shifting of the machining arm, which could result in
serious injury or death.

4. Tighten the clamps to approximately 50 ft-lbs (68 Nm).

3.10 POSITIONING THE COUNTERWEIGHT

The counterweight must be installed when the machine is used in a vertical
machining application. CLIMAX recommends that you always use the
counterweight as it improves the performance of the machine and
produces a flatter surface.

The counterweight arm can be adjusted to balance the machine.

For precise machining and to avoid damage to the machine, the
counterweight and machining arm should always be equally spaced from
the center of the machine.

After positioning the turning arm, do the following to adjust the counterweight to
balance the machine:

P/N 80679, Rev. 10 Page 45

1. Suspend the machine from the two lifting points on top of the main body.

2. Loosen the clamp collars that

WARNING

WARNING

FIGURE 3-28. LOCATION OF CLAMPING SCREWS

FIGURE 3-29. LOCATION OF LOCKING SCREWS

secure the counterweight arm
(see Figure 3-28).

3. Adjust the counterweight arm
until the machine hangs level
within five degrees.

4. Tighten the counterweight arm
screws to approximately
30 ft-lbs (40 Nm).

Check that all mounting hardware is secure. A loose counterweight can fall
off during operation, seriously injuring the operator or bystanders.

If you need to remove the counter­weight arm (to simplify rigging, for
example), first do the following to
remove the counterweight from the
counterweight arm:

1. Attach the rigging to the lifting
eye on the counterweight.

2. Loosen the locking screw adja­cent to the lifting hole (see Fig­ure 3-29).

3. Loosen the counterweight
adjustment clamp screws (see Figure 3-28).

4. Use a 10-mm hex wrench inserted in the hole near the engraving at the end of
the arm to rotate the counterweight arm out of the counterweight.

A collar on the counterweight arm prevents the counterweight assembly from sliding
free from the main housing assembly if the arm is not clamped securely (see Figure 3-

28). This collar has a urethane face that must face towards the main body clamps. An
o-ring between the collar and the shoulder at the end of the arm allows the collar to
absorb the energy from a sliding impact. If you notice that the collar has been
displaced or the o-ring is missing, correct this before you continue using the machine.

Page 46 FF6300 Operating Manual

5. Slide the arm out of the main body.

6. Reinstall the counterweight by reversing this procedure.

Do not remove the stop collar on the counterweight arm. Serious injury or
death can result if the arm is accidentally left unclamped and it slides out of
the main body socket.

3.11 ROTATING THE TOOL HEAD

NOTICE

CAUTION

FIGURE 3-30. DETAIL OF TOOL HOLDER

FIGURE 3-31. LOCATION OF SWIVEL CLAMPING SCREW

The FF6300 is designed to trail
the cutting tool behind the
turning arm. The turning arm
moves in a clockwise direction.
Keep these characteristics in
mind when installing a new tool
in the machine.

Do the following to rotate the tool
head:

1. Loosen the circular clamp col-

lar on the back of the tool head.

Do not loosen the tool head
rapidly. Keep your hand on the
tool head for stability. Quick
disengagement of tool head can
cause it to swing unexpectedly,
and may result in personnel
injury or machine damage.

2. Position the tool head.

3. Tighten the clamp collar.

Engraved markings on the clamp collar
enable you to set angles within ± 0.5°.

P/N 80679, Rev. 10 Page 47

3.12 ADJUSTING THE FEED BOX

FIGURE 3-32. FEED BOX

FIGURE 3-33. DETAIL OF FEED BOX POSITIONS

The machine includes a remote air shutoff valve (seen in Figure 2-7 on page 21).

The feed box (seen in Figure 3-32) is
supplied with two 1/4" air supply
tubes. The feed box will function even
if the tubing connection points are
swapped; the order of connection is not
critical.

The hoses should have approximately
12" (305 mm) of extra length to allow
the arm to move and still keep the
hoses clear of snag hazards.

The feed box has two positions: disen­gaged and engaged (see Figure 3-33).
Push the knob inward to engage the
feed, and pull the knob out to
disengage.

Page 48 FF6300 Operating Manual

3.12.1 Adjusting the feed rate

WARNING

NOTICE

FIGURE 3-34. KNOB REVOLUTIONS MARKED ON THE

MACHINED FLANGE

Do not adjust the feed rate while the machine is rotating, as rotating
machinery can cause serious injuries. Stop the machine completely before
adjusting the feed rate. Follow Section 3.12.2 on page 50 to conduct feed
actuation measurement.

Each rotation of the feed rate adjustment knob (see Figure 3-35) increases the feed rate
approximately 0.006" (0.15 mm). Table 3-2 provides a reference to quickly set the
approximate feed rate.

TABLE 3-2. FEED RATE ADJUSTMENT KNOB

Approximate feed per revolution
of the machining arm

0" (0 mm) 0

0.006" (0.15 mm) 1

0.012" (0.30 mm) 2

0.018" (0.43 mm) 3

0.024" (0.58 mm) 4

0.030" (0.76 mm) 5

0.036" (0.89 mm) 6

* Turn the knob clockwise until it stops to ensure zero

feed.

The values in Table 3-2 are
approximate. If a specific feed
per revolution is required, place
a dial indicator on the arm and
measure the feed amount while
the machine is manually rotated
one revolution, then adjust as
necessary.

Number of knob
rotations

*

P/N 80679, Rev. 10 Page 49

For example, if you are seeking .018"

TIP:

CAUTION

FEED RATE
ADJUSTMENT KNOB

FIGURE 3-35. FEED RATE ADJUSTMENT KNOB AND FEED BOX

ROLLER LEVER

ACTUATOR

PNEUMATIC

VALV E

FIGURE 3-36. PNEUMATIC VALVE LOCATION

feed, do the following:

1. Turn the knob counter-clock­wise until it stops to ensure
zero feed.

2. Locate .018" in the first column
of Table 3-2 on page 49.

3. Note the number 3 in the cell to
the right in the same row.

4. Turn the knob counter-clock­wise three full rotations.

Scribe a reference mark on the
feed rate adjustment knob of
the feed box to track a full
rotation, as shown in Figure 3-

35.

3.12.2 Conducting feed actuation measurement

The feed trips seven times per full rota­tion of the machining arm.

Use one of two ways to trip the feed to
verify the feed rate:

• Manually rotate the

machine arm 360°.

• Using a tool such as a

screwdriver, manually
press the roller lever actua­tor of the pneumatic valve
(see Figure 3-36) near the
top of the spindle. Seven
cycles of the roller lever
actuator correspond with a
360° rotation of the
machining arm.

Use caution when manually cycling the roller lever actuator to avoid a
potential pinch point.

Choose the method that is safest and most convenient for the setup.

Page 50 FF6300 Operating Manual

After setting the approximate feed rate,

FIGURE 3-37. DIAL INDICATOR USED FOR PRECISE ADJUST-

MENT

FIGURE 3-38. LOCATION OF FEED BOX BOLTS

if a more precise reading is helpful,
measure the actual feed rate by using a
dial indicator mounted as shown in
Figure 3-37.

If the resulting feed rate is different
than expected, adjust the feed rate
adjustment knob (see Figure 3-35) by
doing the following:

1. Turn the knob clockwise to

increase the feed rate.

2. Turn the knob counter-clock-

wise to decrease the feed rate.

Repeat step 1 and step 2 until the
desired feed rate is achieved.

3.12.3 Reversing the feed direction

The feed box only feeds in one direction.

You do not need to disconnect the hoses to reverse the feed direction.

To reverse the feed direction:

1. Remove the feed shaft and two

bolts (see Figure 3-38).

P/N 80679, Rev. 10 Page 51

2. Rotate the feed box until the

NOTICE

FIGURE 3-39. LOCATION OF FEED BOX DIRECTION ARROW

FIGURE 3-40. FEED ADJUSTMENT KNOB POSITIONED DOWN
FIGURE 3-41. LOCATION OF FEED HOSES

arrow points in the desired feed
direction (see Figure 3-41).

3. Reinstall the bolts and the feed
shaft.

For some setup configurations,
it may be required to orient the
feed box so that the feed
adjustment knob is facing
downwards (see Figure 3-40).

This feed box orientation retains
full functionality of the machine.

3.12.4 Disconnecting feed hoses

Press down on the collar around the
hose and pull the hoses out. (see Figure
3-41).

Page 52 FF6300 Operating Manual

3.13 BACKFACING ATTACHMENT

NOTICE

Assembling the backfacing attachment

P/N 80679, Rev. 10 Page 53

FIGURE 3-42. BACKFACING ATTACHMENT ON SURFACE MOUNT MACHINE

The optional backfacing attachment is used for surfacing the underside or backside of
flanges, a typical application on heat exchanger tube sheets and some crane pedestals.

The backfacing attachment can only be used with either the ID chuck or the
surface mount.

Do the following to assemble the backfacing attachment:

1. Assemble the FF6300 machine using the ID chuck or surface mount.

2. Remove the tool head by com-

FIGURE 3-43. INSTALLING THE BACKFACING ATTACHMENT TO

THE TURNING ARM

pletely removing the two M8
fasteners that hold the swivel
clamp collar together.

3. Use the four M10 socket head
cap screws to secure the back­facing attachment to the radial
slide plate on the turning arm.
Do not tighten the screws.

4. Adjust the height of the back­facing attachment relative to
the flange.

5. Tighten the screws to approxi­mately 35 ft-lbs (47 N m).

6. Reinstall the tool head to the
circular dove on the bottom of
the backfacing attachment
(Figure 3-43).

7. Tighten the two M8 fasteners
to secure the swivel clamp at
the desired angle.

8. Manually rotate the turning arm one revolution to check for swing clearance.

The backfacing attachment can machine flanges to the thickness and diameter shown
in Figure 3-44 on page 55.

Page 54 FF6300 Operating Manual

FIGURE 3-44. BACKFACING ATTACHMENT DIMENSIONS

P/N 80679, Rev. 10 Page 55

This page intentionally left blank

Page 56 FF6300 Operating Manual

CAUTION

WARNING

WARNING

4 OPERATION

IN THIS CHAPTER:

4.1 PRINCIPLES OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -57

RE-START CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -57

4.2 P

ACHINING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59

4.3 M

4.3.1 P

NEUMATIC-POWERED MACHINING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59
YDRAULIC-POWERED MACHINING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -59

4.3.2 H

DJUSTING THE MACHINE WHEN THE CUT IS COMPLETED - - - - - - - - - - - - - - - - - - - - -61

4.3.3 A

4.4 D

ISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -61

4.1 PRINCIPLES OF OPERATION

Do not operate this machine without adequate training to fully understand safe setup,
operation, and maintenance.

To avoid serious personal injury, keep clear of moving machinery during
operation. Always be aware of the location of all personnel near the
machine.

The FF6300 often is used in dangerous locations (in elevated positions, near other
operating equipment, overhead, etc.). CLIMAX cannot foresee where this machine
will be used; therefore, you must perform a site-specific risk assessment (Section 1.5
on page 6) for each job before starting work.

The FF6300 machine has remote operation features that enable you to choose the
optimum location to work from.

Always follow safe work practices, including site-specific safety
requirements. It is your responsibility to perform a risk assessment before
you set up the machine and each time before you operate the machine.

4.2 PRE-START CHECKS

Rotating machinery can cause serious injuries. Turn off and lock out the
machine before making the pre-start checks.

P/N 80679, Rev. 10 Page 57

Before starting the machine, always check the following:

WARNING

CAUTION

CAUTION

FIGURE 4-1. DETAIL OF HOSE GUIDE BRACKET

• All energy supplies are OFF and the system reset button is released.

• Check that the machine is securely mounted to the work piece.

• Check that all the lines,

cables, and hoses are prop­erly connected and secured
away from moving parts.
A lightweight bracket is
supplied in the tool kit for
securing the hoses as
shown in Figure 4-1.

Broken air or hydraulic lines
can whip around, striking the
operator or bystanders. Always
check that the supply lines to
the machine are secure and cannot be hit by moving parts.

• For hydraulically driven machines check that all hoses and fittings are leak

free. Hydraulic oil leaks could contaminate the environment or cause a
slipping hazard. Clean up any spills, and repair any leaks before operating
this machine.

• Check that all the machine parts are secure, including the tool head, tool

bit, chucks, and clamps.

• Check that the tool head is set at the desired angle and is tight.

• Check that the feed direction and rate are set correctly (Section 3.12 on

page 48).

Page 58 FF6300 Operating Manual

Check that the turning arm is securely clamped to the main body and that it
will not hit any obstructions around the workpiece. Check that there is
clearance by manually rotating the machine one full revolution.

• Check that all handles and tools are removed from the machine.

• Check that all preventative maintenance is complete (Section 5) and the

drip rate is set correctly on the pneumatic conditioning unit (PCU). Refer to
Section 5.3.1 on page 64.

• Check that the emergency stop button is reset.

Metal chips and other debris can damage the machine and degrade its
performance. Ensure all metal chips and other debris are removed from the
machine before and after each use.

DANGER

CAUTION

FEED

ON/OFF

VALVE

SPEED ADJUSTMENT VALVE

FIGURE 4-2. PNEUMATIC POWERED MACHINING VALVES

4.3 MACHINING

See Section 2.3 on page 21 for information on the location and function of the
controls. See Section 3.12 on page 48 for information on the feed box.

To avoid serious injury to hands or arms, do not reach inside the swing of
the turning arm during operation or while the machine is energized.

4.3.1 Pneumatic-powered machining

If the machine stops moving unexpectedly, de-pressurize and lock out the
pneumatic safety valve located on the pneumatic conditioning unit before
performing any troubleshooting.

Refer to the pneumatic conditioning
unit (PCU) controls described in
Section 2.3.1 on page 21 and shown in
Figure 4-2.

Do the following to operate the
machine:

1. Push the START button on the

PCU.

2. Use the SPEED ADJUSTMENT

VA LV E to turn on the drive

motor and to adjust the drive
motor speed to achieve the
desired rotation rate.

3. Turn on the FEED ON/OFF

VA LV E .

4. When the cut is complete, first

stop the feed and then stop the
machine rotation.

4.3.2 Hydraulic-powered machining

Refer to the hydraulic power unit (HPU) controls described in Section 2.3.2 on
page 21.This type of machine has a hydraulic powered rotation with a pneumatic feed.

P/N 80679, Rev. 10 Page 59

CAUTION

Using a different HPU than the one specified in this manual will require a

MAIN

O

BAR

(-) (+)

RPM

I

I

PENDANT 65028
20' CABLE 53432
30' CABLE 62729
50' CABLE 53433

100' CABLE 53434

SPEED CONTROL

FASTER

SPEED CONTROL

SLOWER

HYDRAULIC ON

(Turns on hydraulic
flow to flange facer)

HYDRAULIC OFF

(Turns off hydraulic
flow to flange facer)

START (System reset)
(Starts main electric
drive motor on HPU)

EMERGENCY STOP
(Rotate clockwise to
reset)
(Stops electric drive
motor and oil flow)

separate evaluation.

Do the following to operate:

1. On the HPU controller, turn the emergency stop button clockwise to reset the
emergency stop.

FIGURE 4-3. LOCATION OF HYDRAULIC POWERED ROTATION CONTROLS

2. Press the start button to start the HPU motor.

3. Press the speed control slower button until it is at the minimum.

4. Press the hydraulic on button.

5. Press the speed control faster button to reach the desired speed.

6. Turn the feed rate adjustment knob to the minimum feed or to the desired set-

7. Turn on the feed and adjust the feed rate for the desired cut (Figure 4-2 on

Page 60 FF6300 Operating Manual

ting, if known (Figure 4-2 on page 59).

page 59).

CAUTION

CAUTION

WARNING

8. Use the speed control buttons to adjust the drive motor to achieve the desired

cut.

9. When the cut is complete, first stop the feed and then stop the machine rota-

tion.

Recheck the chuck torque at intervals, including after environmental
changes (such as between night and day) in case of thermal growth.

4.3.3 Adjusting the machine when the cut is completed

Do the following to adjust the machine when the cut is completed:

1. Check that all power sources to the machine drive are isolated and locked out.

The cutting tools can get hot during machining. Wear gloves or other
protective personal protective equipment and be careful of hot surfaces to
avoid burns.

2. Adjust the machine direction, depth of cut, or tool position as needed.

3. Start the machine and feed again to start a new cut.

4. Repeat until the desired surface is achieved.

4.4 DISASSEMBLY

If not properly secured, 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 lifting apparatus before beginning any disassembly steps. Use
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 pneumatic

conditioning unit (PCU).

3. If applicable, de-pressurize the hydraulic system by pulling the knob on the

drain valve on the hydraulic power unit (HPU).

4. Disconnect the hydraulic and air hoses from the machine.

5. Retract the tool from the work piece.

P/N 80679, Rev. 10 Page 61

6. Remove the tool bit, being careful of hot surfaces.

7. Using the supplied hoist rings, attach lifting equipment to the machine.

8. Install setup fingers to each leveling foot (for the ID chuck).

9. Loosen and retract the leveling feet (for the ID chuck).

10. Remove the machine from the work piece.

Page 62 FF6300 Operating Manual

CAUTION

5 MAINTENANCE AND TROUBLESHOOTING

IN THIS CHAPTER:

5.1 OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63

AINTENANCE INTERVALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64

5.2 M

AINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64

5.3 M

5.3.1 C

HECK THE PNEUMATIC CONDITIONING UNIT OIL RESERVOIR LEVELS - - - - - - - - - - - - - - - -64
MPTY THE AIR FILTER WATER TRAP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64

5.3.2 E

NEUMATIC CONDITIONING UNIT EMERGENCY STOP CHECK - - - - - - - - - - - - - - - - - - - -64

5.3.3 P

5.3.4 P

NEUMATIC CONDITIONING UNIT DROP-OUT CIRCUIT CHECK - - - - - - - - - - - - - - - - - - - -65
YDRAULIC POWER UNIT MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -65

5.3.5 H

OVETAIL AND SQUARE WAYS MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - -65

5.3.6 D

5.3.7 L

EADSCREW MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -65

DJUST THE DOVETAIL AND SQUARE WAYS GIB SCREWS - - - - - - - - - - - - - - - - - - - - -66

5.3.8 A

DJUST THE RADIAL SLIDE LEAD NUT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -66

5.3.9 A

5.3.10 T

UBRICATING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -67

5.4 L

ROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -69

5.5 T

5.5.1 T

5.5.2 T

5.5.3 T

5.5.4 T

5.5.5 T

ECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -71

5.6 D

RAM THE TURNING ARM - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -66

HE MACHINE ISN’T TURNING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -69
HE MACHINE ISN’T FEEDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -70
HE FEED IS SLOW OR UNRESPONSIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - -70
HE MACHINE IS PERFORMING POORLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - -71
HE MACHINE IS NOT CUTTING FLAT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -71

5.1 OVERVIEW

This chapter explains periodic maintenance intervals and tasks and provides trouble­shooting guidance.

Failure to properly clean and maintain the machine can result in machine
damage and void the warranty.
Always keep moving machine parts clear of metal chips.

Following the required maintenance schedule is critical to obtaining normal machine
life.

Keep all machine components in clean, working condition.

Check that parts such as the mounting surfaces, hydraulic fittings, and the tools them­selves are free of metal chips, nicks, and burrs.

To prevent corrosion, thoroughly rinse with fresh, clear water any machine parts that
are exposed to salt water.

P/N 80679, Rev. 10 Page 63

5.2 MAINTENANCE INTERVALS

Table 5-1 lists maintenance intervals and tasks, along with the section where each task
is described.

TABLE 5-1. MAINTENANCE INTERVALS AND TASKS

Interval Task See section

Check the pneumatic conditioning unit oil reservoir levels. 5.3.1

Check the pneumatic lines for damage and wear. --

Before each use

Before and after each
use

After each use Perform dovetail and square ways maintenance. 5.3.6

Periodically

As needed

Perform a pneumatic conditioning unit emergency stop check. 5.3.3

Perform a pneumatic conditioning unit drop-out circuit check. 5.3.4

Perform hydraulic power unit maintenance. 5.3.5

Remove debris, oil, and moisture from machine surfaces. --

Perform leadscrew maintenance. 5.3.7

Empty the air filter water trap. 5.3.2

Perform leadscrew maintenance. 5.3.7

Adjust the dovetail and square ways gib screws. 5.3.8

Adjust the radial slide lead nut. 5.3.9

Tram the turning arm. 5.3.10

5.3 MAINTENANCE TASKS

5.3.1 Check the pneumatic conditioning unit oil reservoir levels

1. Check the pneumatic conditioning unit (PCU) oil reservoir levels.

2. Refill as necessary. See Table 5-2 on page 68 for information on recommended
lubricants.

3. Check that the oil drip rate is set at six drops per minute (Figure 2-7 on
page 21).

5.3.2 Empty the air filter water trap

Check and drain the water from the air filter water trap.

5.3.3 Pneumatic conditioning unit emergency stop check

1. With the machine running, press the emergency stop button (Figure 2-7 on
page 21).

2. Check that the machine stops.

Page 64 FF6300 Operating Manual

WARNING

3. Reset the emergency stop by pulling the button up.

4. Check that the machine doesn’t restart.

5.3.4 Pneumatic conditioning unit drop-out circuit check

The pneumatic conditioning unit drop-out circuit prevents the machine from restarting
unexpectedly after air supply to the PCU is lost and restored.

To check the PCU drop-out circuit:

1. Check that the PCU is connected to an air supply and to the FF6300.

2. Check that the air-supply lock-out is open (pulled up).

3. Press the START button.

4. Slowly open the PCU speed adjustment valve until the rotary drive engages.

5. Close (press down) the lock-out valve.

6. Check that the FF6300 stops.

7. Open the lock-out valve.

8. Verify that the machine does not automatically restart when the lock-out valve

is re-opened in step 7.

Do not operate the machine if the pneumatic conditioning unit starts in step

8. Contact CLIMAX for service recommendations.

5.3.5 Hydraulic power unit maintenance

1. Refill the HPU oil reservoir before each use.

2. Replace the oil and filter every two years.

For more information on HPU maintenance, see the HPU operator’s manual that was
included with the FF6300.

5.3.6 Dovetail and square ways maintenance

Lightly lubricate the dovetail and square ways after cleaning and after each work
session. This helps protect the machine precision surfaces from corrosion. See
Figure A-6 on page 86 and Figure A-10 on page 90 for the locations of the dovetail
and square ways.

5.3.7 Leadscrew maintenance

1. Lightly lubricate the leadscrew after cleaning, after each work session, and

periodically during operation to ensure smooth travel. For leadscrew locations,
see Figure A-6 on page 86 and Figure A-10 on page 90.

2. During operation, clean ball screws and ACME leadscrews frequently to pre-

vent thread damage to nut and leadscrew.

P/N 80679, Rev. 10 Page 65

5.3.8 Adjust the dovetail and square ways gib screws

NOTICE

Square way

gib screws

FIGURE 5-1. LOCATION OF LEAD NUT ADJUSTMENT SCREWS

Adjusting the dovetail slide on the tool head is done using five M6 x 1.0 gib screws.
For screw locations, see Figure A-6 on page 86.

Adjusting the square ways on the turning arm is done using three M6 x 1.0 gib screws.
For screw locations, see Figure A-10 on page 90.

The radial slide (square way gib screws) must be snug for the best cutting perfor­mance. Approximately 2–4 in-lbs (.3 Nm) of torque is necessary to turn the radial
travel leadscrew.

Adjustment should be necessary only after many hours of use and only if the machine
is no longer producing a good finish.

If a slide is visibly loose and causing machining problems, tighten the gib screws in
small increments. There should be 2–4 in-lbs (.3 Nm) of drag on the radial leadscrew
and a slight drag on the manual feed handle.

5.3.9 Adjust the radial slide lead nut

The radial slide lead nut is adjustable
to provide reduced backlash. Adjusting
the lead nut is done using two M10 x

1.50 set screws recessed in the swivel
circular dove plate. Adjustment should
be necessary only after many hours of
use and only if the machine is no
longer producing a good finish.

Only adjust the radial slide lead
nut after adjusting the square
way gibs, as described in
Section 5.3.8.

If the slide is visibly loose and causing machining problems, tighten the two set screws
by small increments until a slight drag is felt on the manual feed handle.

After adjustment, check travel over the full length of the leadscrew for tight spots.

5.3.10 Tram the turning arm

Page 66 FF6300 Operating Manual

Do the following if the turning arm becomes misaligned:

1. The bottom surface of the main body assembly can be used as a datum
(Figure 2-1 on page 15 and Figure A-8 on page 88).

2. Tighten the two M8 screws (number 49 in Figure A-8 on page 88) on the top of
the main body assembly, and then back them off a little.

5.4 LUBRICATING THE MACHINE

NOTICE

Table 5-2 on page 68 provides information on recommended lubricants.

Change the oil in the main body drive gear and grease the lower spindle bearing after
every 1000 hours of use, or yearly.

The more frequently oil is used to lubricate the leadscrew and nuts, the
longer they will last.

P/N 80679, Rev. 10 Page 67

FIGURE 5-2. LUBRICATION LOCATIONS

A. Rectangle and dovetail ways—Lubricate the rectangle and dovetail ways daily

during machine use, with AW 32 or equivalent.

B. Leadscrew—Lubricate the leadscrew weekly during machine use, with Nook

E-100 spray lube or equivalent.

C. Thrust bearings—The thrust bearings are lubricated at the factory and should

not need further lubrication.

D. Lower bearing—Lubricate the lower bearing yearly at the Zerk fitting, with

Mobil SHC 460 or equivalent.

E. Main body gear drive—Lubricate the main body gear drive once per year, with

Mobil 634 Gear Oil or equivalent.

F. Mount legs and jacking screws—Lubricate the mount legs and jacking screws

CAUTION

G. Leveling foot—Lubricate the leveling foot daily during machine use, with

Recommended lubricants

CLIMAX recommends the lubricants listed in Table 5-2. Listed alongside the regular
lubricants are biodegradable alternatives. If these lubricants are not available in your
area, contact CLIMAX for alternatives. See Appendix C for MSDS information.

To avoid damage and premature machine wear and to protect your
warranty, use only recommended lubricants.

TABLE 5-2. RECOMMENDED LUBRICANTS

Application Area Lubricant

weekly during machine use and before storage, with Moly Grade Anti-Seize or
equivalent.

AW32 or equivalent.

Biodegradable
Lubricant Viscosity (cSt) Quantity

Daily

Dovetail and square­ways

Unpainted surfaces LPS 2 N/A 38 @ 25 °C As required

Hydraulic power unit

Pneumatic condi­tioning unit

Leadscrew

Chuck jacking
screws

AW 32 hydraulic oil

AWS-46 hydraulic oil
(summer)

AWS-32 hydraulic oil
(winter)

AW 32 hydraulic oil N/A

Dry film graphite lubri-

†

cant

AW 32 hydraulic oil

Moly Grade Anti-Seize N/A N/A 1 cc per screw

CONOCO Ecoterra 32
or Castrol BioBar 32

Each Use

CONOCO Ecoterra 46
or Castrol BioBar 46

CONOCO Ecoterra 32
or Castrol BioBar 32

Weekly

N/A N/A

CONOCO Ecoterra 32
or Castrol BioBar 32

32 @ 40 °C

6 @ 100 °C

46 @ 40 °C

8 @ 100 °C

32 @ 40 °C

6 @ 100 °C

32 @ 40 °C

6 @ 100 °C

32 @ 40 °C

6 @ 100 °C

As required

As required to fill
reservoir to
mid-sight glass level.
Replace oil every
two years.

Refill oil lubricator

Light coating applied
by hand

*

Yearly

Main body gear
drive

Mobil SHC 634 N/A 460 @ 40 °C As required

Page 68 FF6300 Operating Manual

TABLE 5-2. RECOMMENDED LUBRICANTS

Biodegradable

Application Area Lubricant

Feed drive gearbox Polytac EP 2 N/A 129 @ 40 °C 5 cc

Lubricant Viscosity (cSt) Quantity

Lower spindle bear­ing

Unpainted surfaces LPS 2 N/A 7 @ 25 °C As required

Unpainted surfaces LPS 3 N/A N/A As required

Chuck jacking
screws

Machine surfaces

* Always replace hydraulic filters when replacing hydraulic oil. Never assume that oil in drums is clean. Always pump oil

through a 5 micron hydraulic filter before/while filling reservoir.

† Dry film graphite lubricant is preferred on the leadscrew because wet lubricants can attract debris and particulates.

Moblith SHC 460 N/A 414 @ 40 °C As required

Storage

Moly Grade Anti-Seize N/A N/A 1 cc per screw

LPS PreSolve Orange
degreaser (cleaner to
remove LPS 3)

N/A N/A As required

5.5 TROUBLESHOOTING

This section is intended to help you solve basic machine performance problems. For
serious maintenance or if you have questions on the following procedures, contact
CLIMAX.

5.5.1 The machine isn’t turning

If the machine is not rotating, check the following:

1. The power source is connected and energized.

2. The emergency stop is reset (Section 5.3.3 on page 64 for PCU and

Section 2.3.2 on page 21 for HPU).

3. The air regulator is open and not broken (Figure 2-7 on page 21).

4. There is air pressure entering and leaving the PCU. Check the air pressure by

disconnecting the hose quick disconnects and checking for air bleed (Figure 2­7 on page 21).

5. All the valves are open (Figure 4-2 on page 59).

6. All the quick disconnects are fully engaged (Figure A-2 on page 81, Figure A-

8 on page 88, Figure A-17 on page 97, Figure A-18 on page 98, Figure A-23
on page 103, and Figure A-24 on page 104).

7. Check machine movement by first making sure that the power to the machine

drive is isolated and locked out, then by manually rotating the machine accord­ing to the machine power type:

P/N 80679, Rev. 10 Page 69

• To manually rotate the pneumatic machine, insert a 10-mm hex wrench in

NOTICE

FIGURE 5-3. LOCATION OF FEED BOX FILTERS

the hex opposite the motor or push on the end of the turning arm.

• To manually rotate the hydraulic machine, use the cross-connection hose

supplied with the machine to connect the #1 and #2 port hoses. Insert a 10­mm hex wrench in the hex opposite the motor or push on the end of the
turning arm.

5.5.2 The machine isn’t feeding

If the machine isn’t feeding properly, check the following:

1. There is air pressure entering and leaving the PCU. Check the air pressure by
disconnecting the hose quick disconnects and checking for air bleed (Figure 2­7 on page 21).

2. The emergency stop is reset (Section 5.3.3 on page 64 for PCU and
Section 2.3.2 on page 21 for HPU).

3. The feed is engaged (Figure 3-33 on page 48).

4. The air valve assembly is assembled correctly (Figure A-8 on page 88,
Figure A-19 on page 99, and Figure B-1 on page 111). Check that the 3/8" (9.5
mm) and 1/4" (6.4 mm) quick disconnects are connected to the correct hose
connections on the spindle cap.

5. The leadscrew is free to turn in the desired direction. On the end of the turning
arm, insert a 10-mm hex wrench to use as a crank handle and then turn it.

5.5.3 The feed is slow or unresponsive

If the feed is slow or unresponsive, the
most likely cause is dirty air filters on
the feed box.

Clean both filters at the same
time.

Do the following to clean the feed box
air filters:

1. Unscrew and remove the air fil­ters on either end of the feed
box (Figure 5-3).

2. Clean the filters with solvent.

3. Blow out the filters with com­pressed air.

Page 70 FF6300 Operating Manual

4. Replace the filters in the feed box.

5.5.4 The machine is performing poorly

If the machine is performing poorly, check the following:

1. The tool is installed correctly (Section 3.11 on page 47).

2. The machine is tight to the chuck and the mount (for ID chuck, see Section 3.6

on page 32; for OD mount, see Section 3.13 on page 53; for surface mount, see
Section 3.13 on page 53).

3. The turning arm clamp screws are tight (Figure 3-26 on page 44).

4. The gib screws on the radial slide and the tool head are adjusted correctly

(Section 5.3.8 on page 66) and the axis that is not being used is locked using
the handle.

5. The tool head is tight and the adjustable clamp on the tool head (Figure A-6 on

page 86) is locked on the axis that is not being used (Section 3.11 on page 47).

6. The tool head swivel is tight (Figure 3-30 on page 47).

7. The cutting tool or insert is sharp and has the correct geometry for the material

and type of cut.

8. The speed and feed rates are set correctly. If necessary, experiment with differ-

ent speeds and feed rates. Typically, slower speeds and shallower cuts produce
less tool chatter.

5.5.5 The machine is not cutting flat

If the machine is not cutting flat, do the following:

1. Before making a critical finish pass, run the machine continuously for at least

15 minutes to check that the machine is warmed up to operating temperature.

2. Check the machine for level (for ID chuck, Section 3.6 on page 32; for OD

mount, Section 3.7.5 on page 41; for surface mount, Section 3.8.3 on page 43).

3. Tram the turning arm as necessary (Section 5.3.10 on page 66).

5.6 DECOMMISSIONING

Do the following to decommission the FF6300 before disposal:

1. Remove the sight glass from the main body and drain the oil from the drive for

disposal or recycling through appropriate channels and according to local regu­lations..

2. Remove the top plate from the main drive assembly (Figure A-8 on page 88).

3. Dispose of or recycle machine parts according to local regulations.

P/N 80679, Rev. 10 Page 71

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Page 72 FF6300 Operating Manual

6 STORAGE AND SHIPPING

IN THIS CHAPTER:

6.1 STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -73

HORT-TERM STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -73

6.1.1 S

6.1.2 L

ONG-TERM STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -73

HIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -77

6.2 S

6.1 STORAGE

Proper storage of the FF6300 will extend its usefulness and prevent undue damage.

Before storing do the following:

• Clean the machine with solvent to remove grease, metal chips, and
moisture.

• Drain all liquids from the pneumatic conditioning unit.

Store the FF6300 in its original shipping container. Keep all packing materials for
repackaging the machine.

6.1.1 Short-term storage

Short term storage is defined as less than or equal to three months. For short-term
storage:

1. Spray all unpainted surfaces with LPS 2 to prevent corrosion.

2. Apply Moly Grade Anti-Seize to the chuck jacking screws (Figure 3-12 on
page 34).

3. Package the machine in its shipping container as shown in Figure 6-2 on
page 75 or Figure 6-3 on page 76.

6.1.2 Long-term storage

Long term storage is defined as longer than three months. For long-term storage:

1. Spray all unpainted machine surfaces with LPS 3 to prevent corrosion.

2. Package the machine in its shipping container as shown in Figure 6-2 on
page 75 or Figure 6-3 on page 76.

3. Add a desiccant pouch to the shipping container. Replace the pouch
according to the manufacturer’s instructions.

4. Store the shipping container out of direct sunlight in an environment where
the temperature is between -40 ºC and 70 ºC (-4 ºF to 160 ºF).

P/N 80679, Rev. 10 Page 73

STEEL CONTAINER

WOODEN CRATE

FIGURE 6-1. FF6300 IN CONTAINERS

Page 74 FF6300 Operating Manual

STRAP TO SECURE
MACHINE DURING
TRANSPORT

DISCONNECT FOR

TRANSPORT

SPACE FOR ACCESSORIES

FIGURE 6-2. PACKING THE FF6300 WITH ID CHUCK

P/N 80679, Rev. 10 Page 75

FIGURE 6-3. PACKING THE FF6300 WITH OD MOUNT

Page 76 FF6300 Operating Manual

6.2 SHIPPING

The machine ships from CLIMAX with a heavy coating of LPS 3. The recom­mended cleaner is LPS PreSolve Orange Degreaser. During machine use, an
alternate long-term corrosion preventative may have been used. Be sure to use the
correct cleaner for the applied protective coating.

The FF6300 should be shipped in its original shipping container.

Package the machine as shown in Figure 6-2 on page 75 or Figure 6-3 on page 76.

P/N 80679, Rev. 10 Page 77

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Page 78 FF6300 Operating Manual

APPENDIX A EXPLODED VIEWS AND PARTS LISTS

NOTICE

IN THIS CHAPTER:
FIGURE A-1. FEED BOX PNEUMATIC MANUAL FEED ADJUST (P/N 87326) - - - - - - - - - - - - - - - - - - - - - - - - 80

FIGURE A-2. AIR CONTROL ASSEMBLY FOR PNEUMATIC FEED (P/N 87941) - - - - - - - - - - - - - - - - - - - - - - - 81
FIGURE A-3. PNEUMATIC FILTER AND VALVE WITH STAND ASSEMBLY (P/N 59329) - - - - - - - - - - - - - - - - - - - - 82
FIGURE A-4. PNEUMATIC CONDITIONING UNIT 1/2" (13 MM) LOW-PRESSURE DROP-OUT (P/N 78264) - - - - - - - - - - - 84
FIGURE A-5. PNEUMATIC CONDITIONING UNIT 1/2" (13 MM) LOW-PRESSURE DROP-OUT PARTS LIST (P/N 78264) - - - - - - 85
FIGURE A-6. SLIDE TOOL HOLDER ASSEMBLY (P/N 79790) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86
FIGURE A-7. SLIDE TOOL HOLDER ASSEMBLY PARTS LIST (P/N 79790) - - - - - - - - - - - - - - - - - - - - - - - - - 87
FIGURE A-8. MAIN BODY ASSEMBLY (P/N 87913) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88
FIGURE A-9. MAIN BODY ASSEMBLY PARTS LIST (P/N 87913) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
FIGURE A-10. TURNING ARM ASSEMBLY 38" (965 MM) (P/N 80304) - - - - - - - - - - - - - - - - - - - - - - - - - - 90
FIGURE A-11. TURNING ARM ASSEMBLY 38" (965 MM) PARTS LIST (P/N 80304) - - - - - - - - - - - - - - - - - - - - - 91
FIGURE A-12. COUNTERWEIGHT ARM ASSEMBLY (P/N 80324) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92
FIGURE A-13. BACKFACE ATTACHMENT ASSEMBLY (P/N 80362) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
FIGURE A-14. OD MOUNT ASSEMBLY 38–63” (965–1,600 MM) (P/N 80477) - - - - - - - - - - - - - - - - - - - - - - 94
FIGURE A-15. OD MOUNT ASSEMBLY 38–63" (965–1,600 MM) PARTS LIST (P/N 80477) - - - - - - - - - - - - - - - - - 95
FIGURE A-16. OD MOUNT CLAMP KIT (P/N 80622) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
FIGURE A-17. FF6300 PNEUMATIC KIT (P/N 80969) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97
FIGURE A-18. FF6300 HYDRAULIC KIT (6.2 CU.IN. MOTOR WITH QD FTG) (P/N 80970) - - - - - - - - - - - - - - - - - 98
FIGURE A-19. AIR VALVE ASSEMBLY (P/N 87916) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 99
FIGURE A-20. ID CHUCK ASSEMBLY 4 LEG 12–57" (305–1,448 MM) (P/N 81971) - - - - - - - - - - - - - - - - - - - 100
FIGURE A-21. LEVELING FOOT 4" (102 MM) ASSEMBLY (P/N 81977) - - - - - - - - - - - - - - - - - - - - - - - - - 101
FIGURE A-22. SURFACE MOUNT ASSEMBLY (P/N 82309) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102
FIGURE A-23. AIR CONTROL ASSEMBLY FOR PNEUMATIC FEED AND 1/2" (13 MM) DRIVE SUPPLY (P/N 87917) - - - - - - 103
FIGURE A-24. HYDRAULIC KIT 6.2 CUBIC MOTOR (P/N 82555) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 104
FIGURE A-25. BYPASS ASSEMBLY FOR SET UP OF HYDRAULIC MACHINE (P/N 83154) - - - - - - - - - - - - - - - - - 105
FIGURE A-26. BYPASS ASSEMBLY FOR SET UP OF HYDRAULIC MACHINE (P/N 83166) - - - - - - - - - - - - - - - - - 106
TABLE A-1. TOOL KIT (P/N 80327) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 107
TABLE A-2. RECOMMENDED SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 108

P/N 80679, Rev. 10 Page 79

The following diagrams and parts lists are for your reference purposes only.
The machine’s limited warranty is void if the machine has been tampered
with by anyone who has not been authorized in writing by CLIMAX to
perform service on the machine.

PARTS LIST

DESCRIPTIONP/N:QTY

ITEM

PIN DOWEL 3/16 x 3/4

1176311

DETENT PLUNGER BALL 1/4-20 X .531

1306112

RING SNAP 1 OD SPIRAL HEAVY DUTY

1424113

FTG ADAPTER 1/8 NPTM X 1/4 TUBE F PRESTOLOCK NICKEL PLATED184392

4

SCREW 3/8-16 X 2 KHS (KNURLED HEAD)259531

5

BRG ROLLER CLUTCH 1 X 1.312 X .6252595726

SEAL 1.000 ID X 1.312 OD X .125 HM14 LIP259592

7

SPRING COMP .48 OD X .051 WIRE X .882861818

SCREW M5 X .8 X 16 SHCS

3511349

ARM RATCHET

57491110

BRG NEEDLE 1.0 X 1-5/16 X .625

57530111

SCREW M5 X .8 X 40mm SHCS

57541412

HOUSING PNEUMATIC FEED BOX REMOTE ADJUSTABLE

58435113

CLEVIS DOUBLE 6MM PIN 3/8-24 SHAFT

58450114

BUSHING DRIVE DOUBLE ENDED

58451115

SHAFT FEED

58519116

SCREW 6MM DIA X 20MM X M5 X 0.8 SHLDCS

58588117

SCREW M6 X 1.0 X 60mm SHCS

59156218

PLATE FEED ADJUST

87322119

NUT 3/8-16 ACON HS G8 ZINC

87411120

CYLINDER AIR 40MM DIA 10MM STROKE DOUBLE ACTING

87842121

15

20

1714

21

12

19

9

5

4

8

13

3

13

6

18

11

1

2

6

10

16

7

7

Page 80 FF6300 Operating Manual

FIGURE A-1. FEED BOX PNEUMATIC MANUAL FEED ADJUST (P/N 87326)

PARTS LIST

DESCRIPTIONP/N:QTYITEM

WASHER THRUST .75 OD X .312 ID X .031077011

FTG QD NIPPLE 1/2B 1/2 NPTM PNEUMATIC

1320912

FTG QUICK COUPLER 1/2B 1/2 NPTM FEMALE AIR

1661013

FTG QUICK COUPLER 3/8B 1/4 NPTF FEMALE AIR

3569014

LABEL DIRECTION OVAL HANDLE BALL VALVE

357721

5

VALVE BALL 1/4 NPTF X 1/4 NPTF VENTED OVAL HANDLE

5920316

ASSY PNEUMATIC FILTER & VALVE WITH STAND

593291

7

HOSE ASSY 801 1/4 X 1/4 NPTMS ENDS X 180

5933018

FTG ADAPTER 1/2 NPTF X 1/4 NPTM

7802519

6

4

8

5

1

2

3

7

9

P/N 80679, Rev. 10 Page 81

FIGURE A-2. AIR CONTROL ASSEMBLY FOR PNEUMATIC FEED (P/N 87941)

ASSEMBLED VIEW

PARTS LIST

DESCRIPTIONP/N:QTY

ITEM

WASHER 5/16 FLTW SAE

1348961

NUT 5/16-18 NYLON INSERT LOCKNUT

1972962

SCREW 5/16-18 X 5/16 SSSFP

27895163

BRACKET 90DEG JOINER MODU-TEK

4676144

ENDCAP 1 X 1 FOR 1.63SQ MODU-TEK EXTRUSION467646

5

BRACKET 1X2 SLOT HALF WEB LEFT MODU-TEK

4676516

VALVE SHUT OFF VS22 SERIES

467771

7

BRACKET 1X2 SLOT HALF WEB RIGHT MODU-TEK

4678318

1.63 X 1.63 X 3.375L MODU-TEK EXTRUSION

4680229

SCREW M5 X 0.8 X 12MM BHCS BLACK FINISH53617210

SCREW 5/16-18 X 3/4 T-BOLT

59436611

1.63 X 1.63 X 7.00L MODU-TEK EXTRUSION

59437412

RING O 2mm X 23mm ID X 25mm OD

59442113

NUT PLATE M5 X .08 AND 5/16-32 .75 X 1.25 X .25

59705214

SCREW M5 X 0.8 X 40MM SHCS

59754215

FILTER/REGULATOR PARTICULATE 1/2NPTF METAL BOWL GLASS

78054116

PRESSURE GAUGE, 0-160 PSI, 1/8 NPT CENTER BACK MOUNT

83486117

2

1

11

9

4

12

7

10

13

15

8

6

14

4

3

5

9

16

17

Page 82 FF6300 Operating Manual

FIGURE A-3. PNEUMATIC FILTER AND VALVE WITH STAND ASSEMBLY (P/N 59329)

This page intentionally left blank

P/N 80679, Rev. 10 Page 83

ASSEMBLED

SCALE 1 : 5

18

3

21

21

21

25

17

31

33

1

5

27

36

29

28

30

7

35

37

19

4

11

32

16

10

14

3

34

26

12

13

6

24

8

23

15

20

2

38

11

9

40

39

Page 84 FF6300 Operating Manual

FIGURE A-4. PNEUMATIC CONDITIONING UNIT 1/2" (13 MM) LOW-PRESSURE DROP-OUT (P/N 78264)