Climax KM3000 User Manual

KM3000 KEYMILL

Cut a new, full-depth, 6 inch (152.4mm)
keyway in less than 4 minutes.*

The Climax KM3000 Portable Key Mill is a
simple, rugged, dependable machine tool
designed to cut keyways in shafts without
extensive dismantling. The automatically
centering V-base is quick and easy to set
up. Clamps on any shaft from 1.5 - 4.5
inches (38.1 - 114.3 mm) in diameter with
the standard bar clamp. Cuts stub-end
keyways or mid-shaft keyways, or clamp
the machine to a flat surface, and you can
cut motor mount slots. With the optional
shim kit you can cut keyways or slots in
shafts as small as 0.75 inch (19.1 mm) in
diameter.

Compact & Powerful

• Compact, rugged, portable milling
machine for on-site keyway and other
milling jobs.

• Self-centering and self-aligning V-base.

• Needs only 1.5 inches (38.1 mm) of shaft
for clamping

• Clamps on shafts up to 10.5 inches
(266.7 mm) diameter with optional chain
clamp.

• Slotted V-base allows you to cut right to
the end of the shaft.

Efficient Operations with High Quality
Components

• Vertical and horizontal travel via hand
crank.

• Dovetail ways for accurate cutting action.

• Standard Weldon-type spindle accepts
5/8 inch end mills, or 16 mm shank end
mills on metric machines.

• Precision Acme thread leadscrew with
roller thrust bearings.

• Zeroing-type vertical adjustment dial
calibrated to control cutter depth in 0.001
inch (0.1 mm) increments.

• Sealed aluminum alloy gear box permits
operation at any angle.

• Precision ground quill housing ensures
smooth operation.

3

* Actual cutting time for a keyway
1 x 0.5 x 6 inches (25.4 x 12.7 x 152.4 mm)
was 3 minutes 10 seconds. This time was
achieved in C1018 steel with a sharp end
mill.

2014
KM3

SPECIFICATIONS

US Metric

Machine Performance Ranges

Stroke (slide travel) max. 6.0 inches 152.4 mm

Vertical travel max. 1.75 inches 44.5 mm

No load variable spindle speed
minimum 365 rpm 365 rpm

maximum 675 rpm 675 rpm

Spindle hole diameter INCH 0.625 inches
METRIC 16.0 mm

Maximum end mill diameter 1.25 inches 31.75 mm

Maximum shaft diameter:
standard bar clamp 4.5 inches 114.3 mm

with optional chain clamp 10.5 inches 266.7 mm

Minimum shaft diameter:
standard bar clamp 1.5 inches 38.1 mm

with optional shim kit 0.75 inches 19.1 mm

Minimum clamping space required
on stub shaft 1.5 inches 38.1 mm

Power Options

Power, electric
120V or 230V, 50-60Hz 1.25 kW 1.25 kW

Power, pneumatic 1.2 Hp 0.9 kW

Power, hydraulic 4.7 Hp 3.5 kW

Measures

Overall length 12.5 inches 317.5 mm

Overall width 6.6 inches 167.6 mm

Overall height 11.63 inches 295.4 mm

Base size 4.38 x 6.75 inches 111.3 x 175.1 mm

Operating weight (with speed control) 70 lbs. 31.8 kg

Shipping weight (with speed control) 82 lbs. 37.2 kg

Shipping dimensions 13 x 14 x 20 inches 330 x 360 x 508 mm

Machining Ability Example

Material C1018 steel C1018 steel

Metal removal rate 1 inch3/minute 16.4 cm3/min

Keyway dimensions 1 x 0.5 x 6 inches 25.4 mm x 12.7 mm x 152.4 mm

Cutting Time 3 minutes and 10 seconds 3 minutes and 10 seconds

All dimensions should be considered reference. Contact your Climax Representative for precision dimensions. Specifications are subject to change without notice. There are no systems or components
on this machine that are capable of producing hazardous EMC, UV or other radiation hazards. The machine does not use lasers nor does it create hazardous materials such as gasses or dust.

page 2

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OPERATIONAL DIMENSIONS

12.73 (323.3) max

12.73 [323] MAX
55]

2.18 [

2.18 (55.4)

11.16 [283] MIN

11.16 (283.5) min

12.91 (327.9) max

12.91[328] MAX

6.98 [177]

6.98 (177.3)

Dimensions in inch (mm)

10.18 (258.6)

10.18 [259]

1.62 (41.2)

1.62 [41

]

2.18 [55]

2.18 (55.4)

6.75 [171]

6.75 (171.5)

1.5-4.5 [38-114]

STANDART CLAMP

UP TO 10.5[266] WITH

OPTIONAL CHAIN CLAMP

1.5 - 4.5 (38.1 - 114.3) standard clamp
Up to 10.5 (266.7) with optional

DOWN TO .75[19]WITH

chain clamp

OPTIONAL SHIM KI

Down to 0.75 (19.05) with optional

shim kit

3.12 (79.2)

3.12 [79]

1.09 [28]

1.09 (27.7)

3.79 [96]

3.79 (96.3)
Max

MAX

10.54 [268] -4.54[115]

10.54 (267.7) - 4.54 (115.3)

6.0 (152.4) travel

6[152] TRAVEL

6.68 (169.7)

6.68 [170]

T

2.75 (69.9)

2.75 [70]

1.45 [37]

1.45 (36.8)

0.98 (24.9) min - 2.73 (69.3) max

.98 [25] MIN-2.73[69] MAX

1.75[44.5] TRAVEL

1.75 (44.5) travel

page 3

4.36 [111]

4.36 (110.7)

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TOOL CONFIGURATIONS

No. Description

KM3000 Portable Key Mill, Electric
Standard key mill Model KM3000 complete with 1 Hp (0.75 kW)
electric motor, instruction manual, tool kit, and bar clamp. Order
collets and end mills separately. Shipped in wooden crate.

37000 KM3000, inch 120V with Speed Control
As above with inch calibration and 120 V motor, inch spindle, and
electric speed control.

16000 KM3000, inch 120 V with no speed control

As above with inch calibration and 120 V MOTOR, in-line switch and
standard U.S. cord set.

16001 KM3000, inch 230V with speed control, CE Compliant

As above with inch calibration and 230 V motor, inch spindle and
electric speed control.

16003 KM3000, metric 120V with no speed control

As above with metric calibration and 120 V motor, metric spindle,
inline switch and standard U.S. Cord set.

16004 KM3000, metric 230V with speed control, CE Compliant

As above with metric calibration and 230 V motor, metric spindle,
and electric speed control.

39572 KM3000, metric 120V with Speed Control

As above with metric calibration and 120 V motor, metric spindle,
and electronic speed control.

36783 KM3000, metric 120V with Speed Control, CE Compliant

As above with metric calibration and 120 V motor, metric spindle,
and electronic speed control.

39571 KM3000, metric 230V with no Speed Control, CE-Compliant

As above with metric calibration and 230 V motor, metric spindle,
and no speed control.

NOTE: Drawings are for reference only, are not to scale, and

may not represent actual product.

KM3000 Portable Key Mill, Pneumatic (with pneumatic
conditioning unit), all CE-Compliant

Standard key mill Model KM3000 complete with 1.2 Hp (0.89 kW)
pneumatic motor*, instruction manual, tool kit, and bar clamp.
Order collets and end mills separately. Shipped in wooden crate.

16002 KM3000, pneumatic, inch

As above with inch calibration.

16005 KM3000, pneumatic, metric

As above with metric calibration.

*Motor requires 40 ft3/min (1 m3/min) at 90 psi (620 kPa).

10378 Chain clamp assembly

Chain, clamping blocks and bolts for attaching key mill to shafts up
to 10.5 inch (266.7 mm) diameters. Net weight 7 lb (3.2 kg).

10381 Cross milling adapter

Allows key mill to be clamped 90 degrees to shaft axis.
Net weight 7.l8 lb (3.5 kg).

11669 Shim kit

Shims fit inside V- base to enable key mill to be mounted to shafts
with diameters as small as 0.7 inch (19.1 mm). Net weight 3.4 lb (1.6 kg).

page 4

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TOOL CONFIGURATIONS

No. Description

KM3000 Portable Key Mill, Hydraulic*, all CE-Compliant
Standard key mill Model KM3000 complete with instruction manual, tool
kit, and bar clamp. Order collets and end mills separately.
Shipped in wooden crate.

16008 KM3000, inch hydraulic 274 rpm

As above with inch calibration and hydraulic motor producing 274 spindle
rpm at 6 gal/min (22.3 liter/min).

16009 KM3000, inch hydraulic 430 rpm

As above with inch calibration and hydraulic motor producing 430 spindle
rpm at 6 gal/min (22.3 liter/min).

45134 KM3000, metric hydraulic 430 rpm

As above with metric calibration and hydraulic motor producing 430
spindle rpm at 6 gal/min (22.3 liter/min).

16010 KM3000, hydraulic 664 rpm

As above with inch calibration and hydraulic motor producing 664 spindle
rpm at 6 gal/min (22.3 liter/min).

*Hydraulic power unit sold separately.

37388 KM3000 inline switch 120V

Provides on/off control of the KM3000 motor. No variable speed. Used
when variable speed is not required. Fits current generation of KM motors
only, not older models. Has standard NEMA 5-15 straight blade plug with
ground. Overall length is 96 inches (244cm).

37389 KM3000 inline switch 230V, CE-Compliant

36549 shown

Provides on/off control of the KM3000 motor. No variable speed. Used
when variable speed is not required. Fits current generation of KM motors
only, not older models. Has european Schuko style plug. Overall length is
244 cm (96 inches).

36549 KM3000 speed control assembly 120V

Provides on/off and variable speed of the KM3000 motor. Fits current
generation of KM motors only, not older models. Has standard NEMA 5-15
straight blade plug with ground.

36685 KM3000 speed control assembly 230V, CE-Compliant

Provides on/off and variable speed of the KM3000 motor. Fits current generation
of KM motors only, not older models. Has european Schuko style plug.

36950 KM3000 speed control assembly and retrofit kit

Provides on/off and variable speed of the KM3000 motor. Includes 36549
speed control assembly and a new end cap assembly (34142) for the
motor so that older machines can use the current design controller. Has
standard NEMA 5-15 straight blade plug with ground.

NOTE: Drawings are for reference only, are

not to scale, and may not represent actual

page 5

product.

Climax Portable Machining & Welding Systems Web site: climaxportable.com

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End mill sets

SAE and metric 2-flute end mills are available. Short flutes for maximum
rigidity. See separate end mill price list for availability.

10385 End mill set, inch

Seven end mills from

10386 End mill set, inch

8 end mills from

inch and smaller.

10387 End mill set, metric

Five end mills: 8 mm, 10 mm, 12 mm, 16 mm, and 18 mm, plus two collets,
one with 16mm OD with 10mm ID, the other with 16mm OD and 12mm ID.

22387 End mill set, metric

Eight end mills: 5 mm, 6 mm, 8 mm, 10 mm, 12 mm, 14 mm,16 mm,
18 mm, plus three collets.

1

/4 - 1 inch in 1/8 inch increment, plus 3/8 inch I.D. collet for end mills 7/16

1

/4 - 1 inch in 1/8 inch increments, plus collet.

3

/16 - 1 inch in 1/16 inch increments, and 7 end mills from

APPLICATION PHOTOS

As versatile as your imagination

Here are some examples:

1. Attach angles to the sides of the base, and
clamp the KM3000 down to cut motor mount
slots or bore holes.

2. Clamp on shafts up to 10.5 inches (266 mm)
dia. with optional chain clamp.

3. Mounted in a vice, the KM3000 can cut
keyways in small shafts and mill other small
parts such as gear pullers.

4. Special fixtures allow the KM3000 to cut ID
keyways and slots in large tubing, etc.

5. Use the KM3000 in tight places, like the shaft
on a paving machine.

6. Cut flats on drill pipe section with the optional
cross milling adapter and stamp ID marks if
you wish.

7. Mounted vertically on a stationary milling
machine, the KM3000 can cut a mounting
pad for a readout instrument.

The KM3000 is widely used by
these industries:

• Construction

• Mining

• Power Generation

• Ship building

• Pulp and paper

• Steel and aluminum

1

2

Typical applications:

• Key slots on crank shafts

• Keyways on tapered shafts

• Keyways on pump shafts

• Motor and pump repair

• Mill radius slots in turbine shafts

• Cutting new keyways on paper rolls

• Chipper and conveyor repair

• Keyways on motors

page 6

5

3

4

Vertical adjusting screw

Zeroing type dial

In-line switch (speed con-
trol available)

1 Hp (0.75 kW) universal type
electric motor

6

7

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Spindle

(5/8 inch or

16 mm options

available)

Self-aligning

V-base

Bar clamp

APPLICATIONS

ID Keyway Cutting

Slotting

OD Keyway Cutting

Cross Milling

Mount on end
Only 1.5 inches (38.1 mm) of shaft required
for mounting the KM3000.

page 7

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Mount in the middle
The machine can be leveled for
cutting long keyways.

Tapered shafts
Mounting on tapered shafts require shimming.

CLIMAX GLOBAL LEARNING CENTER

Climax has been teaching the fundamentals and fine points of portable
machine tool operation for practically as long as we’ve been inventing and
building the tools.

At the Global Learning Center situated in our corporate headquarters near
Portland, Oregon, we provide training for machine tool operators on
portable machine tool safety and machine setup and operation. Trainees
also receive technical tips and tools to improve operational efficiencies, with
the vast majority of every program devoted to hands-on activities and skill
development.

The Climax instructional team includes specialists in shipbuilding, power
generation, civil engineering, bridge re-building, petrochemical and other
industries.

Whether it’s a regularly scheduled course at the Global Learning Center, or custom curriculum conducted at your facility, your machinists will benefit from
courses developed by some of the most respected authorities in the business.

Call us today to register for a regularly scheduled class, or talk to us about how we can customize a training program for your specialized application.

Call Climax for:

On-site Training

Need some refresher courses in
setting up and operating your Climax
machine tool?

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Climax has been solving complicated
on-site machining and welding
problems for our customers since

1964.

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Worldwide Telephone: [phone]
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Perth

Copyright © 2012 Climax Portable Machining & Welding Systems. All Rights
Reserved. Climax has taken reasonable measures to ensure the accuracy
of the information contained in this document. However, Climax makes no
warranties or representations with respect to the information contained herein;
and Climax shall not be held liable for damages resulting from any errors or
omissions herein, or from the use of the information contained in this document.