Climax KM4000 User Manual

KM4000 KEYMILL

Designed to cut extra-wide keyways, stress relief
pockets, motor mounts slots, and more.

A compact, rugged, portable milling
machine, the fully CE-Compliant KM4000
Portable Key Mill is designed to cut extra­wide keyways, stress relief pockets, motor
mount slots, and more.

High quality, heavy-duty machine

• Cuts new keyways up to 3.25 inches
(82.6 mm) wide and 7.88 inches (200.2
mm) long in one setup.

• Two-inch (50.8 mm) lateral travel allows
cutting wide pockets or slots with a single
end mill.

• Universal type motor and triple gear
reduction provide plenty of torque.

• Permanently sealed lubrication, so
machine can be operated at any angle.

• The leadscrew is a precision Acme thread
and is fitted with roller thrust bearings.

• Anti-friction bearings used throughout.

• Dovetail ways machined for smooth
movement in both longitudinal and
transversal directions.

• Features zeroing-type adjusting dial for
controlling cutter depth.

• Contoured base is self-centering and self­aligning on the shaft.

• Electronic speed control offers precision
control of spindle speeds while retaining
full torque over available rpm range.

Compact, easy to set up, versatile

• Needs only 8.5 inches (215.9 mm) of
shaft for clamping, or only 10.5 inches
(266.7 mm) of shaft for clamping from an
obstruction.

• Mounts on shafts from 4 - 24 inches
(101.6 - 609.6 mm) in diameter.

• Mounts anywhere along the shaft.

• Rapid longitudinal travel can be made
with a drill motor for quick setups.

Technical Data

• 0.75 inches (19.05 mm) is the standard
spindle size for inch-machines

• 20 mm (0.79 inches) is the standard
spindle size for metric machines.

• Many different machine variations are
possible, contact your Climax Sales
Representative for more information.

10

2013
KM4

SPECIFICATIONS

US Metric

Overall length 18.5 inches 469.9 mm

Overall width 14.0 inches 355.6 mm

Overall height 13.25 inches 336.6 mm

Base size 9.0 x 18.5 inches 228.6 x 469.9 mm

Slide travel, longitudinal 7.88 inches 200.2 mm

Slide travel, transversal 2.0 inches 50.8 mm

Vertical travel max 3.0 inches 76.2 mm

Power, electric: 120V or 230V, 50-60Hz 1.0 Hp 0.75 kW

Power, pneumatic 1.2 Hp 0.9 kW

Power, hydraulic 4.0 Hp 2.98 kW

No load variable spindle speed
minimum 350 rpm 350 rpm

maximum 675 rpm 675 rpm

Spindle hole diameter INCH 0.75 inches 19.1 mm
METRIC 0.79 inches 20 mm

Maximum end mill diameter 1.25 inches 31.75 mm

Maximum shaft diameter:
standard bar clamp 18.0 inches 457.2 mm

with optional chain clamp 24.0 inches 609.6 mm

Minimum shaft diameter:
standard bar clamp 8.0 inches 203.2 mm

with optional shim kit 4.0 inches 101.6 mm

Minimum clamping space required
on stub shaft 8.0 inches 203.2 mm
obstructed shaft 10.5 inches 266.7 mm

NOTE

(

2.2 inches (55.88 mm) of the obstruction)

One end mill included Ø 0.75 inches Ø 19.1 mm

Operating weight 195 lbs. 89 kg

Shipping weight (with speed control) 250 lbs. 114 kg

Shipping dimensions 24 x 24 x 19 inches 610 x 610 x 483 mm

Machining Ability Example

: The KM4000 can cut keyways within

Material C1018 steel C1018 steel

3

Metal removal rate 1 inch

Keyway dimensions 1.0 x 0.5 x 8.0 inches 25.4 mm x 12.7 mm x 203.2 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.

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/minute 16.4 cm3/min

DIMENSIONS, SETUP & OPERATION

Longitudinal travel:

7.88 (200.2)

Vertical travel:

3.0 (76.2)

2.12

(53.8)

Dimensions in inch (mm)

Lateral travel

2.0 (50.8)

13.25

(336.6)

3.4

(86.4)

6.0

(152.4)

18.5 (469.9)

24.5 (622.3)

Set-up and Operation

Insert the end mill in the spindle of the KM4000 Portable Key Mill,
and clamp it on that shaft - it’s that simple. On a straight shaft, an
experienced operator can mount the machine and be ready to cut
a new keyway in less than 15 minutes! Shimming to tapered
shafts may take a little longer.

0.305 - 3.305

7.747 - 83.947

4.55 (115.6)

9.0 (228.6)

11.5 (292.1)

14.0 (355.6)

16.0 (406.4)

The 2.0 inch (50.8 mm) lateral travel of the KM4000 allows you to
cut wide keyways or slots with a less expensive, smaller end mill.
The calibrated cross slide is positioned with the hand crank.

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

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TOOL CONFIGURATIONS

No. Description

KM4000 Portable Key Mill, Electric, all CE-Compliant

Standard key mill Model KM4000 complete with 1.0 Hp (0.75 kW) electric
motor, chain clamp, end mill, hex wrenches, crank, speed control, and instruc

tion manual. Shipped in wooden crate.

10505 KM4000, inch 120V
Inch, 120V motor. 3/4-inch spindle
Approx. net weight 240 lb (110 kg).

10508 KM4000, metric 120V

Metric. 120V motor. 20 mm spindle
Approx. net weight 240 lb (110 kg).

10506 KM4000, inch 230V

Inch, 230V input /120V output motor. 3/4-inch spindle
Approx. net weight 240 lb (110 kg).

10509 KM4000, metric 230V

Metric, 230V input / 120V output motor. 20 mm spindle
Approx. net weight 240 lb (110 kg).

KM4000 Portable Key Mill, Pneumatic, all CE-Compliant

Standard Key Mill Model KM4000 complete with 1.2 hp (0.9 kW) pneumatic
motor*, chain clamp, end mill, hex wrenches, crank, and instruction manual.
Shipped in wooden crate.

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

may not represent actual product.

10507 KM4000 - inch

As above with 3/4-inch spindle.
Approx. net weight 245 lb (112 kg)

10510 KM4000 - metric

As above with 20 mm spindle
Approx. net weight 245 lb (112 kg)

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

KM4000 Portable Key Mill, Hydraulic, all CE-Compliant

Standard Key Mill Model KM4000 complete with 4.0 Hp (2.98 kW) hydraulic
motor, chain clamp, end mill, hex wrenches, crank, and instruction manual.
Shipped in wooden crate.

16297 KM4000 - hydraulic 274 rpm
3/4-inch spindle. Hydraulic motor delivers approx. 274 rpm at the
spindle @ 6 gal/min (22.3 liter/min).
Approx. net weight 233 lb (106 kg).

16314 KM4000 - hydraulic 430 rpm

3/4-inch spindle. Hydraulic motor delivers approx. 430 rpm at the
spindle @ 6 gal/min (22.3 liter/min).
Approx. net weight 233 lb (106 kg).

16315 KM4000 - hydraulic 664 rpm

3/4-inch spindle. Hydraulic motor delivers approx. 664 rpm at the
spindle @ 6 gal/min (22.3 liter/min).
Approx. net weight 233 lb (106 kg).

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

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

Tool ConfiguraTions

No. Description

59246 Pneumatic conditioning unit
Required to protect air motor warranty. Includes:
lubricator, filter, stand, and air line. Sold only as a unit.
Approx. net weight 11 lbs (5 kg).

10493 Chain clamp assembly

20 inch (508 mm)chains for use in addition to standard chain clamp assembly.
Used to attach key mill to shafts 18 - 24 inches (457.2 - 609.6 mm) in diameter.
Approx. net weight 8.6 lbs (3.9 kg).

11851 Shim kit

Shims fit inside base to enable the key mill to be mounted on shafts as small
as 4.0 inches (101.6 mm) in diameter.
Approx. net weight: 3.4 lbs (1.6 kg).

13737 Tool kit

Hand crank and hex wrenches necessary to operate the key mill.
Approx. net weight 0.5 lbs (0.3 kg)

36549 Speed Control Assembly 120V

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

36685 Speed Control Assembly 230V, CE-Compliant

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

36950 Speed Control Assembly and Retrofit Kit

Provides on/off and variable speed of the motor. Includes Part Number 36549
Speed Control Assembly with the new end cap assembly (Part Number 34142)
for the motor to retrofit older machines to the current controller. Standard
NEMA 5-15 straight blade plug with ground.

NOTE: Drawings are for reference only, are not to
scale, and may not represent actual product.

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

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

ApplicAtions

The KM4000 is widely used by these industries:

• Construction

• Bridge building & repair

• Power Generation

• Ship building

• Pulp and paper

• Steel and aluminum

Typical applications:

• Keyways on tapered shafts

• Milling stress relief pockets on bridge decks

• Cut motor mount slots in plate or
I-beams

• Cut inspection windows in vessels

• Cut keyways on motors

Mounting applications include:

Mounting on end of shaft

Needs only 8.5 inches (215.9 mm) of shaft for clamping, or only 10.5 inches (266.7 mm) of shaft for clamping from an obstruction.
(

NOTE

: The KM4000 can cut keyways within 2.2 inches (55.88 mm) of the obstruction)

Mount in the middle

The machine can be leveled for cutting long keyways.

Tapered shafts

Mounting on tapered shafts requires shimming

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

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

Training at the 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 Climax 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.

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

Worldwide Phone: [phone] N. America Toll-Free: 1.800.333.8311 Fax: [phone] E-mail: [e-mail]

CLIMAX GLOBAL LOCATIONS

Edmonton

World Headquarters

Portland

Houston

Monterrey

Cincinnati

European Headquarters

Manchester

Charlotte

Baton Rouge

Manchester

Cologne

Production Facilities

Rental Locations

International Distributors

Regional Sales & Technical Support Offices

Gdansk

Singapore

Perth

Call Climax for:

On-site Training

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

Special Projects

Climax has been solving complicated
on-site machining and welding problems for
our customers since 1964.

World Headquarters

2712 E. Second Street
Newberg, Oregon 97132 USA
Worldwide Telephone: [phone]
N. America Toll-Free: 1.800.333.8311
Fax: [phone]
Email: [e-mail]

Rentals

With 16 worldwide rental depot locations,
you are never far away from a Climax
portable machine tool.

Connect with us:

European Headquarters

Am Langen Graben 8
52353 Düren, Germany
Telephone:(+49) (0) 2421.9177.0
Fax: (+49) (0) 2421.9177.29
Email: [e-mail]

Copyright © 2013 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.