The versatile PM5000 three-axis hydraulic
milling machine consists of a 12" (305 mm)
wide bed with an 8" (203 mm) wide saddle.
A 22" (559 mm) long cross carriage ram
provides up to14" (356 mm) travel and can
be centered across the bed, extended over
either side of the bed, or positioned parallel
to the bed. The bed’s dovetail ways feature
a high-lubricity polymer for smooth
operation.
The milling head is belt driven. A drawbolt
holds the machine tool in the spindle. The
spindle has a 3" (76.2 mm) diameter hard
chrome-plated quill and hardened helical
drive gears. The spindle gear box rotates
around the spindle centerline. The heavyduty quill clamp can be indexed in 90
increments and offset mounted to increase
0
machining reach. Spindle travel is provided
by a 6" (152 mm) dovetail slide with manual
feed. Tools attach by a #40 machine tool
taper with drawbolt retention. Power feeds
are available for the X and Y axes.
Standard or heavy-duty power feeds are
available. The standard feed can be used in
normal horizontal milling applications.
Vertical or overhead milling requires the
heavy-duty power feed. Combine this unit
with remote pendant controls and mount it
in various positions on the end of the bed or
cross carriage to avoid obstructions. Three
hydraulic spindle motors are available so
you can match the spindle rpm range to
your application. Five and ten hp hydraulic
power units are available.
2 05/99
Applications
Press Platens
Versatile spindle positioning makes the Model PM5000
ideal for machining damaged areas on the platens of
large presses, hammers, and injection molding machines.
Weldment Milling
Fabrications often need to have weldments milled flush to
establish true equipment mounting surfaces. The Model
PM5000 is quick to set up for milling long straight
surfaces.
Mounting Pad Milling
During construction or retrofit, use the PM5000 to mill the
surface of pads for mounting winches, cranes, pumps,
compressors, and turbines.
Power Generation
When motors mounted on steel pads embedded in
concrete go out of alignment, the motor mount can be remachined in-place using a Model PM5000. Repair
horizontal joints on turbines and pumps too.
Model PM5000 Setup & Operation
Versatile setup...even for
overhead machining.
Setup of the Model PM5000 Portable Mill consists of
positioning it where you want it in relation to the
work piece and clamping or bolting it securely in
place. Mounting rigidity is very important to any
successful milling operation with a portable milling
machine. The best way to mount the machine is to
weld attachment points right on the piece to be
machined. This ties the machine to the work piece
and eliminates vibration, flexing and other sources
of chatter. If you are using an overhead frame for
mounting the machine upside down, be sure it is rigid
enough to handle the weight of the machine and the
side forces that occur during milling operations.
Jacking screws adjust the PM5000 for accurate
machining.
Milling overhead press frames and platens or other
similar applications is easy with the Model PM5000
mill. It takes about five minutes to remove the
spindle, reposition the quill housing and replace the
spindle. To avoid obstructions, the gear box can be
rotated 180
on either end of the cross carriage ram and the bed.
Offset the cross carriage ram over the bed to extend
or decrease tool head reach.
0
. The power feeds can also be mounted
05/99 3
Components & Accessories
Power Feeds
Three types of power feed units are available
with the Model PM5000 Portable Mill. The
standard feed unit with 1/8 hp electric motor has
feed speed and direction controls right on the
feed unit itself. While adequate for horizontal
milling, these units are not recommended for
vertical milling.
The heavy-duty feed units with 1/8 hp electric
motors have local controls. These units provide
the power necessary for vertical milling. Either
type of feed unit has three mounting positions.
Hydraulic Power Units
Several 5 hp/6 gpm (3.73 kW/22.7 liter/min)
variable displacement piston pump hydraulic
power units with various electrical configurations
are available.
Riser Blocks (not shown)
Vertical reach can be increased by inserting a
riser block between the bed saddle and the cross
carriage ram. One-inch to six-inch (25.4 mm to
152.4 mm) thick blocks are available. A riser is
required if the machine is used for overhead
milling.
Spindle Drive Motors
Spindle speed range is determined by the
hydraulic motor that is used. A wide range of
speeds is available with a series of hydraulic
motors.
4 05/99
PM5000 Specifications
Inch (mm)For precise dimensions consult your factory representative.
Mounting face8 x 8 (203.2 x 203.2)
Travel (varies)48(1219.2)
72(1828.8)
96(2438.4)
(B) RAM & CROSS SLIDE:
Height (w/saddle)7.62(193.5)
Width (w/saddle)8.92(226.6)
Length22.0(558.8)
Cross slide mounting face 6 x 6 (152.4 x 152.4)
Cross slide travel** 7.63 - 14.0 (193.8 - 355.6)
** Machining area varies by application.
Indexable in 90°, offset in 3.38" (85.85) increments.
(C) VERTICAL SLIDE:
Height
2.0(50.8)
Width6.0(152.4)
Length12.0(304.8)
Mounting face 6 x 6 (152.4x152.4)
Travel6.0(152.4)
(D) FEED ASSEMBLIES:
Feed assemblies are required for both X and Y
axis.
MANUAL FEED:.20"/rev (5.08 mm/rev)
STANDARD ELECTRIC FEED, 115v:
Manual feed (handwheel).10"/rev(2.54 mm/rev)
Electric feed0-10"/min (0-254 mm/min)
HEAVY-DUTY ELECTRIC FEED, 115v:
Manual feed (handwheel).10"/rev (2.54 mm/rev)
Electric feed0-24"/min (0-609.6 mm/min)
(F) MILLING HEAD ASSEMBLY:
SPINDLE:
Quill diameter3(76.2)
Tool sizes available #40 taper
0
QUILL CLAMP: Indexable, 90
increments.
MILLING HEAD GEAR BOX:
Drive ratio (belt drive)1:1
Hydraulic rpm varies by motor selected (see pg. 13)
27.44
(697.0) max
shown with ram offset
27.44
(697.0)
Milling head gear box can be rotated around
spindle centerline 1800.
PM5000 milling area (dimensions to the centerline of the
spindle). Total work surface available by offsetting and
rotating the ram and milling head, When milling overhead,
entire area can be milled by offsetting the ram.
7.63
(193.8)
max
10.0 (254.0) + bed length
3.8 max
(96.5)
7.63
(193.8)
05/99 5
PM5000 Operational Dimensions
Inches (mm)
23.68
(601.6)
22.0
(558.8)
8.0 (203.2)
8.92 (226.57)
2.0 (50.8)
4.96 (125.98)
3.0 (76.2)
13.6
(345.4)
1.0 (25.4) Typ
2.75 (69.85)
(285.75)
5.67 (144.02)
X
11.25
10.0 (25.4)
Typ
6.0 (152.4)
Y
.66 (16.8)
diameter
10.50 (266.7)
7.62
(193.55)
4.96
(125.98)
1.0 (25.4)
8.0 (203.2)
12.0 (304.8)
21.3
*
(541.0)
6 05/99
48 (1219.2) Travel
X
Y
58.0 (1473.2)
4.0 (101.6
MAIN BED ASSEMBLY
72 (1828.8) Travel
82.0 (2082.8)
1.0 (25.4)
When the vertical slide is mounted in
*
the center position, the milling head can
be positioned up or down 2.12 (53.8).
96 (2438.4) Travel
106.0 (2692.4)
3.0 (76.2)
Model PM5000 Test Data
MACHINE ACCURACY
Parameters:
5 hp 6 gpm (3.73 kW, 22.7 L /min) hydraulic
power unit.
Mist coolant.
Recommended milling cutter with sharp milling
inserts (see chart below).
A-36 steel plate.
Skilled operator.
Accurate alignment equipment (laser, optics,
etc.)
Inches (mm)
Results:
.004 (.102) flatness over 9 x 48 (228.6 x
1219.2) area (ram on one side of the bed)
(A-36 steel plate).
.006 (.152) flatness over 9 x 48 (228.6 x
1219.2) area on each side of bed (ram moved
straight across to opposite side of bed) (A-36
steel plate). Improved accuracies may be
obtained by resetting the Z-axis and re-
tramming the milling head.
Machine components trammed.
Bed fully supported.
Milling completed in one setup with machine in
horizontal position.
The cross slide ram can be repositioned and indexed in
90o increments for maximum versatility. For maximum
accuracy, re-tram the milling head and reset after
repositioning any components.
ram extended
to the left
ram extended
to the right
positionable in
3.38 (85.85)
increments
index in 90
increments
o
MILLING HEAD POSITIONS
Because the quill clamp is symmetrical, the milling
head can be indexed in 90o increments around the
vertical slide on the ram. This allows the milling head to
GEAR BOX POSITIONS
The lightweight aluminum gear box can be rotated
around the spindle centerline 180o to clear obstructions.
3.84 (97.5)
machine down, overhead, or to the side. The milling
head can also be offset to increase tool reach. For
maximum accuracy, re-tram and reset the milling head
after repositioning any components.
13.50 (342.9) max
A
C
D
19.95 (506.7) max
(without risers)
B
quill
12.6 (320.0) max / 6.6 (167.6) min
Vertical slide in center position
with no risers. Can be offset
2.13 (54.1) in two directions.
0.85 (21.6) without risers
and with vertical slide
mounted in lowest position
Minimum "A"With handwheel -D-Without handwheel -DRequired to clear -B-17.8 (452.2) w/o riser15.6 (396.3) w/o riser
Required to clear -C-20.8 (528.4) with 3 (76.2) riser17.8 (452.2) w/o riser
10.88
(276.35)
18.0
(457.2)
8 05/99
PM5000 Feed Assemblies
Feed units available:
•Manual
•Standard electric with local control
•Heavy-duty electric with local control
•Heavy-duty electric with remote control
4.2 (106.7)
4.75
(120.7)
MANUAL FEED (X-AXIS)MANUAL FEED (Y-AXIS)
ST ANDARD ELECTRIC FEED
Standard feed system recommended for horizontal applications only. For vertical or
overhead applications use the heavy-duty feed system.
Inches (mm)
Manual and electric feed units are available for X and Y
axes. The Z-axis comes complete with manual feed
(electric feed is not available).
MANUAL FEED
5.7 (144.8)
6.3 Dia.
(160.0)
(Includes limit switches)
3.2 (81.3)
Side Mounting
8.75 (222.2)
12.0
(304.8)
8.25 (209.6)
Upright Mounting
HEA VY-DUTY ELECTRIC FEED
(Includes limit switches)
Recommended for vertical or overhead applications
4.86 (123.4)
17.5
(444.5)
5.25 (133.3)
12.0
(304.8)
9.5 (241.3)
Side A
Side B
10 (254)
Side A mounted to bed
(multiple feed positions
shown)
Rotated gear box Side B mounted to
bed with handwheel repositioned
(multiple feed motor positions shown)
05/99 9
(G)
Hydraulic motor
PM5000 Components
(B)
Ram and cross slide
assembly (Y-axis)
(C)
Vertical slide
assembly (Z-axis)
(A)
Main bed
assembly
(X-axis)
(D)
Feed control
assembly (manual
shown)
(F)
Milling head assembly
(E)
(D)
Feed control
assembly (manual
shown)
To accommodate a wide range of applications, the Model PM5000 Portable Mill is ordered as a combination of components. To order a complete
machine you must specify the following:
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
Main bed assembly (X-axis)
Ram and cross slide assembly (Y-axis)
Vertical slide assembly (Z-axis)
Feed control assembly (manual or electric)
for X and Y axes (electric assemblies include limit switches)
Tool kit
Milling head assembly
Hydraulic motor
Hydraulic power unit (not shown)
Optional riser assembly (not shown)
Tool kit
X-axis
Z-axis
Y-axis
10 05/99
The Model PM5000 is a made-to-order machine. Expect longer lead times
when ordering.
PM5000 Work Sheet
Inch (mm) NOTE: Contact your factory representative for additional information and lead times.
Main bed has a 8" (203.2 mm) slide and 12" (304.8
mm) wide mounting flange. Flush-mount leadscrew
bearings enable the machine to fit into areas as small
as the length of the bed (plus the length of one feed
mechanism). Assembly features a full-length leadscrew and anti-friction, high lubricity polymer on the
ways.
2721848" (1219.2 mm) travel main bed assembly
2721972" (1828.8 mm) travel main bed assembly
2722096" (2438.4 mm) travel main bed assembly
22643(B) 14" (355.6 mm) travel ram and cross slide
The ram and cross slide assembly feed the milling
head across the main bed. Because the ram and main
bed saddle have the same bolt hole pattern, the ram
can be offset in 3.38"(85.85 mm) increments and/or
positioned 90o around the saddle. The cross slide
features dovetail ways and a full-length leadscrew.
The vertical slide assembly mounts to the ram and
cross slide saddle to provide vertical movement for the
milling head. Because the cross slide saddle and the
vertical slide have the same bolt hole pattern, the
vertical slide can be of fset and/or positioned 90o around
the saddle. The vertical slide features dovetail ways, a
full-length leadscrew, and handwheel.
(D) Manual feed assembly
Handwheel assembly fits into either end of the
leadscrew. Dial is graduated in .010" increments. One
full turn of the dial equals .200" (5.08 mm). Though the
machine can use more than one type of feed, each axis
must have its own feed assembly. (The Z-axis includes
its own handwheel.)
12 05/99
(D) Standard electric feed assembly
1/8 hp (.09 kW) electric feed assembly attaches directly
to either end of the main bed or ram leadscrews and
provides 2:1 reduction feed. Unit has three mounting
positions to clear obstructions. Feed speed and
direction controls are on the feed unit. Dial is graduated
in .001" increments. One full turn equals .100" (2.54
mm). Feed speed is up to 10" (254 mm) per minute.
Includes switches (not shown). Recommended for
horizontal applications only.
21786Electric feed assy, 48" (1219.2 mm) travel main bed
21509Electric feed assy, 72" (1828.8 mm) travel main bed
22747Electric feed assy, 96" (2438.4 mm) travel main bed
21512Electric feed assy, ram and cross slide
Drawings may not represent
actual product.
PM5000 Components
NO.DESCRIPTION
(D) Heavy-duty electric feed assembly with local
control
1/8 hp (.09 kW) feed assembly attaches directly to
either end of the base or ram leadscrews and provides
2:1 reduction feed. Unit has three mounting positions to
clear obstructions. Dial is graduated in .001" increments.
One full turn equals .100" (2.54 mm). Electric power
feed speed is up to 24" (609.6 mm) per min. Assembly
includes limit switches (not shown). Recommended for
vertical and overhead applications.
29619Heavy-duty electric feed assembly with local
29621Heavy-duty electric feed assembly with local control,
29615Heavy-duty electric feed assembly with local control,
29617Heavy-duty electric feed assembly with local control,
30545Heavy-duty electric feed assembly with local control,
30464Heavy-duty local feed controller
20997(E) T ool Kit
20667(F) #40 Milling Head Assembly
control, 48" (1219.2 mm) main bed
72" (1828.8 mm) main bed
96" (2438.4 mm) main bed
ram and cross slide
cross feed
Complete set of tools, including instruction manual and
hex wrenches.
The hydraulically powered milling head mounts to the
vertical slide assembly. The milling head can be
positioned in 90o increments around the saddle. The
compact aluminum gear box, with belt drive and a 1:1
drive ratio, can be rotated up to 180o around the end of
the vertical slide to fit in tight places. A draw bolt and
drive lugs hold the milling cutter securely in the spindle.
(G) Hydraulic Drive Motors
Reversible motors with SAE 2-bolt mounting flange to
mount to the milling head gear box. Motor ports are
7/8-14 SAE O-ring type.
hydraulic power unit.
5 hp; 6 gpm (22.7 L/min) 1200 psi (8268 kPa)*
*For 50 Hz operation, torque remains constant and
rpm decreases by 16%.
Fittings are included with the
Power unit specifications:
Drawings may not represent
actual product.
20684Motor, hydraulic:
21530Motor, hydraulic:
20231Motor, hydraulic:
39828
displacement3.6 in359.0 cm
motor rpm363
motor torque563 in-lbs 64 N•m
displacement5.9 in396.8 cm
motor rpm221
motor torque955 in-lb108 N•m
displacement7.3 in3119.7 cm
motor rpm177
motor torque1209 in-lbs 137 N•m
Hydraulic motor fitting kit - 1/2" fittings (not shown)
Fitting kit includes fittings needed to connect motors
listed above to power unit hoses with 1/2" female quick
disconnect fittings.
every Climax hydraulic power unit.
3
3
3
These fitting kits are included with
05/99 13
PM5000 Components
NO.DESCRIPTION
(H) 5 hp (3.73 kW) hydraulic power unit
Variable displacement piston pump power unit comes
complete with a 5 gallon (19 liter) reservoir, START/STOP
pendant, speed control, pressure gauge, 20 foot (6 meter)
x 3/8" (9.5 mm) hydraulic hoses with quick disconnect
fittings, and 7/8-14 SAE O-ring fittings for hydraulic motor.
Order motor separately.
Drawings may not represent
actual product.
253183-Phase electric powered hydraulic power unit
Variable displacement piston pump power unit comes
complete with starter/overload relay, oil cooler, return line
oil filter, 10 gallon (38 liter) reservoir, control pendant with
20 foot (6 meter) cord, and a pair of 20 foot (6 meter) x
3/8" (9.5 mm) hydraulic hoses with quick disconnect
fittings, and 7/8-14 SAE O-ring fittings for hydraulic motor.
Order motor separately.
315253-Phase electric powered hydraulic power unit
-1Remote pendant (spindle RPM control only), 5 hp
(3.73 kW) electric hydraulic power unit
Multifunction pendant replaces standard pendant. Functions
include: Emergency Stop, Power Unit On, Jog/Run selector,
Slow/Fast Motor Speed Control. To order add “-1” to the
desired power unit number. Example: “25318-1.”
Order pendant when ordering power unit or return
power unit to Climax for upgrade.
PM5000 Components
NO.DESCRIPTION
(I) Riser assembly
Riser assembly raises the milling head up from the
main bed. Assembly includes riser, studs and nuts, and
key.
For overhead milling, riser(s) totaling a
minimum of 3" (76.2 mm) are required. Risers
totaling 5" (127 mm) or more are recommended.