Climax PM4200 User Manual

PM4200 MILLING MACHINE
Variable bed lengths and milling head options offer enhanced versatility.
Quality Machine Design with Power-Packed Performance
• Precision machined dovetail ways and adjustable gibs provide smooth accurate travel.
Powerful
• Hydraulic, pneumatic, and electric motors are available to provide power for milling spindle.
• Feed options include manual, electric, and pneumatic.
• Optional HSK spindle.
Versatile
• Two different milling head options are available; the spindle, and the flexible HSK 40A spindle.
• 120V and 230V electric feed options are available in addition to manual feed for fine adjustment.
• The electric feed option provides infinitely variable rates from 0 to 20 IPM, with push-button rapid traverse.
• Forward, neutral and reverse modes are controlled by a simple shift lever.
Rigid and Durable
• Compact yet rigid design for hard to reach and limited clearance applications.
3
4-inch Weldon shank
Flexible
• Cross slide allows mounting of milling spindle on either side of the bed.
• An extended ram may be used in conjunction with the more powerful and versatile HSK spindle.
• The optional HSK milling head swivel plate accessory allows 360° range of spindle angles
• Optional sub-plates are available for extra bed rigidity and installation versatility.
Quick and Easy Setup
• The PM4200 3-axis portable milling machine provides precise and versatile on the job milling capabilities. It is designed to be attached either to the work piece or to a support structure beside it.
• Beds are available in 20, 49 and 78 inch (508, 1244.6 and 1981.2 mm) travel.
9
Applications Include:
• The PM4200 is commonly used for milling large cumbersome parts.
• Many customers use the PM4200 machines when welding up and re-machining worn parts on production machinery like stamping presses.
• Long motor mount slots are easily machined, often without dismantling since the mill can be mounted right on the workpiece.
• Motor mounts and pump bases are easily machined, especially in tight locations.
2013 PM42
SPECIFICATIONS
US Metric
Bed Length 29, 58 or 87 inches 736.6, 1473.2 or 2209.8 mm
Bed Travel (X Travel) 20, 49 or 78 inches 508.0, 1244.6 or 1981.2 mm
Cross Slide Travel (Y-Axis) 8 inches (Weldon) 203.2 mm 12 inches (HSK) 304.8 mm
Spindle Reach from edge of bed 8.85 inches (Weldon) 224.8 mm 12 inches (HSK) 304.8 mm
Tool Head Vertical Travel 3 inches (Weldon) 76.2 mm 4 inches (HSK) 101.6 mm
No Load Spindle Speed
Weldon Electric 230-525 RPM
Weldon Hydraulic 282-696 RPM
Weldon Pneumatic Up to 510 RPM
HSK Electric Up to 800 RPM
HSK Hydraulic 369-1006 RPM
HSK Pneumatic Up to 1100 RPM
Spindle Size 0.75 inch (Weldon) 19.1 mm 40A (HSK)
Milling Head Gearbox Ratio 2.15:1 (Weldon Spindle)
6.25:1 (HSK Spindle) Electric
1:1 (HSK Spindle) Hydraulic
1:1 (HSK Spindle) Pneumatic
Spindle Power
3/4" Weldon Shank
120V or 230V Electric 1 HP 0.75 kW
Hydraulic Motor Assemblies J Series with 24 inch (609.6 mm) hose and QD
Max Motor RPM @5.5 gpm (20.8 L/m)
65263 0.79 in3 (13 cm3) J SERIES 116 696
65094 1.21 in3 (19.8 cm3) J SERIES 81 469
3
65095 1.93 in
(31.6 cm3) J SERIES 46 283
Pneumatic * 1.55 HP 1.15 kW
HSK Spindle
120V or 230V Electric 3.5 HP 2.6 kW
Hydraulic J Series with 24 inch (609.6 mm) hose and QD
Min Motor RPM @5.5 gpm (20.8 L/m)
65094 (1.21 in3 (19.8 cm3) J SERIES) 175 1009
65095 (1.93 in3 (31.6 cm3) J SERIES) 99 606
68455 Pneumatic Right Angle * 1.55 HP 1.15 kW
68584 Pneumatic Direct Drive * 1.35 HP 1.01 kW
* Air motor requires 32 FT3/min (0.9m3/min) at 90 PSI 550 kPa
Min Motor RPM @1 gpm (3.8 L/min)
Max Motor RPM @1 gpm (3.8 L/min)
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
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
SPECIFICATIONS
Available Standard Options
Bed Lengths 29, 58, or 87 inches (736.6, 1473.2 or 2209.8 mm)
Rams Weldon Top Slide
HSK Extended Ram
Blank Tool Post
Spindles Weldon ¾-inch Spindle
HSK 40A Spindle
Spindle drive available in electric, hydraulic and pneumatic versions.
Basic configuration includes:
• Bed
• Top slide (inch or metric)
• Gearbox
• Spindle & quill assembly (inch or metric)
• Vertical adjustment leadscrew (inch or metric)
• Cross slide
• Leadscrew
• Feed assembly (manual, pneumatic, or electric)
• Spindle motor (electric, pneumatic, or hydraulic)
Weldon Top Slide
HSK Extended Ram
Blank Tool Post
Dimensions
Overall Length
US Metric
bed length + 8.8 inches bed length + 223.5 mm
Overall Width Weldon 13.22 - 20.22 inches 335.8 - 513.6 mm
HSK 28.5 inches 723.9 mm
Overall Height with electric motor
Weldon 13.6 - 16.6 inches 345.4 - 421.6 mm
HSK 17.6 - 21.6 inches 447.0 - 548.6 mm
Weight (without motor)
US Metric
Bed lengths
29 inch (736.6 mm) Weldon 332 lb 151 kg
29 inch (736.6 mm) HSK 40A 381 lb 173 kg
58 inch (1573.2 mm) Weldon 544 lb 248 kg
58 inch (1573.2 mm) HSK 40A 593 lb 270 kg
87 inch (2209.8 mm) Weldon 710 lb 323 kg
87 inch (2209.8 mm) HSK 40A 759 lb 345 kg
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 3
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
TOOL CONFIGURATIONS
Configure your PM4200:
1 Select a Base Unit 2 Select Shipping Containers 3 Select Main Bed Feed Control 4 Select a Topslide, Spindle Drive or Extended Ram Assembly 5 Select HSK Milling Head Assembly 6 Select Tooling 7 Select Collets 8 Select Hydraulic Motor for Spindle 9 Select HPU 10 Select Hose, Pendant, and Cable Assemblies (2-Axis) To generate the correct part number for the machine, simply circle the part number needed in each step, and contact your Climax representative.
1
Base Unit (w/o Leadscrew)
(Includes bed assembly, tool kit, and operating manual) 20 Inches (508 mm) of travel, 29 inch (736.6 mm) bed 65206
49 Inches (1244.6 mm) of travel, 58 inch (1473.2 mm) bed 65207
78 Inches (1981.2 mm) of travel, 87 inch (2209.8 mm) bed 65208
2
Shipping Containers
Wood Crate for 20 Inch (508.0 mm) Travel Bed 65084
Metal Container for 20 Inch (508.0 mm) Travel Bed 65403
Wood Crate for 49 Inch (1244.6 mm) Travel Bed 65085
Metal Container for 49 Inch (1244.6 mm) Travel Bed 65404
Wood Crate for 78 Inch (1981.2 mm) Travel Bed 69211
Metal Container for 78 Inch (1981.2 mm) Travel Bed 65405
3
Main Bed Feed Control
20 Inch (508.0 mm) Travel Bed w/Leadscrew
120V Feed Assembly 72057
230V Feed Assembly 65359
Manual Feed Assembly 65305
Pneumatic Feed Assembly 65309
Bearing Block (does not include feed or handwheel) 65353
49 Inch (1244.6 mm) Travel Bed w/Leadscrew
120V Feed Assembly 72058
230V Feed Assembly 65360
Manual Feed Assembly 65306
Pneumatic Feed Assembly 65310
Bearing Block (does not include feed or handwheel) 65354
78 Inch (1981.2 mm) Travel Bed w/Leadscrew
120V Feed Assembly 72059
230V Feed Assembly 65361
Manual Feed Assembly 65307
Pneumatic Feed Assembly 65311
Bearing Block (does not include feed or handwheel) 65355
4
Topslide, Spindle Drive or Extended Ram Assembly
Electric
120V Weldon Shank Topslide Assembly - INCH 65217
120V Weldon Shank Topslide Assembly - METRIC 65218
230V Weldon Shank Topslide Assembly - INCH 65219
230V Weldon Shank Topslide Assembly - METRIC 65220
Hydraulic
Weldon Shank Topslide Assembly - INCH 65221
Weldon Shank Topslide Assembly - METRIC 65222
Pneumatic
Weldon Shank Topslide Assembly - INCH 65223
Weldon Shank Topslide Assembly - METRIC 65224
Extended RAM Assembly (Only for HSK Milling Head)
Extended RAM Assembly 12 inch (304.8 mm) Travel 71970
Tool Post Blank
Tool Post Blank Slide Assembly 38167
5
HSK Milling Head Assembly
(Only for Extended RAM Assembly)
120V Electric HSK 40A Milling Head Assembly (w/motor) 64667
230V Electric HSK 40A Milling Head Assembly (w/motor) 66342
Hydraulic HSK 40A Milling Head Assembly 65262
Pneumatic HSK 40A Milling Head Assembly - Right Angle 68455
Pneumatic HSK 40A Milling Head Assembly - Direct Drive 68584
6
Tooling
HSK Taper
HSK 40A Taper 3 Inch (76.2 mm) Face Mill w/inserts 64984
HSK 40A Taper Collet Holder ER-32, 0.08 - 0.81 Inch (2.0 - 20.6 mm) 64985
Square Carbide Inserts 0.528 inch 47229
Weldon Shank Inch
Weldon Shank Face Mill Kit 2 x 3⁄4 Inch 39634
Weldon Shank Fly Cutter 2-1⁄2 inch Dia. Head x 3⁄4 Inch 20713
Carbide Inserts (SEHW1204AFN KC725M) 39631
Weldon Shank Metric
Weldon Shank Face Mill 2 X 20 mm 43985
Weldon Shank Fly Cutter 2-1⁄4 Inch (57.2 mm) Dia. Head x 20 mm 31625
Carbide Inserts (SEKT1404AEENGP2 KC725M) 66356
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Collets
Collet ER-32, 3⁄4 - INCH 64986
Collet ER-32, 20 mm - METRIC 66344
Collet Set ER-32, 1⁄3, 13⁄16, 1⁄16 Inch Increments - INCH 66345
Collet Set ER-32, 3 - 20 mm, 1 mm Increments - METRIC 66346
8
Hydraulic Motor for Spindle
HSK
Hydraulic Motor Assembly 1.21 Inch3 (19.8 cm3) 65094
Hydraulic Motor Assembly 1.93 Inch3 (31.6 cm3) 65095
Hydraulic Motor Assembly 3.00 Inch3 (49.2 cm3) 65096
Weldon
Hydraulic Motor Assembly 0.79 cu Inch (12.9 cu cm) 65263
Hydraulic Motor Assembly 1.21 cu Inch (19.8 cu cm) 65094
Hydraulic Motor Assembly 1.93 cu Inch (31.6 cu cm) 65095
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HPU (Pendant, Cables & Hoses required)
5HP HPU 200V-208V 66386
5HP HPU 230V 66387
5 HP HPU 380V - 415V 66389
5HP HPU 460V 66388
5HP HPU 575V 66390
10
Hose and Pendant Cable Assembly (2-Axis)
Hose and Cable Kit 1⁄2 x 20 ft. (609.6 cm) 65146
Hose and Cable Kit 1⁄2 x 50 ft. (1524.0 cm) 65152
Hose and Cable Kit 1⁄2 x 100 ft. (3048.0 cm) 65155
Expand the capabilities of your PM4200 with the following Accessories:
20 inches (508 mm) of travel, 29 inch (736.6 mm) Bed Sub-Plates 39659
49 inches (1244.6 mm) of travel, 58 inch (1473.2 mm) Bed Sub-Plates 39795
78 inches (1981.2 mm) of travel, 87 inch (2209.8 mm) Bed Sub-Plates 39793
Milling Head Swivel Plate Assembly (for HSK only) 66217
page 4
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
OperatiOnal DimensiOns
Model Bed length Mounting holes Spacing
PM4200-20 29 inch (736.6 mm) 6 10 inch (254 mm)
PM4200-49 58 inch (1473.2 mm) 12 10 inch (254 mm)
PM4200-78 87 inch (2209.8 mm) 18 10 inch (254 mm)
Electric Feed
Lifting Eye
Vertical Adjustment
Motor
Gearbox
Top Slide
Bed
Spindle/Quill
Clamping Screws
PM4200 with Weldon Spindle
page 5
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
OperatiOnal DimensiOns
.563 [14.3] THRU  1.000 [25.4]
2.2 [55.9] .85 [21.6]
8 [203.2] TRAVEL
13.0 [330.2] MIN
21.0 [533.4] MAX
13.6 [345.4] MIN
16.6 [421.6] MAX
3.54 [90.0]
0.6 [15.2] MIN
3.6 [91.4] MAX
2.18 [55.4]
4.5 [114.3]
PM4200 with Weldon Shank
11.38 [289.1]
8.88 [225.6]
8.687 [220.6]
10.18 [258.6]
Spindle
C
B
A
4.5 [114.3]
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Blank Tool Post
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
OperatiOnal DimensiOns
Electric Feed
Lifting Eye
Bed
Top Slide
Gearbox
Vertical Adjustment
Spindle/Quill
PM4200 with HSK Spindle and Extended Ram
Motor
28.5
21.6
37.8 [960.1] FOR 20 [508.0] TRAVEL BED
66.9 [1696.7] FOR 49 [1244.6] TRAVEL BED
95.8 [2433.3] FOR 78 [1981.2] TRAVEL BED
PM4200 W/ 12 INCH (304.8 MM) TRAVEL RAM FOR HSK SPINDLE
10.00 [254.0]
10.18 [258.6]
8.69 [220.7]
3.45 [87.6]
12.0 [304.8] MAX
page 7
Climax Portable Machining & Welding Systems Web site: climaxportable.com
Worldwide Phone: 1.503.538.2185 N. America Toll-Free: 1.800.333.8311 Fax: 1.503.538.7600 E-mail: Info@cpmt.com
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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.
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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.
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