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Climax BB4500 Operating Manual

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P/N 92974
June 2019
Revision 1
BB4500-
BB5000
BORING MACHINE
OPERATING MANUAL
BB4500
BB5000
ORIGINAL INSTRUCTIONS

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  • Page 1 BB4500- BB5000 BORING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS BB4500 BB5000 P/N 92974 June 2019 Revision 1...
  • Page 3 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, pro-...
  • Page 4 CLIMAX GLOBAL LOCATIONS Page B BB4500-BB5000 Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 92974, Rev. 1 Page C...
  • Page 6 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.

  • Page 7: Table Of Contents

    BB4500-BB5000 label locations ........
  • Page 8 ..............63 TORAGE Page ii BB4500-BB5000 Operating Manual...
  • Page 9 APPENDIX A BB4500 ASSEMBLY DRAWINGS ........65 APPENDIX B BB5000 ASSEMBLY DRAWINGS .
  • Page 10 This page intentionally left blank Page iv BB4500-BB5000 Operating Manual...
  • Page 11 1-2 RDU label locations ..............9 2-1 BB4500-BB5000 components with Eibenstock motor (BB5000 shown) ......12 2-2 RDU.
  • Page 12 B-30 Leadscrew assembly (P/N 28654) ..........113 C-1 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz CE schematic (P/N 88035 C00467) 120...
  • Page 13 C-3 BB4500-BB5000 Eibenstock controller 2nd gen 120V domestic assembly (P/N 88037 C00465) . . . 122 C-4 BB4500-BB5000 Eibenstock controller 2nd gen 120V CE assembly (P/N 88038 C00466) ..123 C-5 BB5000 motor 230V and 460V fan assembly (P/N 91811 E00034) ......124 C-6 BB5000 servo motor 230VAC and 460VAC power cable assembly (P/N 91811 E00048) .
  • Page 14 This page intentionally left blank Page viii BB4500-BB5000 Operating Manual...
  • Page 15 2-17 BB4500-BB5000 boring bar dimension identification ........
  • Page 16 A-1 BB4500 recommended spare parts ........

  • Page 17: Introduction

    The first page of each chapter includes a summary of the chapter contents to help you locate specific information. The appendices contain supplemental product information to aid in setup, operation, and maintenance tasks. Read this entire manual to familiarize yourself with the BB4500-BB5000 before attempting to set it up or operate it. AFETY ALERTS Pay careful attention to the safety alerts printed throughout this manual.

  • Page 18: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS CLIMAX leads the way in promoting the safe use of portable machine tools and valve testers. Safety is a joint effort. You, the end user, must do your part by being aware of your work environment and closely following the operating procedures and safety precautions contained in this manual, as well as your employer’s safety...

  • Page 19: Machine - Specific Safety Precautions

    and interfaces that can cause severe impact, pinching, cutting, and other injuries. Except for stationary operating controls, avoid contact with mov- ing parts by hands or tools during machine operation. Remove gloves and secure hair, clothing, jewelry, and pocket items to prevent them from becoming entangled in moving parts.

  • Page 20: Risk Assessment And Hazard Mitigation

    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 Porta- ble Machine Tool and the workpiece as a whole. Page 4 BB4500-BB5000 Operating Manual...

  • Page 21: Risk Assessment Checklist

    ISK 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 con- sider.

  • Page 22: Labels

    ABELS 1.7.1 Label identification The following warning and identification labels should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements. 1-4. BB4500-BB5000 ABLE LABELS P/N 59037 P/N 29154 Warning label: Serial number read the operating...

  • Page 23: Bb4500-Bb5000 Label Locations

    The following figures display the location of the labels on the RDU and AFU. For further identification of location placement, refer to the BB4500 exploded views in Appendix A on page 65 and the BB5000 exploded views in Appendix B on page P/N 92974, Rev.
  • Page 24 80510 78735 78742 80510 78735 78742 1-1. AFU IGURE LABEL LOCATIONS Page 8 BB4500-BB5000 Operating Manual...
  • Page 25 1-2. RDU IGURE LABEL LOCATIONS P/N 92974, Rev. 1 Page 9...
  • Page 26 This page intentionally left blank Page 10 BB4500-BB5000 Operating Manual...

  • Page 27: Overview

    - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -29 TEMS REQUIRED BUT NOT SUPPLIED The BB4500 and BB5000 are similar machines. The BB4500 has a smaller range but the same major components.

  • Page 28: Bb4500 Features

    Figure 2-1 shows the BB4500-BB5000 major components, defined in Table 2-1. Leadscrew 2-1. BB4500-BB5000 (BB5000 IGURE COMPONENTS WITH IBENSTOCK MOTOR SHOWN 2-1. BB5000 ABLE COMPONENT IDENTIFICATION Number Component Rotational drive unit (RDU) Spherical bearing mount (single arm shown) Tool head assembly...

  • Page 29: Bb5000 Features

    BB5000 FEATURES The BB5000 can be used easily in small workspaces. CLIMAX’s mounting com- ponents provide the flexibility to handle tough boring jobs. The BB5000's through- bar design allows you to mount the rotational drive and feed unit anywhere along the bar.

  • Page 30: Axial Feed Unit

    The fixed leadscrew may be mounted either to the RDU or to the axial leadscrew- mounting block. For the BB4500, standard leadscrews have 12" (305 mm) or 24" (610 mm) of travel. For the BB5000, standard leadscrews have 12" (305 mm), 24" (610 mm), or 36"...

  • Page 31: Bb4500 Boring Bar

    All bars have 0.5" (12 mm) square tool bit mounting holes spaced at 10" or 6" (254 or 152 mm) intervals. CLIMAX offers a drill jig with a tool sleeve kit for cutting intermediate tool bit holes for special applications. Contact CLIMAX for custom hole spacing patterns.

  • Page 32: Spherical Bearing Mounts

    ARM SPHERICAL BEARING MOUNT Double-arm spherical bearing mounting brackets are better for those applications requiring extra sup- port, such as when boring holes exceed 8" (203 mm) in diameter. 2-8. U IGURE NIVERSAL SPHERICAL BEARING MOUNT Page 16 BB4500-BB5000 Operating Manual...

  • Page 33: Controls

    ONTROLS Table 2-2 shows the power options available for the BB4500-BB5000. Please note that only the BB5000 has the servo drive option. 2-2. P ABLE OWER OPTIONS Power type range Power Reference 10 hp HPU : 0 – 246 RPM at 60 Hz mains power Section 2.4.1 on...

  • Page 34: Hydraulic Power Unit And Hydraulic Motors

    2-5. A ABLE VAILABLE SPECIFICATIONS If using an HPU not supplied by CLIMAX, the hydraulic requirement is 10 gpm at 2,000 psi (37.85 lpm at 138 bar). Hydraulic motors with different displacement ratings are available. Please note the following: •...

  • Page 35: Bb5000 Servo Motors

    Refer to the correct “Maximum bar RPM” column in Table 2-6 for hydraulic motor performance. 2-6. H ABLE YDRAULIC MOTOR SPECIFICATIONS Maximum bar RPM Part number Part number Torque at for motors with for motors with Motor capacity 8.36 gpm 10 gpm (37.9 60 series QD ISO 16028 QD...
  • Page 36 3–230 RPM Bar rated torque (continuously 3–167 RPM: 147.9 ft-lbs (200.4 Nm) running): Bar maximum torque: 3–230 RPM: 443.7 ft-lbs (600.4 Nm) Rotation: Variable speed and reversible Motor Manufacturer: Mitsubishi Speed rated continuous: 2,000 RPM Page 20 BB4500-BB5000 Operating Manual...

  • Page 37: Electric Motor

    NOTICE Table 2-8 shows the four mains power plugs for the control box that CLIMAX offers. If the plug needed is not included in Table 2-8, the end user must cut off the factory-installed plug and install their own. 2-8. C...
  • Page 38 Shifting gears while the machine is under load could damage the motor and gearbox components. CLIMAX’s portable machine tools require a three-wire extension cord. Extension cords of inadequate wire size may cause a significant drop in mains voltage with a consequent loss of power.
  • Page 39 Table 2-12 and Table 2-13 list the service parts for both motors. 2-12. 120V ABLE SERVICE PARTS Part number Description Quantity 83595 Rotor complete 82698 Carbon brush 83593 PCB / circuit board 83594 Stator complete 2-13. 230V ABLE SERVICE PARTS Part number Description Quantity...

  • Page 40: Air Motor

    The PCU (shown in Figure 2-12 on page 25) provides clean dry air and lubrication to the air motor. Install the PCU in the air supply circuit immediately before the BB4500 or BB5000. WARNING Always stop the machine and lock out/tag out the PCU before making adjustments to controls or machine components.

  • Page 41: Dimensions

    72" (1,828.8 mm) bar 74.5” x 6.5” x 7” (1,892 x 165 x 178 mm) 49.5” x 30.5” x 41” (1,257 x 775 x 1,041 mm) The following figures show the BB4500-BB5000 machine and operating dimen- sions. P/N 92974, Rev. 1...
  • Page 42 2-13. BB4500 IGURE DIMENSIONS 6.91 (176) 4.75 (121) 8.57 (218) 2-14. BB5000 IGURE DIMENSIONS Page 26 BB4500-BB5000 Operating Manual...

  • Page 43: Specifications

    2-17. BB4500-BB5000 ABLE BORING BAR DIMENSION IDENTIFICATION Number Component Stroke Workpiece: distance between outer edges of the workpiece = X PECIFICATIONS 2-18. S ABLE COMPONENT MASS Component Mass in lbs (kg) Motor: 43 lbs (20 kg) Adapter assembly (P/N 51536):...

  • Page 44: Electrical Specifications

    2.6.1 Electrical specifications CLIMAX electrical equipment is suitable for use in the physical environment and operating conditions specified below. When the physical environment or the oper- ating conditions are outside those specified, consult CLIMAX before putting the electrical equipment into service.

  • Page 45: Items Required But Not Supplied

    TEMS REQUIRED BUT NOT SUPPLIED The only item required but not supplied in your CLIMAX product kit is a welder to weld on the tack plate when mounting the bearings onto the workpiece. P/N 92974, Rev. 1 Page 29...
  • Page 46 This page intentionally left blank Page 30 BB4500-BB5000 Operating Manual...

  • Page 47: Setup

    - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47 WITH SMALL DIAMETER BARS This section describes the setup and assembly procedures for the BB4500-BB5000 boring machine.

  • Page 48: Lifting And Rigging

    The machine ships from CLIMAX with a heavy coating of LPS 3. The recom- mended cleaner is LPS PreSolve Orange Degreaser. All parts must be cleaned before use. IFTING AND RIGGING WARNING Do not lift the BB4500-BB5000 boring machine when fully assembled, as it can weigh up to 444 lbs (201 kg).

  • Page 49: Bar And Mounting Bracket Assembly

    3.3.1 Bar and mounting bracket assembly To roughly align a CLIMAX boring bar in a workpiece, use centering cones. These cones approximately center the bar until bearing supports and brackets are secured with clamps or welds, as appropriate. Cone sets are...
  • Page 50 Loosen the hex bolts. b) Adjust the four set screws until the bearing is centered. c) Tighten the hex bolts. 3-4. C IGURE ENTERING THE SPHERI CAL BEARINGS Page 34 BB4500-BB5000 Operating Manual...

  • Page 51: Tooling And Tool Head Assembly

    3-3. S ABLE PHERICAL BEARING IDENTIFICATION Number Component Loosen bolts to adjust bearing Adjust screws to center bearings in brackets 9. Mount the tack weld plates to the spherical bearing mounting brackets. If more 3-5. P IGURE OSITIONING THE SPHERICAL BEARINGS clearance is required, weld 1"...

  • Page 52: Placing The Tool Bit Into The Bar

    This gives you multiple positions of the tool bit. CLIMAX has designed these so that you can use a variety of tool bit types. The cutting speed is primarily determined by the hardness of the metal being machined and the type of tool bit used.

  • Page 53: Rdu And Afu Assembly

    The maximum recommended cutting depth is 0.125" (3 mm). Tighten the tool bit mounting screws. CLIMAX offers a bore measuring tool specially built for setting the tool bit height and checking the actual bore diameter. Contact CLIMAX for more information on this tool.
  • Page 54 5. Tighten the clamp collar over the collet, as shown in Figure 3-11 on page 39. Turn the collar screw until the collar is snug, but the bar slides easily through the unit. In most boring applications, this collar can remain loose. Page 38 BB4500-BB5000 Operating Manual...
  • Page 55 3-11. C IGURE LAMP COLLARS ON THE 3-5. C ABLE LAMP COLLARS INSTALLATION IDENTIFICATION Number Component Tighten the clamp collars Jam nut Leadscrew (Screw one end into the AFU, the other end into the RDU. Tighten the jam nut.) 6. Hold the motor assembly so that the motor shaft is able to slide into the RDU housing.

  • Page 56: Axial Feed

    If the axial feed box fails to feed the tool head, check the shear pins. Replacement pins are included with the AFU. To replace a pin, see Section 5.3.1 on page 59. CAUTION Feeding the bar into a fixed object could damage the internal feed clutches. 3-12. AFU IGURE COMPONENTS Page 40 BB4500-BB5000 Operating Manual...

  • Page 57: Setting The Feed Rate

    3-6. AFU ABLE COMPONENT IDENTIFICATION Number Component Arrow #1 Push to feed in direction of arrow #1 Feed shaft Feed stop pin Feed adjusting knob for direction #1 Auto-stop arm assembly Push to feed in direction of arrow #2 Drive bushing Arrow #2 3.4.2 Setting the feed rate...

  • Page 58: Automatic Feed Stop

    When the axial feed box nears the stop arm, the stop arm will depress the feed stop screw assembly to stop the axial feed. Do the following to retract the tool head: 1. Place the feed box in NEUTRAL 2. Hand crank the tool bit away from the workpiece. Page 42 BB4500-BB5000 Operating Manual...

  • Page 59: Power Connection

    OWER CONNECTION 3.5.1 Hydraulic machines For the BB4500-BB5000, do the following to connect the hydraulic power: 1. Disconnect the mains power to the HPU. 2. Inspect all electrical cables and check the oil level in the hydraulic reser- voir.

  • Page 60: Bb5000 Servo Drive Machine

    Do not operate the motor if it is wet or in a hazardous environment. Servo motor pendant Table 3-9 on page 45 shows the functions of the pendant controls (seen in Figure 3-16 on page 45) used to operate a servo-motor powered machine. Page 44 BB4500-BB5000 Operating Manual...
  • Page 61 Turn to change the direction of bar rotation. Warns that a fault condition is imminent unless the load is Overload indicator reduced. NOTICE The 230V and 460V units cannot be converted between voltages. There is no servo drive for the BB4500. P/N 92974, Rev. 1 Page 45...

  • Page 62: Electrical Machines

    120V motors are rated at 20 amps full load; 230V motors are rated at 11.5 amps full load. 3.5.4 Pneumatic machines For your safety and protection, the BB4500-BB5000 pneumatic sys- tem has an air control valve with a brightly colored oval handle (seen in Figure 3-17) clearly indicating the airflow direction.

  • Page 63: Bb4500-Bb5000 With Small Diameter Bars

    BB4500-BB5000 WITH SMALL DIAMETER BARS For the BB4500, boring bars with a diameter of less than 1.75" (44 mm) are easily adapted to accept the standard RDU, AFU, and the spherical bearing mounting brackets (see Figure 3-18). For the BB5000, boring bars with a SPHERICAL diameter of less than 2.25"...
  • Page 64 Do the following to install the small-bore kit, or for installing collets for the RDU, AFU, or spherical bearings: 1. Remove a snap ring from one end of the small bore kit collet. SPHERICAL AFU SNAP RDU SNAP RING BEARING RING SNAP RING 3-20. S IGURE NAP RING REMOVAL Page 48 BB4500-BB5000 Operating Manual...
  • Page 65 3-12. S ABLE NAP RING REMOVAL IDENTIFICATION Number Component AFU snap ring RDU snap ring Spherical bearing snap ring 2. Insert the small bore kit adapter 1.25" (32 mm) ID collet into the existing 2.25" (57 mm) ID collet. SPHERICAL AFU SMALL RDU SMALL BEARING...
  • Page 66 AFU SNAP RDU SNAP SPHERICAL RING RING BEARING SNAP RING 3-22. S IGURE NAP RING REPLACEMENT 3-14. S ABLE NAP RING REPLACEMENT IDENTIFICATION Number Component AFU snap ring RDU snap ring Spherical bearing snap ring Page 50 BB4500-BB5000 Operating Manual...

  • Page 67: Operation

    OPERATION IN THIS CHAPTER: 4.1 P - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -51 OPERATION CHECKS 4.2 T - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -52...

  • Page 68: Tool Bit Selection

    (located on the control pendant) for one of the follow- ing results: • Counter-clockwise to decrease RPM. • Clockwise to increase RPM. 4.3.1.2 Electrical drive Do the following to start the electrical drive: 1. Set the rotation speed on the speed control to minimum. Page 52 BB4500-BB5000 Operating Manual...
  • Page 69 2. Turn on power at the motor controller. 3. Adjust the bar rotation speed as required by the bore size, tooling, and material requirements. 4. Adjust the feed rate. The motor has thermal and current overload protections built in. If the motor is pushed beyond its protected range, it will stop.

  • Page 70: Shutdown

    4-1. D IGURE ISENGAGING THE AXIAL FEED 4-1. A ABLE XIAL FEED DISENGAGEMENT IDENTIFICATION Number Component Push to feed in direction of arrow #1 Page 54 BB4500-BB5000 Operating Manual...

  • Page 71: Disassembly

    Use a brush. 4. Retract the tool from the workpiece. ISASSEMBLY Do the following to disassemble the BB4500-BB5000: 1. Turn off and disconnect power to the unit. 2. Remove the tool head. 3. Disconnect the leadscrew from the rotational drive unit (RDU).
  • Page 72 6. Loosen the clamp ring holding the RDU to the spherical bearing. 7. Loosen the clamp collar holding the RDU to the boring bar. 8. Remove the RDU. 9. Slide the boring bar from the workpiece. 10. Remove all mounting accessories. Page 56 BB4500-BB5000 Operating Manual...

  • Page 73: Maintenance

    MAINTENANCE IN THIS CHAPTER: 5.1 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -57 AINTENANCE CHECKLIST 5.2 A - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -58...

  • Page 74: Approved Lubricants

    59 As needed Sharpen or replace the tool bits. PPROVED LUBRICANTS CLIMAX recommends using the following lubricants at the locations indicated. CAUTION Avoid damage, premature machine wear, and protect your warranty by using only approved lubricants. 5-2. A...

  • Page 75: Maintenance Tasks

    5-2. A ABLE PPROVED LUBRICANTS ONTINUED Application Area Lubricant Quantity Frequency Per use through Air motor AW 32 6 oz the lubricator ACME screw Boring bar WD 40 Per use by hand required Tool heads Unpainted surfaces Cutting fluid DoAll AL2000 As required required Long-term rust pre-...

  • Page 76: Electric Motor Assembly

    CLIMAX representative should remove and reinstall it. If the handle needs to be removed, contact CLIMAX. Failure to do this could cause severe damage to the machine or bodily injury. 5-1. E IGURE...

  • Page 77: Bb5000 Servo Motor

    Appendix D on page 141. 5.3.7 4:1 RDU gearbox Improperly packed bearings or improperly torqued bearing nuts will significantly damage the gearbox. Have the gearbox serviced at CLIMAX every six months in order to maintain the warranty. 5.3.8 Cutting fluid Only use water-based cutting fluids with the CLIMAX air mist system.

  • Page 78: Troubleshooting

    Check for faulty wiring. not run • Check the reset switch in the electrical box. • Check the fuses in the electrical box. Servo motor does not stop See Appendix D on page 141. when turned to zero Page 62 BB4500-BB5000 Operating Manual...

  • Page 79: Storage And Shipping

    STORAGE AND SHIPPING IN THIS CHAPTER: 6.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63 TORAGE 6.1.1 S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63...

  • Page 80: Decommissioning

    RDU and dispose of the drive assembly separately from the rest of the machine components. Refer to the BB4500 exploded views in Appendix A on page 65 and the BB5000 exploded views in Appendix B on page 83.

  • Page 81: Appendix Abb4500 Assembly Drawings

    APPENDIX A BB4500 ASSEMBLY DRAWINGS Drawing list A-1. A (P/N 43378) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66...

  • Page 82: Igure A-1. Axial Feed Unit Assembly (P/N 43378)

    A-1. A (P/N 43378) IGURE XIAL FEED UNIT ASSEMBLY Page 66 BB4500-BB5000 Operating Manual...

  • Page 83: Igure A-2. Axial Feed Unit Assembly Parts List (P/N 43378)

    A-2. A (P/N 43378) IGURE XIAL FEED UNIT ASSEMBLY PARTS LIST P/N 92974, Rev. 1 Page 67...

  • Page 84: Igure A-3. Boring Heads Set Assembly (P/N 43576)

    TOOL HEAD METRIC 4 TO 6 DIA 1-3/4 BAR BB4500 43563 PARTS LIST ITEM P/N: DESCRIPTION 35214 SCREW M8 X 1.25 X 12mm SSSCP 40697 SCREW M12 X 1.75 X 30mm SHCS TOOL HEAD METRIC 6 TO 8 DIA 1-3/4 BAR BB4500...

  • Page 85: Oring Heads Set 4-10 Metric Diameter Assembly (P/N 43576)

    PARTS LIST ITEM P/N: DESCRIPTION 43563 TOOL HEAD METRIC 4 TO 6 DIA 1-3/4 BAR BB4500 43564 TOOL HEAD METRIC 6 TO 8 DIA 1-3/4 BAR BB4500 43565 TOOL HEAD METRIC 8 TO 10 DIA 1-3/4 BAR BB4500 A-4. B 4–10...

  • Page 86: Igure A-5. Boring Heads Set Diameter Assembly (P/N 43575)

    PARTS LIST ITEM P/N: DESCRIPTION 43492 TOOL HEAD 4 TO 6 DIA 1-3/4 BAR 43493 TOOL HEAD 6 TO 8 DIA 1-3/4 BAR BB4500 43494 TOOL HEAD 8 TO 10 DIA 1-3/4 BAR A-5. B 4–10" (P/N 43575) IGURE ORING HEADS SET...

  • Page 87: Igure A-6. Rdu 2 Nd Gen Assembly (P/N 53912)

    A-6. RDU 2 (P/N 53912) IGURE ND GEN ASSEMBLY P/N 92974, Rev. 1 Page 71...

  • Page 88: Igure A-7. Rdu 2 Nd Gen Assembly (P/N 53912)

    HANDLE PULL 1/4 CBORE MTG 2.17 X 5.75 X 1.02W COATED 53613 SPACER .67 OD X .266 ID X 1.875 LG 53910 CLAMP RING RDU MOUNT BB4500 HD 53911 COLLET MAIN DRIVE BB4500 4TH GEN 53913 KEY MAIN DRIVE BB4500 HD...

  • Page 89: Igure A-8. Hydraulic Motor Assembly (P/N 39848)

    PARTS LIST ITEM P/N: DESCRIPTION 11238 WASHER LOCK 1/2 11826 SCREW 1/2-13 X 1-1/4 HHCS SEE CHART 39828 KIT FTG 1/2 HYD QUICK COUPLERS 78619 LABEL WARNING HOT SURFACE GRAPHIC 1.95" TALL TRIANGLE YELLOW (KB) PART No DESCRIPTION MOTOR HYD P/N 39837 MOTOR ASSY HYD 2.2 CU IN KEYED 1/2 FTG 27477...

  • Page 90: Igure A-9. Single Arm Mount Assembly (P/N 43262)

    SCREW 5/16-18 X 1-3/4 SSSFP 43264 MOUNT BRG SPHERICAL ARM BB45000 STD 43265 BRACKET MOUNTING ARM 43266 PLATE BEARING SCAB 45365 SCREW 5/16-24 X 1.500 HHCS FLANGED BLK OX A-9. S (P/N 43262) IGURE INGLE ARM MOUNT ASSEMBLY Page 74 BB4500-BB5000 Operating Manual...

  • Page 91: Igure A-10. Universal Mount Assembly (P/N 43267)

    PARTS LIST ITEM P/N: DESCRIPTION 11223 SCREW 1/2-13 X 7 SHCS 11879 SCREW 1/2-13 X 5 SHCS 13489 WASHER 5/16 FLTW SAE 14036 SCREW 1/2-13 X 2 SHCS 22662 WASHER 1/2 FLTW HARDENED 1-1/8 OD X 1/8 THK 27273 SCREW 1/2-20 X 3/4 SSSFP 36962 BEARING MOUNT RING 1-3/4 36965...

  • Page 92: Igure A-11. Double Arm Bearing Mount Assembly (P/N 43279)

    MOUNT BRG SPHERICAL 1-3/4 ID W/CLAM STD 43266 PLATE BEARING SCAB 43277 BRACKET MOUNTING DOUBLE ARM 45365 SCREW 5/16-24 X 1.500 HHCS FLANGED BLK OX A-11. D (P/N 43279) IGURE OUBLE ARM BEARING MOUNT ASSEMBLY Page 76 BB4500-BB5000 Operating Manual...

  • Page 93: Arge And Small Set Cones Assembly

    SET CONES SETUP 6 TO 10 DIA 1-3/4 KEYED BAR 43384 PARTS LIST ITEM P/N: DESCRIPTION 42228 CONE SETUP 6 TO 10 BB4500 1-3/4 BAR 29092 SCREW MOD 3/8-24 X 1-3/16 SSSFD 29091 PIN STOP 42228 CONE SETUP BB4000 6" TO 10"...

  • Page 94: Igure A-13. Eibenstock Motor Assembly (P/N 88012)

    SCREW 5/16-18 X 3-1/2 SHCS 12646 SCREW 1/2-13 X 1-1/4 SHCS 15724 KEY 1/4 SQ X 1.37 SQ BOTH ENDS 56300 LABEL CLIMAX LOGO .66 X 1.75 59037 LABEL WARNING - WEAR EAR PROTECTION 59044 LABEL WARNING - CONSULT OPERATOR'S MANUAL 1.5 DIA 75648...

  • Page 95: Igure A-14. Eibenstock Motor Assembly -- Gen Only

    A-14. E IGURE IBENSTOCK MOTOR ASSEMBLY ONLY P/N 92974, Rev. 1 Page 79...

  • Page 96: Igure A-15. Eibenstock Motor Assembly Parts List -- Gen Only

    A-15. E IGURE IBENSTOCK MOTOR ASSEMBLY PARTS LIST ONLY Page 80 BB4500-BB5000 Operating Manual...

  • Page 97: Ool Kit

    A-1. BB4500 ABLE RECOMMENDED SPARE PARTS Part Component Description Quantity number Rotational 12395 Clamp collar drive unit 12436 Leadscrew Leadscrew assembly 27356 1-5 Acme Nut 29552 Clamp collar 27015 Shear pin 25957 Clutch Axial feed box assembly 27197 Lead nut...
  • Page 98 3/8" Hex wrench 10601 5/16" Hex wrench 10600 5/32" Hex wrench 25710 Tool bit HSS 1/2 sq x 4" 43697 Operating Manual 82949 Bag tool 14 x 5.5 x 6 polyester 39099 Filter element replacement Page 82 BB4500-BB5000 Operating Manual...

  • Page 99: Appendix Bbb5000 Assembly Drawings

    APPENDIX B BB5000 ASSEMBLY DRAWINGS Drawing list B-1. A (P/N 28636) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84 IGURE XIAL FEED UNIT ASSEMBLY B-2.

  • Page 100: Igure B-1. Axial Feed Unit Assembly (P/N 28636)

    B-1. A (P/N 28636) IGURE XIAL FEED UNIT ASSEMBLY Page 84 BB4500-BB5000 Operating Manual...

  • Page 101: Igure B-2. Axial Feed Unit Assembly Parts List (P/N 28636)

    B-2. A (P/N 28636) IGURE XIAL FEED UNIT ASSEMBLY PARTS LIST P/N 92974, Rev. 1 Page 85...

  • Page 102: Igure B-3. Hd Axial Feed Unit Assembly (P/N 91518)

    B-3. HD (P/N 91518) IGURE AXIAL FEED UNIT ASSEMBLY Page 86 BB4500-BB5000 Operating Manual...

  • Page 103: Igure B-4. Hd Axial Feed Unit Assembly Parts List (P/N 91518)

    PARTS LIST ITEM P/N: DESCRIPTION 10538 BRG THRUST .625 ID X 1.125 OD X .0781 11823 WASHER THRUST .625 ID X 1.125 OD X .030 12388 BRG BALL 2.7559 X 4.3307 X .7874 12395 CLAMP COLLAR SPLIT HINGED 2-1/2 ID 16505 SEAL 1.375 ID X 1.750 OD X .197 (KB) 19561...

  • Page 104: Igure B-5. Air Motor Ce Assembly (P/N 28697)

    MOTOR AIR 3HP 475 RPM FS 228 RPM MAX 93TQ 26845 WRENCH HEX 3/8 SHORT ARM BONDHUS BALLDRIVER 28611 SCREW 1/2-13 X 1-1/4 SHCS MODIFIED 28612 FLANGE MTG AIR MOTOR BB5000 B-5. A (P/N 28697) IGURE IR MOTOR ASSEMBLY Page 88 BB4500-BB5000 Operating Manual...

  • Page 105: Igure B-6. Air Motor Ce Assembly (P/N 28614)

    PARTS LIST ITEM P/N: DESCRIPTION 10516 SCREW 5/16-18 X 3/4 FHSCS 15109 MOTOR AIR 3.2HP 975 RPM FS 485 RPM MAX 47.3TQ 26845 WRENCH HEX 3/8 SHORT ARM BONDHUS BALLDRIVER 28611 SCREW 1/2-13 X 1-1/4 SHCS MODIFIED 28612 FLANGE MTG AIR MOTOR BB5000 B-6.

  • Page 106: Igure B-7. Pneumatic Connection Assembly (P/N 15088)

    58380 FTG QUICK COUPLER UNIVERSAL 1 NPTM 59248 PNEUMATIC CONDITIONING UNIT 1 IN W/ L.P. DROP OUT AND E-STOP CE 62564 FTG QUICK COUPLER UNIVERSAL 1/2 NPTF B-7. P (P/N 15088) IGURE NEUMATIC CONNECTION ASSEMBLY Page 90 BB4500-BB5000 Operating Manual...

  • Page 107: Igure B-8. Hydraulic Motor Assembly (P/N 39848)

    PARTS LIST ITEM P/N: DESCRIPTION 11238 WASHER LOCK 1/2 11826 SCREW 1/2-13 X 1-1/4 HHCS SEE CHART 39828 KIT FTG 1/2 HYD QUICK COUPLERS 78619 LABEL WARNING HOT SURFACE GRAPHIC 1.95" TALL TRIANGLE YELLOW (KB) PART No DESCRIPTION MOTOR HYD P/N 39837 MOTOR ASSY HYD 2.2 CU IN KEYED 1/2 FTG 27477...

  • Page 108: Igure B-9. Setup Cone Assembly (P/N 26383)

    SCREW MOD 3/8-24 X 1-3/16 SSSFD 29091 PIN STOP 29095 CLAMP COLLAR MODIFIED 17125 SCREW 5/16-24 X 1-1/2 SHCS 26507 SET CONE SETUP 2.75 TO 8.37 DIA BB5000 B-9. S (P/N 26383) IGURE ETUP CONE ASSEMBLY Page 92 BB4500-BB5000 Operating Manual...

  • Page 109: Igure B-10. Single Arm Mount Assembly (P/N 37472)

    PARTS LIST ITEM P/N: DESCRIPTION 14036 SCREW 1/2-13 X 2 SHCS 17145 WASHER 1/2 FLTW HARDENED 1-1/8 OD X 3/16 THK 19869 PLATE SPACER TACK WELD MTG 21798 WASHER 5/16 FLTW HARDENED 26248 ASSY BRG SPHERICAL 2-1/4 ID W/ CLAMP COLLAR 26251 BRACKET MTG SPHERICAL BRG 1-ARM 26252...

  • Page 110: Igure B-11. Double Arm Mount Assembly (P/N 37473)

    ASSY BRG SPHERICAL 2-1/4 ID W/ CLAMP COLLAR 26252 SCREW 1/2-20 X 2 SSSFP 26517 MTG BRACKET SPHERICAL BRG 2-ARM 45364 SCREW 5/16-24 X 2 HHCS FLANGED BLK OX B-11. D (P/N 37473) IGURE OUBLE ARM MOUNT ASSEMBLY Page 94 BB4500-BB5000 Operating Manual...

  • Page 111: Igure B-12. Air Motor Ce Assembly (P/N 36959)

    PARTS LIST ITEM P/N: DESCRIPTION 26248 ASSY BRG SPHERICAL 2-1/4 ID W/ CLAMP COLLAR 41514 MOUNT UNIVERSAL BORING BARS BB5000 NO BEARING B-12. A (P/N 36959) IGURE IR MOTOR ASSEMBLY P/N 92974, Rev. 1 Page 95...

  • Page 112: Igure B-13. Id Bearing Mount Assembly (P/N 46293)

    1.5 INCH CHUCK JAW (KB) 46294 SCREW 1/4 DIA X 1 X 10-24 SHLDCS 46303 BOLT JACKING 1/2 ID BRG MOUNT 46589 (NOT SHOWN) MANUAL INSTRUCTION BB5000 ID BEARING MOUNT B-13. ID (P/N 46293) IGURE BEARING MOUNT ASSEMBLY Page 96 BB4500-BB5000 Operating Manual...

  • Page 113: Igure B-14. Set Cones Setup Assembly (P/N 49060)

    SET CONES SETUP 6 TO 10 DIA 1-3/4 KEYED BAR 43384 PARTS LIST ITEM P/N: DESCRIPTION 42228 CONE SETUP 6 TO 10 BB4500 1-3/4 BAR 29092 SCREW MOD 3/8-24 X 1-3/16 SSSFD 29091 PIN STOP 42228 CONE SETUP BB4000 6" TO 10"...

  • Page 114: Igure B-15. Servo Drive 460 Ce Assembly (P/N 52876)

    B-15. S 460 CE (P/N 52876) IGURE ERVO DRIVE ASSEMBLY Page 98 BB4500-BB5000 Operating Manual...

  • Page 115: Igure B-16. Servo Drive 460 Ce Assembly Parts List (P/N 52876)

    B-16. S 460 CE (P/N 52876) IGURE ERVO DRIVE ASSEMBLY PARTS LIST P/N 92974, Rev. 1 Page 99...

  • Page 116: Igure B-17. Rdu 12:1 Assembly (P/N 53165)

    B-17. RDU 12:1 (P/N 53165) IGURE ASSEMBLY Page 100 BB4500-BB5000 Operating Manual...

  • Page 117: Igure B-18. Rdu 12:1 Assembly Parts List (P/N 53165)

    PARTS LIST ITEM P/N: DESCRIPTION 10160 SCREW 1/4-20 X 3/4 SHCS 10588 SCREW DRIVE #2 x 1/4 HOLE SIZE .089 11684 SCREW 5/16-18 X 3/4 SSSCP 11821 BRG CUP 4.4375 OD X .750 WIDE 11822 BRG CONE 2.75 ID X 1.00 WIDE 12387 BRG THRUST 1.259 ID X 1.937 OD X .0781 12395...

  • Page 118: Igure B-19. Rdu No Mount Modified Assembly (P/N 93090)

    B-19. RDU (P/N 93090) IGURE NO MOUNT MODIFIED ASSEMBLY Page 102 BB4500-BB5000 Operating Manual...

  • Page 119: Igure B-20. Rdu No Mount Modified Assembly Parts List (P/N 93090)

    PARTS LIST ITEM P/N: DESCRIPTION 11684 SCREW 5/16-18 X 3/4 SSSCP 11694 SCREW 1/2-13 X 2-1/2 11777 SCREW 1/4-20 X 1-1/2 SHCS 11821 BRG CUP 4.4375 OD X .750 WIDE 11822 BRG CONE 2.75 ID X 1.00 WIDE 12387 BRG THRUST 1.259 ID X 1.937 OD X .0781 12395 CLAMP COLLAR SPLIT HINGED 2-1/2 ID 16594...

  • Page 120: Igure B-21. Servo Drive 230V Ce Assembly (P/N 54321)

    B-21. S 230V CE (P/N 54321) IGURE ERVO DRIVE ASSEMBLY Page 104 BB4500-BB5000 Operating Manual...

  • Page 121: Igure B-22. Servo Drive 230V Ce Assembly (P/N 54321)

    B-22. S 230V CE (P/N 54321) IGURE ERVO DRIVE ASSEMBLY P/N 92974, Rev. 1 Page 105...

  • Page 122: Igure B-23. Servo Motor Rdu Adapter Assembly (P/N 51536)

    KEY 1/4 X 1/4 X 1.00 RAD BOTH ENDS 51530 SHAFT BB5000 RDU TO SERVO 51531 HOUSING ADAPTER BB5000 RDU INPUT TO PLANETARY 53195 KEY 10mm x 8mm x 2.5 LONG RADIUS BOTH END B-23. S (P/N 51536) IGURE ERVO MOTOR ADAPTER ASSEMBLY Page 106 BB4500-BB5000 Operating Manual...

  • Page 123: Igure B-24. Servo Motor Guard Assembly (P/N 52937)

    PARTS LIST ITEM P/N: DESCRIPTION 10160 SCREW 1/4-20 X 3/4 SHCS 52916 GUARD SERVO MOTOR REAR PLATE 52936 SCREW M8 X 1.25 X 80MM SHCS 53462 HANDLE PULL 1/4 CBORE MTG 2.0 X 5.12 X 1.02W PLASTIC COATED 53484 LABEL "HANDLE WITH CARE" 56079 WASHER RUBBER 1/4 X 1/2 X .093 B-24.

  • Page 124: Igure B-25. Servo Shroud Fan Assembly (P/N 56773)

    SCREW 8-32 X 1-1/2 BHSCS 56772 WASHER #8 FLTW RUBBER .93 THICK 56774 FAN 4.69" SQUARE X 1" 24 VDC 80CFM 56775 GUARD FAN STEEL WIRE 4.13" SQUARE BOLT PATTERN B-25. S (P/N 56773) IGURE ERVO SHROUD FAN ASSEMBLY Page 108 BB4500-BB5000 Operating Manual...

  • Page 125: Igure B-26. Servo Drive Motor Non -Ce Assembly (P/N 71071)

    PARTS LIST ITEM PART No. DESCRIPTION 51536 ADAPTER BB5000 RDU TO SERVO MOTOR 52937 GUARD ASSY BB5000 SERVO MOTOR 53464 LABEL WARNING HOT HAND 53482 LABEL WARNING VOLTAGE 53483 LABEL WARNING VOLTAGE CABLE 56773 SHROUD FAN BB5000 SERVO ASSY 71068 ASSY BB5000 SERVO DRIVE 230VAC CONTROLS MOTOR AND CABLES NOT CE 2ND GEN B-26.

  • Page 126: Igure B-27. Servo Drive Motor Non -Ce Assembly (P/N 71072)

    53483 LABEL WARNING VOLTAGE CABLE 56773 SHROUD FAN BB5000 SERVO ASSY 71067 ASSY BB5000 SERVO DRIVE 460VAC CONTROLS MOTOR AND CABLES NOT CE 2ND GEN B-27. S 460V (P/N 71072) IGURE ERVO DRIVE MOTOR ASSEMBLY Page 110 BB4500-BB5000 Operating Manual...

  • Page 127: Igure B-28. Eibenstock Motor Assembly -- Gen Only

    B-28. E IGURE IBENSTOCK MOTOR ASSEMBLY ONLY P/N 92974, Rev. 1 Page 111...

  • Page 128: Igure B-29. Eibenstock Motor Assembly Parts List -- Gen Only

    B-29. E IGURE IBENSTOCK MOTOR ASSEMBLY PARTS LIST ONLY Page 112 BB4500-BB5000 Operating Manual...

  • Page 129: Igure B-30. Leadscrew Assembly (P/N 28654)

    B-30. L (P/N 28654) IGURE EADSCREW ASSEMBLY P/N 92974, Rev. 1 Page 113...

  • Page 130: Able B-1. Bb5000 Recommended Spare Parts

    HANDLE CRANK MODIFIED Axial Feed- 27015 PIN DOWEL MODIFIED .187 DIA X .75 GROOVED box Assembly 27197 LEAD NUT BB4500 BB5000 AXIAL FEED 92494 SCREW ASSY FEED STOP GEN 2 10191 SCREW 3/8-16 X 1 SHCS 11691 SCREW 1/2-13 X 1-1/2 SHCS...

  • Page 131: Able B-3. Hydraulic Metric Spare Parts

    SCREW 1/2-20 X 2 SSSFP 26850 HANDLE CRANK MODIFIED 27015 SP PIN DOWEL MODIFIED .187 DIA X .75 GROOVED 27197 LEAD NUT BB4500 BB5000 AXIAL FEED 92494 SCREW ASSY FEED STOP GEN 2 27356 NUT 1-5 ACME 7/8 TALL 1-1/2 HEX FINISHED 29207...

  • Page 132: Able B-4. Bb5000 Tool Kit

    BIT TOOL HSS 12MM X 2.5 LH ROUGHING SINGLE 29652 WRENCH HEX 3MM SHORT ARM 55924 WRENCH TEE 3/8 HEX 34116 LABEL ACCESSORY BAG #1 BB5000 33785 WRENCH TORX T-45 14251 WRENCH TEE 3/16 HEX Page 116 BB4500-BB5000 Operating Manual...
  • Page 133 B-4. BB5000 ABLE TOOL KIT ONTINUED Part Description number 29199 WRENCH HEX 1/2 LONG ARM 35516 HAMMER DEAD BLOW 1-3/4 DIA HEAD 29041 WRENCH END 1-1/2 (SINGLE OPEN END) 82949 BAG TOOL 14 X 5.5 X 6 POLYESTER P/N 92974, Rev. 1 Page 117...
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  • Page 135: Appendix Cschematics

    APPENDIX C SCHEMATICS Schematic list C-1. BB4500-BB5000 E 230V 50-60 IGURE IBENSTOCK CONTROLLER ND GEN SCHEMATIC (P/N 88035 C00467) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 C-2.
  • Page 136 C-1. BB4500-BB5000 E 230V 50-60 (P/N 88035 C00467) IGURE IBENSTOCK CONTROLLER ND GEN SCHEMATIC Page 120 BB4500-BB5000 Operating Manual...
  • Page 137 C-2. BB4500-BB5000 E 230V 50-60 (P/N 88036 C00468) IGURE IBENSTOCK CONTROLLER ND GEN HZ DOMESTIC ASSEMBLY P/N 92974, Rev. 1 Page 121...
  • Page 138 C-3. BB4500-BB5000 E 120V (P/N 88037 C00465) IGURE IBENSTOCK CONTROLLER ND GEN DOMESTIC ASSEMBLY Page 122 BB4500-BB5000 Operating Manual...
  • Page 139 C-4. BB4500-BB5000 E 120V CE (P/N 88038 C00466) IGURE IBENSTOCK CONTROLLER ND GEN ASSEMBLY P/N 92974, Rev. 1 Page 123...
  • Page 140 C-5. BB5000 230V 460V (P/N 91811 E00034) IGURE MOTOR FAN ASSEMBLY Page 124 BB4500-BB5000 Operating Manual...
  • Page 141 C-6. BB5000 230VAC 460VAC (P/N 91811 E00048) IGURE SERVO MOTOR POWER CABLE ASSEMBLY P/N 92974, Rev. 1 Page 125...
  • Page 142 C-7. BB5000 E 120V 12AWG (P/N 88649 E00170) IGURE IBENSTOCK MOTOR CABLE ASSEMBLY ND GEN SCHEMATIC Page 126 BB4500-BB5000 Operating Manual...
  • Page 143 C-8. BB5000 E 230V 14AWG (P/N 88650 E00171) IGURE IBENSTOCK MOTOR CABLE ASSEMBLY ND GEN SCHEMATIC P/N 92974, Rev. 1 Page 127...
  • Page 144 C-9. BB5000 E 120V L5-30P (P/N 88652 E00172) IGURE IBENSTOCK POWER CABLE ASSEMBLY ND GEN DOMESTIC PLUG Page 128 BB4500-BB5000 Operating Manual...
  • Page 145 C-10. BB5000 E 120V CE 332P4W (P/N 88653 E00173) IGURE IBENSTOCK POWER CABLE ASSEMBLY ND GEN SLEEVE PLUG P/N 92974, Rev. 1 Page 129...
  • Page 146 C-11. BB5000 E 230V CE CEE7/7 S (P/N 88654 E00174) IGURE IBENSTOCK POWER CABLE ASSEMBLY ND GEN CHUKO PLUG Page 130 BB4500-BB5000 Operating Manual...
  • Page 147 C-12. BB5000 E 230V L6-15P (P/N 88655 E00175) IGURE IBENSTOCK POWER CABLE ASSEMBLY ND GEN DOMESTIC PLUG P/N 92974, Rev. 1 Page 131...
  • Page 148 E-STOP E-STOP START START 1 1 3 3 5 5 SHUTOFF C-13. P (P/N 59248) IGURE NEUMATIC CONDITIONING UNIT SCHEMATIC Page 132 BB4500-BB5000 Operating Manual...
  • Page 149 C-14. BB4500-BB5000 E 230V 50-60 (P/N 88035 B00367) IGURE IBENSTOCK CONTROLLER ND GEN ASSEMBLY P/N 92974, Rev. 1 Page 133...
  • Page 150 C-15. BB4500-BB5000 E 230V 50-60 (P/N 88036 B00368) IGURE IBENSTOCK CONTROLLER ND GEN HZ DOMESTIC ASSEMBLY Page 134 BB4500-BB5000 Operating Manual...
  • Page 151 C-16. BB4500-BB5000 E 120V (P/N 88037 B00365) IGURE IBENSTOCK CONTROLLER ND GEN DOMESTIC ASSEMBLY P/N 92974, Rev. 1 Page 135...
  • Page 152 C-17. BB4500-BB5000 E 120V CE (P/N 88038 B00366) IGURE IBENSTOCK CONTROLLER ND GEN ASSEMBLY Page 136 BB4500-BB5000 Operating Manual...
  • Page 153 C-18. BB5000 460VAC CE (P/N A00099) IGURE SERVO CONTROLLER RD GEN ASSEMBLY P/N 92974, Rev. 1 Page 137...
  • Page 154 C-19. BB5000 E 120V (P/N A00100) IGURE IBENSTOCK CONTROLLER ND GEN DOMESTIC ASSEMBLY Page 138 BB4500-BB5000 Operating Manual...
  • Page 155 C-20. BB5000 (P/N B00024) IGURE SERVO PENDANT ASSEMBLY P/N 92974, Rev. 1 Page 139...
  • Page 156 This page intentionally left blank Page 140 BB4500-BB5000 Operating Manual...

  • Page 157: Appendix Dservo Controls Adjustment

    APPENDIX D SERVO CONTROLS ADJUSTMENT This procedure applies only to the BB5000 servo controls (MR-J3), for the purpose of manually adjusting the parameter in order to reset the motor zero speed. When a new servo amplifier has been installed and the motor does not stop when the speed control knob is turned to zero, do the following: 1.
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  • Page 159: Appendix Esds

    APPENDIX E Contact CLIMAX for the current Safety Data Sheets. P/N 92974, Rev. 1 Page 143...
  • Page 160 This page intentionally left blank Page 144 BB4500-BB5000 Operating Manual...

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