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Climax BB8100 Operating Manual Original Instructions

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BB8100
BORING MACHINE
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
PN: 57064
June 2019
Revision 5

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  • Page 1 BB8100 BORING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS PN: 57064 June 2019 Revision 5...
  • 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...
  • Page 4 CLIMAX WORLDWIDE LOCATIONS Page B BB8100 Operating Manual...
  • Page 5 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 6 CE INFORMATION Page D BB8100 Operating Manual...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ......................1 ........................1 BOUT THIS MANUAL ....................... 1 AFETY ARNING YMBOLS ........................2 ENERAL AFETY ..................3 ACHINE PECIFIC AFETY RACTICES ................4 SSESSMENT AND AZARD ITIGATION ....................5 SSESSMENT HECKLIST ......................6 NSPECTING THE ACHINE ........................
  • Page 8 General hydraulic system ....................52 Hydraulic motor ........................52 Hydraulic filter and fluid ....................... 52 ........................54 ROUBLESHOOTING STORAGE ........................55 SPECIFICATIONS ......................56 TOOL KIT AND SPARE PARTS ................... 66 EXPLODED VIEWS AND PARTS ................69 Page ii BB8100 Operating Manual...
  • Page 9 SCHEMATICS ......................95 SDS ..........................99 P/N 57064, Rev. 5 Page iii...
  • Page 10 This page is intentionally left blank Page iv BB8100 Operating Manual...

  • Page 11: Introduction

    INTRODUCTION This manual describes how to use the Model BB8100 Portable Boring Bar. This precision machine tool is designed for on-site boring without costly disassembly of equipment. All parts and components meet CLIMAX’s strict quality standards. For maximum safety and performance, read and understand the entire manual before operating the boring bar.

  • Page 12: General Safety

    The primary challenge for most on-site maintenance is that repairs are often done under difficult conditions. CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. As the operator of this machine, you are expected to do your part by closely examining the job site and following the operating procedures outlined in this manual, your own company rules, and local regulations.

  • Page 13: Machine Specific Safety Practices

    Machine Specific Safety Practices All aspects of the machine have been designed with safety in mind. Following are safety practices that you should keep in mind when using the CLIMAX BB8100 Boring Bar Machine. PERSONAL PROTECTIVE EQUIPMENT (PPE) RADIATION HAZARDS...

  • Page 14: 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 Portable Machine Tool and the workpiece as a whole. Page 4 BB8100 Operating Manual...

  • Page 15: Risk Assessment Checklist

    Risk 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 consider. Use these checklists as part of your risk assessment: 1-1.

  • Page 16: Inspecting The Machine

    Inspecting the Machine Your CLIMAX product was inspected and tested prior to shipment, and packaged for normal shipment conditions. CLIMAX does not guarantee the condition of your machine upon delivery. When you receive your CLIMAX product, perform the following receipt checks.

  • Page 17: Basic Components

    Basic Components Figure 1. Components P/N 57064, Rev. 5 Page 7...
  • Page 18 This page is intentionally left blank Page 8 BB8100 Operating Manual...

  • Page 19: Overview

    OVERVIEW Model BB8100 Portable Boring Bar is a moving-head style line-boring machine. The 8" (203 mm) diameter machine will bore 14.5–85.6" (368.3–2,174.2 mm) diameters and face 23.1–97.7" (586.7–2,481.6 mm) diameters. Rotational drive assembly The rotational drive assembly can be positioned anywhere along the bar.

  • Page 20: Hydraulic Power

    (7.6-meter) long hoses and quick disconnect fittings. A multi-function pendant controls the power unit and the machine. Several hydraulic power units are available. Obtain more information by calling CLIMAX. CAUTION To avoid damaging the power unit pump, connect the hydraulic motor to the power unit before plugging in and turning on the power unit.

  • Page 21: Bearing Support Assemblies

    To reverse motor rotation, switch the hydraulic hoses at the motor. The hydraulic fluid that passes through the motor lubricates the motor during operation. Motors with various displacement ratings are available. Contact your CLIMAX sales representative for more information. Bearing support assemblies The portable boring bar can be set up using two ID-mount bearing assemblies, two end- mount bearing assemblies, or a combination of bearing assemblies.

  • Page 22: Id-Mount Non Self-Aligning Bearing Support Assembly (With Spider)

    This will prevent the bar from sliding through the support bearings or falling. To prevent over tightening of the bearings, the clamp collars should be placed above at least two support bearings in a vertical orientation. Figure 9. Clamp collar Page 12 BB8100 Operating Manual...

  • Page 23: Boring Bar And Leadscrew Assembly

    Torque to 100 ft.-lbs. Boring bar and leadscrew assembly Model BB8100 uses an 8" diameter bar. Standard bar lengths are 8 feet to 20 feet (2.44 to 6.10 m) long in 2-foot (.61 m) increments. Bars of other lengths are available upon request.
  • Page 24 Figure 11. Available facing heads and some mounting configurations Refer to Table 5 on page 39, Table 6 on page 40, and Table 7 on page 41 (depending on the travel head size) for the facing range of each. Page 14 BB8100 Operating Manual...

  • Page 25: Setup

    SETUP WARNING Rotating and moving parts can seriously injure the operator. Turn off and lock out the machine before setting it up. Before setting up the portable boring bar, decide where you will place each assembly on the bar. Because the rotational drive and tool head assemblies can be anywhere along the bar, make sure to provide room for them when setting up the machine.

  • Page 26: End-Mount Bearing Support Assembly Setup

    4. Slide the bearing assemblies onto each end of the bar. 5. Using a hoist, hold the bar and bearings near the center of the bore. Alignment should be within 1/8" (3 mm). Figure 13. Attaching bearing assemblies Page 16 BB8100 Operating Manual...
  • Page 27 WARNING Swinging or falling machinery can seriously injure the operator. Securely wrap the hoist around the bar and bearings before lifting the machine. 6. If using existing holes on your workpiece, make sure they align with the slots in the spider. Tap 5/8" (0.63 mm) or 1/2" (13 mm) new holes if necessary. If holes are to be tapped, hold the spider against the work piece and mark the locations of the slots in the spiders.

  • Page 28: Id-Mount Bearing Support Assembly Setup

    6. Using a dial indicator and the jaw crankshafts, center the bar in the work piece. Turn the crankshafts until the jaws are tight in the bore. Do not exceed 22 ft-lbs (30 Nm) of torque. Page 18 BB8100 Operating Manual...
  • Page 29 7. If you wish to mount the rotational drive assembly between the bearing supports, do it now. See “Rotational drive assembly setup” on page 21 for instructions. 8. If mounting another ID-mount bearing, repeat Steps #3 through #7. If mounting an end-mount bearing support assembly, see “End-mount bearing support assembly setup”...
  • Page 30 Setup D Centering block Centering block Extension closest to Extension farthest closest to the center farthest from the the center of the from the center of of the spider center of the spider spider the spider Page 20 BB8100 Operating Manual...

  • Page 31: Rotational Drive Assembly Setup

    Rotational drive assembly setup The rotational drive assembly can be placed anywhere on the boring bar. Figure 16. Rotational drive assembly CAUTION The boring bar is not hardened. To prevent damage, do not strike it against the bearing supports or the work piece. 1.

  • Page 32: Mounting The Axial Feed Assembly To The Bar

    3. Tighten the two mounting bolts into the end cap to secure the feed assembly to the bar. 4. Secure the axial feed unit stop rod to a stationary structure so it will trip the feed mechanism. The rod should be sufficiently free to be removed if necessary. Page 22 BB8100 Operating Manual...

  • Page 33: Attaching The Mechanical Rapid Feed (Optional Equipment)

    Attaching the Mechanical Rapid Feed (optional equipment) The optional mechanical rapid feed attachment fits between the axial feed assembly and the end of the boring bar. It has a side port for a standard 7/16” drill socket, used to rapid advance the feed.
  • Page 34 Electric feed with rapid feed shown below for the BB7000/7100 model. A special adaptor plate allows you to easily connect the electric feed/ mechanical gearbox assembly to CLIMAX 3.5, 5, 6, and 8" (88.9, 127, 152.4, and 203.2 mm) boring bars. Adapters are also available for competitive boring systems.

  • Page 35: Mounting An Optional Electric Axial Feed Assembly

    Mounting an optional electric axial feed assembly The electric feed unit consists of the adaptor plate, manual override, electric motor assembly, and remote pendant control. The axial feed unit can be mounted to either end of the boring bar. The locating nose and hex nut hole of the feed unit fit into the locating nose seat and protruding hex shaft of the boring bar end cap.

  • Page 36: Setting The Axial Feed Rate

    26 for instructions to set the feed to NEUTRAL. If the bar is not moving, see “Setting feed direction when the bar is stopped” on page 26 for instructions to set the feed to NEUTRAL. Page 26 BB8100 Operating Manual...

  • Page 37: Setting The Feed Rate

    3. Replace the stop rod, if necessary. 4. Check that the tooling is not moving. Setting the feed rate Axial feed rate is fully adjustable up to 0.040" (1.016 mm) per revolution. Adjust the feed rate by lifting the spring plunger with one hand and turning the hand wheel with the other.

  • Page 38: To Lock The Tool Carrier On The Bar For Other Operations

    1. Loosen the setscrew on the side of the tool carrier. 2. Tighten or loosen the adjustment screw. 3. Tighten the setscrew to keep the adjustment screw in position. Figure 18. Adjustment and set screws in the tool carrier Page 28 BB8100 Operating Manual...

  • Page 39: To Remove The Brass Nut

    To remove the brass nut 1. Do not remove all the screws. 2. Remove the screws on each corner of the brass nut. 3. If there is too much play in the brass nut, the center set screw can be tightened.

  • Page 40: Micro Adjustment Boring Head

    0.001" (0.025 mm) change in diameter. The dove tail adjustment set screws are set to the correct load by CLIMAX and should not be necessary to re-adjust them. These set screws have Vibratite-VC3 in order to avoid losing tension during vibration.
  • Page 41 Proper maintenance would involve cleaning and lubricating the dove tail surfaces and the dial screw threads and groove, and if the lock set screw feels loose after a while, applying the provided Vibrative vc-3. Table 2. Micro adjust boring head tool range table BB 8100 M ICRO ADJUST BORING HEAD TOOL RANGE TABLE 14.5–85.6"...
  • Page 42 44–52" (1,118–1,321 mm) 49.9–57.9" (1,267–1,471 mm) 55.8–73.8" (1,417–1,875 mm) 61.7–69.7" (1,567–1,770 mm) 67.6–75.6” (1,717–1,920 mm) 73.5–81.5" (1,867–2,070 mm) 79.4–86.6" (2,017–2,200 mm) The tool holder must be shortened to avoid hitting the bar OD at the minimum diameter. Page 32 BB8100 Operating Manual...

  • Page 43: Boring Head Setup

    Boring head setup 1. Select the required parts using the boring head tool range in Table 2 on page 31 and Table 3 on page 2. Using the drawing as a guide, assemble the stack up blocks on to the tool carrier symmetrically on both sides of the tool carrier, from tallest to shortest.

  • Page 44: Facing Head

    Table 5 on page 39, Table 6 on page 40, and Table 7 on page 41 depending on the travel head size. 5. Mount the spacers, if necessary, to the tool carrier. CLIMAX recommends using the same number of spacers on both sides of the tool carrier to ensure smooth tool travel.

  • Page 45: Facing Head Radial Feed

    Figure 22. Facing head mounted directly to the tool Figure 23. Facing head mounted with spacers to the carrier tool carrier The facing head may mount directly to the tool carrier, or with spacers from the boring head stack blocks as shown above. Facing head radial feed Radial feed is either manual or automatic.
  • Page 46 Figure 25. Facing head Figure 26. Facing head directly Figure 27. Facing head mounted on directly mounted with mounted with feed engagement spacers with feed box crank attached straight crank handle knob attached attached Page 36 BB8100 Operating Manual...
  • Page 47 NOTE CLIMAX recommends a maximum trip of 15 To set the radial feed rate to less than 0.008" (0.2 mm) per revolution, move the trip mechanism away from the center of the radial feed box. To increase the feed rate, move the trip mechanism toward the center of the radial feed box.
  • Page 48 (feed is radially out to in). NOTICE The trip arm must be facing away from the boring bar when directly mounted to the tool carrier to ensure clearance for the boring bar. Figure 30. Feed trip arm and bar rotation Page 38 BB8100 Operating Manual...
  • Page 49 Table 5 shows the facing range for the 5" (127 mm) travel head (P/N 21115). Table 5. Facing Range for the 5" (127 mm) travel head (P/N 21115) UMBER OF BLOCKS REQUIRED FOR THE THICKNESS SHOWN 4.5" (114 ANGE ) SHCS 2.95"...
  • Page 50 (678.18–1,084.58 mm) 32.6--48.6" (828.04–1,234.44 mm) 38.5--54.5" (977.9–1,384.3 mm) 44.4--60.4" (1,127.76–1,534.16 mm) 50.3--66.3" (1,277.62–1,684.02 mm) 56.2--72.2" (1,427.48–1,833.88 mm) 62.1--78.1" (1,577.34–1,983.74 mm) NOTICE The facing ranges shown for these tables are calculated with the tool feed radially out. Page 40 BB8100 Operating Manual...
  • Page 51 Table 7 shows the facing range for the 12" (305 mm) travel head (P/N 22359). Table 7. Facing range for the 12" (305 mm) travel head (P/N 22359) UMBER OF BLOCKS REQUIRED FOR THE THICKNESS SHOWN 4.5" (114 ANGE ) SHCS 2.95"...

  • Page 52: Installing The Facing Slide Arm Onto The Tool Carrier

    The rotating lifting eyes provide the flexibility and safety during setup operations. 2. Secure arm with the clamp bars (P/N 54551) with 3/4-16 x 2 screws (P/N 28757) – four per clamp bar and torque to 100 ft-lbs (135 Nm). Page 42 BB8100 Operating Manual...

  • Page 53: Adjusting The Tool Carrier For Perpendicularity

    DANGER Failure to properly torque the four 3/4-16 x 2 SHCS (P/N 28757) to 150 ft-lb (210 Nm) can result in unexpected slippage of the tool arm which can result in injury or be fatal. Adjusting the tool carrier for perpendicularity The tool carrier is equipped with four set screws that allow you to adjust the slide arm...

  • Page 54: Hydraulic Power Preparation And Connection

    5. Adjust the speed of the bar rotation by pressing the HIGH/LOW VOLUME CONTROL button on the pendant. CAUTION To avoid damaging the pump and voiding the warranty, connect the hydraulic motor to the power unit pump before turning on the power unit. Page 44 BB8100 Operating Manual...

  • Page 55: Operation

    OPERATION Pre-start checks WARNING Rotating machinery can cause serious injury. Turn off and lock out power before making pre-start checks. Before operating the portable boring bar 1. Tie down the rotational drive unit torque arms and the axial feed unit stop rod. 2.

  • Page 56: Using The Remote Pendants

    Damage to the cutter, the boring machine and your work piece may occur if the bar rotation is stopped while the power feed is engaged and the cutting tool is in contact with the workpiece. Page 46 BB8100 Operating Manual...

  • Page 57: Hpu Pendant

    HPU pendant Additional information about the HPU function, construction, and maintenance schedule can be found in the HPU manual. Feature Description Run/Jog Runs or jogs the hydraulic power unit. Increases or decreases the rotational speed. Bar Off Turns off the hydraulic power unit. (red) Bar On Turns on the hydraulic power unit.

  • Page 58: Starting The Machine

    In case of emergency press POWER UNIT OFF on the control pendant. 1. Press at the pendant to stop the power unit. POWER UNIT OFF 2. After all parts of the machine has stopped, use a brush to remove chips. Page 48 BB8100 Operating Manual...

  • Page 59: Repetitive Machining

    WARNING To avoid serious personal injury from flying chips, do not use compressed air to remove chips. 3. If you will be machining the work piece again, see “Repetitive machining”. If you are done machining, see “Disassembly”. Repetitive machining 1. Reverse the tool head feed direction. 2.

  • Page 60: Alternative Disassembly

    13. Loosen the taper bore adapters in the bearings. 14. Place a clean wooden “crib” in the bottom of the bore. 15. Remove the bearing supports from the workpiece. 16. Slide the bar out of the bore using the crib. Page 50 BB8100 Operating Manual...

  • Page 61: Maintenance

    MAINTENANCE Recommended lubricants LUBRICANT BRAND WHERE USED Gear grease UNOBA EP #0 Bearing cartridges Rotation drive oil Mobil SHC 634 Synthetic Gear box cone drives Light oil LPS 2 Unpainted surfaces Cutting oil UNOCAL KOOLKUT Tool bits, work piece Way oil Mobil VACTRA Heavy-Medium Way Oil Dovetail ways Hydraulic oil...

  • Page 62: Bearing Support Assembly

    “Hydraulic filter and fluid” on page 52. Hydraulic filter and fluid Though the hydraulic power unit requires little maintenance, changing the filter and fluid is required for proper operation. Initially, change the filter after 72 hours of operation to remove Page 52 BB8100 Operating Manual...
  • Page 63 impurities from the system. From then on, replace the filter every 150-200 hours. Use a high- quality 10-micron industrial-grade filter. If the filtering system has a change-warning gage, replace the filter whenever the gage indicates. Clean hydraulic fluid will help keep the power unit and motor running properly.

  • Page 64: Troubleshooting

    Check hydraulic connections for plugs or leaks. Check that the power unit and electrical supply are compatible. Hydraulic power unit motor does not run Check that the power unit is plugged in. Check for faulty wiring. Page 54 BB8100 Operating Manual...

  • Page 65: Storage

    STORAGE Proper storage of Model BB8100 Portable Boring Bar will prevent undue deterioration or damage of the machine. 1. Before storing, wipe the machine down with solvent to remove grease, metal chips, and moisture. 2. To prevent rusting, spray with a moisture-displacement material such as Jet- Lube 550 for short-term storage, LPS 3 for long-term storage.

  • Page 66: Specifications

    SPECIFICATIONS Page 56 BB8100 Operating Manual...
  • Page 67 Figure 35. Dimensions of the self-aligning bearing assembly without spider Figure 36. Dimensions of the non-aligning bearing assembly without spider P/N 57064, Rev. 5 Page 57...
  • Page 68 Page 58 BB8100 Operating Manual...
  • Page 69 P/N 57064, Rev. 5 Page 59...
  • Page 70 Page 60 BB8100 Operating Manual...
  • Page 71 P/N 57064, Rev. 5 Page 61...
  • Page 72 Page 62 BB8100 Operating Manual...
  • Page 73 P/N 57064, Rev. 5 Page 63...
  • Page 74 Page 64 BB8100 Operating Manual...
  • Page 75 P/N 57064, Rev. 5 Page 65...

  • Page 76: Tool Kit And Spare Parts

    WRENCH HEX SET 5/64 TO 3/4 15 PIECES Piece 40708 CLAMP COLLAR 8 ID TWO PIECE W/ SET SCREWS Piece 57064 MANUAL INSTRUCTION BB8100 Piece 71726 SP (PLM) - WRENCH TENTHSET DEPTH ADJUSTING SIZE 10 Piece 71727 WRENCH TENTHSET COMPRESSION ADJUSTING SIZE 10...
  • Page 77 PART NO. DESCRIPTION WHERE USED 17449 8" Jaw 17700 Screw 5/8-18 x 5-1/2 SHCS 11823 Thrust washer 10538 Thrust bearing 10858 Gear worm 17447 Crank shaft 10217 3/16 square key 14274 Thrust Washer 13174 Thrust bearing 17508 Worm nut 17520 Screw assembly jam feed 21053 Thrust washer...
  • Page 78 Mechanical Unit Axial feed assembly Electric Unit 14303 Stop rod 17825 Carrier nut 10453 Screw 3/8-16 x 1-1/4 SHCS 17864 Carrier key Tool carrier 10191 Screw 3/8-16 x 1 SHCS 11678 Screw 10-32 x 3/8 BHSCS Page 68 BB8100 Operating Manual...

  • Page 79: Exploded Views And Parts

    The following diagrams and parts lists are for your reference purposes only. The machine Limited Warranty is void if the machine has been tampered with by anyone who has not been authorized in writing by CLIMAX to perform service on the machine. P/N 57064, Rev. 5...
  • Page 80 Page 70 BB8100 Operating Manual...
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  • Page 105 SCHEMATICS P/N 57064, Rev. 5 Page 95...
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  • Page 109 Contact CLIMAX for the current Safety Data Sheets. P/N 57064, Rev. 5 Page 99...
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