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BB6100 BORING BAR OPERATING MANUAL ORIGINAL INSTRUCTIONS PN: 57017 May 2019 Revision 3...
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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...
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CLIMAX WORLDWIDE LOCATIONS Page B BB6100 Operating Manual...
TABLE OF CONTENTS INTRODUCTION ........................1 Limited Warranty ............................1 Alerts ................................. 2 Safety Precautions ............................. 2 Machine Specific Safety Practices ......................3 Risk Assessment and Hazard Mitigation ....................5 Risk Assessment Checklist ........................6 OVERVIEW ..........................7 About this manual ............................8 2.1.1 Recommended tools ..........................
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Tool carrier maintenance ........................50 Hydraulic power unit and motor ........................ 50 STORAGE ..........................51 Tool kit ..............................51 Spare Parts ..............................53 EXPLODED VIEWS AND PARTS LISTS ................55 SCHEMATICS ........................91 SDS ............................95 Page ii BB6100 Operating Manual...
CLIMAX. About This Manual CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot guarantee that the information contained in this manual is correct for applications other than the application described in this manual. Product specifications are subject to change without notice.
Safety Precautions CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. You, the machine operator, 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 guidelines.
Work Area – Keep the work area around the machine clear of clutter. Keep all cords and hoses away from the work area when operating the machine. Lifting – Many CLIMAX machine components are very heavy. Whenever possible, lift the machine or its components using proper hoisting equipment and rigging.
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To reduce the likelihood of these disorders, follow these guidelines: Use minimum hand grip force Keep wrists straight Avoid exposure to continue vibration Avoid repeated bending of wrists and hands Keep hands and arms warm and dry Page 4 BB6100 Operating Manual...
Risk Assessment and Hazard Mitigation Machine Tools are specifically designed to perform precise material-removal operations. Stationary Machine Tools include lathes and milling machines and are typically found in a machine shop. They are mounted in a fixed location during operation and are considered a complete, self-contained machine.
I checked that all affected personnel understand the danger zone and are clear of it. I evaluated and mitigated any other potential risks specific to my work area. Page 6 BB6100 Operating Manual...
OVERVIEW Machining range from 8.8–38" (224–965 mm) diameter and faces from 7.5–42.1" (191–1,069 mm) are quickly restored to original condition with the CLIMAX BB6100 Portable Boring Machine. This modular machine tool shown in Figure 2-1 is dedicated to on-site restoration of worn internal diameters to precise roundness and dimensional accuracy ready to accept new bearings, sleeves, shafts, or similar mating parts.
About this manual This manual describes the most effective setup and operation of your Model BB6100 Portable Boring Machine. All parts meet CLIMAX’s strict quality standards. For maximum safety and performance, read the entire manual before operating this machine. 2.1.1 Recommended tools CLIMAX includes a general tool kit with the machine.
SETUP Before proceeding with set-up of the BB6100, determine the best placement of each module on the bar. The RDU and tool head assemblies can be located anywhere along the bar. Make sure to allow space for them while planning your set-up.
2. Inspect the bar for nicks or cuts. Dress the bar smooth with a honing stone if necessary. Clean the bar with solvent to remove dirt and chips. A bar with nicks or gouges can severely damage mating parts, including the tool carrier and RDU. Page 16 BB6100 Operating Manual...
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3. Slide the boring bar into the workpiece. 4. Slide the bearing supports onto the ends of the bar. 5. Using a hoist, hold the bar and bearings in the approximate center of the bore. Alignment within 1/8" (3 mm) is sufficient. 1/8”...
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13. For mounting another end-mount bearing support, repeat steps #8 through #10. If using an ID-mount bearing assembly, see Section 3.4 on page 19. CLIMAX recommends no fewer than two support assemblies to obtain adequate machine stability. The maximum recommended unsupported bar length is 5 feet (1.5 m).
3.3.2 Clamping the bearing assembly to the bar Do the following to clamp the bearing assembly to the bar: 1. Remove the screws holding the lock plate. 2. Slide the lock plate away from the lock nut. 3. Rotate the lock nut using both hands until it is snug. This is the zero reference point.
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If using the small plate chuck, do the following before moving on to step 5: a. Screw short or long jacking bolts into the sides of the plate chuck. 3. S IGURE MALL PLATE CHUCK LEFT AND JACKING SCREW RIGHT b.
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Mount the bearing to the chuck body using spring washers, flat washers, and screws. 5. Slide one bearing support assembly onto the boring bar. 6. Position the bearing in the bore. 7. Use a dial indicator to precisely align the boring bar to the bearing. Page 22 BB6100 Operating Manual...
8. Center the bar by evenly adjusting the jacking screws then tighten the hex-head cap screws. 9. Slide the bar and bearing support into the work piece. 10. Using a dial indicator and the jacking screws, center the bar inside the work piece.
The RDU can be placed anywhere along the boring bar. CAUTION The boring bar is not hardened. To prevent damage to the bar, do not strike it against the bearing supports or the work piece. Page 24 BB6100 Operating Manual...
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When mounting the RDU, the slot in the drive hub must align with the lead screw slot in the bar. 6. A IGURE LIGN THE DRIVE HUB SLOT WITH THE LEAD SCREW 1. Inside the torque arms are mounted to (radial direction is optional) RDU housing. 2.
4. Secure the stop rod to a stationary object to engage the feed mechanism. If the axial feed unit is moved to the opposite end of the bar, the feed direction will be reversed. Check the feed direction before operating the machine. Page 26 BB6100 Operating Manual...
WARNING A loose trip rod can cause damage and injury. Secure the trip rod to a fixed object. 3.7.1 Setting feed direction and rate Feed direction and feed rate are set using the feed adjustment knob. Axial feed rate is variable from 0.003–0.020"...
To reduce the rate of feed, pull the plunger and lock in the out position then turn the adjustment knob clockwise. To increase the feed rate, pull the plunger and lock in position then turn the adjustment knob counterclockwise. The feed is adjustable while the machine is running. Page 28 BB6100 Operating Manual...
8. M IGURE INIMUM FEED LEFT AND MAXIMUM FEED RIGHT 3.7.7 Stopping the feed To quickly stop the boring head from feeding, pull the stop rod out of the torque hub on the axial feed unit. This is helpful when cutting up to a shoulder. Mounting the Electric Axial Feed Assembly The electric feed unit consists of the adaptor plate, manual override, electric motor assembly, and remote pendant control.
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Mechanical override assembly Adapter plate Bar end cap NOTICE If the axial feed unit is moved to the opposite end of the bar, the feed direction will reverse. Check feed direction before operating the machine. Page 30 BB6100 Operating Manual...
3.8.1 Setting the Axial Feed Rate The feed potentiometer controls the axial feed rate. Turning the knob counterclockwise decreases the feed rate; turning the knob clockwise increases the feed rate. Axial feed rate is adjustable and variable from 0.010–0.500" (0.25–13 mm) per minute.
Each division in the dial screw resolves in 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.
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BB6100 Micro adjust boring head tool range table 8.8–40.8" (224–1,036 mm) diameter Bore range diameter Number of spacer blocks required 2" (51 mm) 4" (102 mm) 8" (203 mm) block block block 8.8–12.8" (224–325 mm) 12.8–16.8" (325–427 mm) 16.8–20.8" (427–528 mm) 20.8–24.8"...
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BB6100 Solid tooling boring head tool range table 9.7–42.2" (246–1,072 mm) diameter Number of spacer blocks required Bore range diameter 0.75" (19 2" (51 mm) 4" (102 8" (203 mm) mm) block block mm) block block 9.7–12.7" (246–323 mm) 11.2–14.2" (285–361 mm) 13.7–16.7"...
3. Mount the boring head and the counterweight on the stack up blocks. Number Component Stack-up blocks Boring head Tool carrier Counterweight Page 36 BB6100 Operating Manual...
2. Remove the screws on each end of the brass nut. (If there is too much play in the brass nut, the center set screw can be tightened.) 10. R IGURE EMOVING THE BRASS NUT Page 38 BB6100 Operating Manual...
3. Using the previous boring head tool range table, select the required spacers and screws. Clamp all parts tightly to the tool carrier. 4. Grind a 1/2" square HSS tool bit (see following illustration) or install inserted carbide tool holder with insert. Geometry shown is for a left-hand tool.
Range Table and Mechanical Facing Head exploded view drawing to see how the parts fit together). 2. Mount the facing head onto the tool carrier. 3. Secure a sharpened tool bit in the tool carrier. Page 40 BB6100 Operating Manual...
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CAUTION The facing head is operational in only one direction. Check that the bar rotates in the correct direction the tool bit faces appropriately. Number Component Feed trip Facing head Set screws Tool bit Cutting depth setting screw Rotation Tool carrier Boring bar 4.
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The counterweight mounts on the side of the tool carrier opposite of the facing head. The components figure shows spacers for one side only. Use an identical spacer stack for each side. The facing head can bore diameters as small as 23.25" (590.55 mm). Page 42 BB6100 Operating Manual...
3.17 Hydraulic power preparation and connection CAUTION Connect the hydraulic motor to the power unit pump prior to turning on the power unit. Failure to do so will damage the pump and void all warranties. The hydraulic motor mounts to the rotational drive unit. Hydraulic hoses with quick disconnect fittings connect to hydraulic power unit and the hydraulic motor.
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OPERATION Using the remote pendants Operator controls for the machine are located on the remote pendants, described below. CAUTION The bar rotation and the axial feed are independent of each other. Be sure the feed is OFF when the bar is not running. 4.1.1 Feed pendant The following is a description of the feed pendant controls:...
With a socket on the hexagon shaft, run with an electric drill or speed wrench. To re-engage the feed, remove the socket, turn the feed on slow, and shift the feed lever to the forward position. Page 46 BB6100 Operating Manual...
Pre-startup checks Do the following before operating the boring bar: 1. Tie down the RDU torque arms and the axial feed unit stop rod. 2. Use only properly sharpened tool bits. 3. Secure all machine parts, including the bearing assemblies, the tool carrier, and the boring head.
10. Place a wooden support in the bottom of the bore to support the bar. 11. Remove the bearing supports from the work piece. 12. Slide the bar out of the bore using the wooden support. Page 48 BB6100 Operating Manual...
Before operating the boring bar, pump light oil into the oiler in the side of the carrier. Be careful not to damage the scrapers. Before storage, lightly oil all parts to prevent rusting. Hydraulic power unit and motor See the HPU manufacturer’s documentation for information about your HPU and its maintenance. Page 50 BB6100 Operating Manual...
To prevent rusting, spray with a moisture-displacement material such as JET-LUBE 550 for short-term storage, LPS 3 for long-term storage. Store the machine in the container provided. Place desiccant bags or vapor wrap around the machine to absorb moisture. Tool kit 4 . BB6100 (P/N 54262) ABLE TOOL KIT DESCRIPTION...
The following diagrams and parts 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 57017, Rev. 3...
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11. 4- 3.5 ID (P/N 92850) IGURE JAW CHUCK FACE ADJUSTING BEARING ASSEMBLY Page 56 BB6100 Operating Manual...
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12. 4- 3.5 ID (P/N 92850) IGURE JAW CHUCK FACE ADJUSTING BEARING ASSEMBLY PARTS LIST P/N 57017, Rev. 3 Page 57...
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