1. Manuals
  2. Brands
  3. Climax Manuals
  4. Welding System
  5. BW2600
  6. Operating manual

Climax BW2600 Operating Manual

Autoborewelder
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
BW2600
AUTOBOREWELDER
BW2600 OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 85555
January 2019
Revision 6

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BW2600 and is the answer not in the manual?

Questions and answers

Related Manuals for Climax BW2600

Summary of Contents for Climax BW2600

  • Page 1 BW2600 AUTOBOREWELDER BW2600 OPERATING MANUAL ORIGINAL INSTRUCTIONS P/N 85555 January 2019 Revision 6...
  • 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 BW2600 Operating Manual...
  • Page 5 CE DOCUMENTATION P/N 85555, Rev. 6 Page C...
  • Page 6 CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has been performed properly. This warranty is available to the customer purchasing parts or labor for a period of 90 days after delivery of the part or repaired machine or 180 days on used machines and components.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS HAPTER ECTION 1 INTRODUCTION ............1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 OW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...
  • Page 8 Short-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73 Page ii BW2600 Operating Manual...
  • Page 9 TABLE OF CONTENTS (CONTINUED) HAPTER ECTION 6.1.2 Long-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73 HIPPING APPENDIX A...
  • Page 10 This page intentionally left blank Page iv BW2600 Operating Manual...
  • Page 11 3-6 BW2600 and radial mount on mounting rod ....... . .
  • Page 12 6-1 BW2600 Shipping container with components packed ........
  • Page 13 LIST OF FIGURES (CONTINUED) IGURE B-5 Power entry module assembly (P/N 86514) ..........102 B-6 Power and control harness assembly (P/N 86516).
  • Page 14 This page intentionally left blank Page viii BW2600 Operating Manual...
  • Page 15 2-1 BW2600 front panel controls ........
  • Page 16 This page intentionally left blank Page x BW2600 Operating Manual...

  • Page 17: Introduction

    ABEL LOCATIONS OW TO USE THIS MANUAL This manual describes the setup, operation, maintenance, storage, shipping, and decommissioning of the BW2600 bore welding machine. NOTICE For maximum safety and performance, read this entire manual before attempting to set up or operate the machine.

  • Page 18: General Safety Precautions

    ENERAL SAFETY PRECAUTIONS CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a joint effort. You must do your part by: • Being aware of your work environment •...

  • Page 19: Machine - Specific Safety Precautions

    All persons in the area of the machine need to have proper shielding from the radiation produced while welding. Moving parts – Many CLIMAX machines have numerous exposed moving parts and interfaces that can cause severe impact, pinching, cutting, and other injuries.

  • Page 20: Risk Assessment And Hazard Mitigation

    Due to the unique nature of welding tool applications, identi- fying one or more hazards that must be addressed is typical. When performing the on-site risk assessment, it is important to consider the portable welding tool and the workpiece as a whole. Page 4 BW2600 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 be considering.

  • Page 22: Labels

    ABELS Table 1-4 shows the labels that should be on your machine. If any are defaced or missing, contact CLIMAX immediately for replacements. 1-4. L ABLE ABELS 37576 P/N 29154 Warning label: electri- Serial number plate cal shock danger 46902...
  • Page 23 1-4. L ABLE ABELS P/N 86158 P/N 90487 BW2600 label Run position label P/N 90627 Step indicator label P/N 85555, Rev. 6 Page 7...

  • Page 24: Label Locations

    ABEL LOCATIONS The following figures display the location of labels on each component of the BW2600 by part number. For further identification of label placement refer to Appendix A on page 75. 1-1. T IGURE OP LABEL LOCATIONS Label P/N: 86036, 86158, 90487, 90627 1-2.
  • Page 25 1-3. S IGURE IDE LABEL LOCATIONS Label P/N: 46902, 90487 P/N 85555, Rev. 6 Page 9...
  • Page 26 This page intentionally left blank Page 10 BW2600 Operating Manual...

  • Page 27: Overview

    CLIMAX for assistance. EATURES AND COMPONENTS The BW2600 is a feature-rich bore welder based on the BW1000 architecture and provides some BW3000 features. The BW2600 can weld bores between the range of 0.87–5" (22–127 mm) with the full range of torches.
  • Page 28 Reversible rotation (described on page 15) • Axial adjustment (described on page 13) AXIAL FEED KNOB DRAG BRAKE ADJUSTMENT AXIAL FEED KNOB POSITION LABEL STEP ADJUSTMENT KNOB STEP AMOUNT INDICATOR 2-1. BW2600 IGURE CONTROLS AND COMPONENTS Page 12 BW2600 Operating Manual...

  • Page 29: Features

    FILL STOP/ START welding in the cam detent opening. It is typically used for 2-2. BW2600 S IGURE KIP OR FILL CONTROLS buildup in worn areas. See Section 4.6 on page 58 for how to set the detent for the feature.
  • Page 30 Feed engage/disengage The BW2600 only feeds by retract- ing the spindle. STEP AMOUNT Pushing in the axial feed knob INDICATOR towards the housing disengages the feed and allows free movement of the spindle. Pulling out the axial feed knob away from the housing engages the feed.:...
  • Page 31 PENDANT KNOB PORT CLIMAX manufactures many interface kits for use with world- wide suppliers of MIG welding units. The customer’s wire feed system connects to the BW2600 WIRE FEED WIRE FEED POWER POWER CONTACTOR at the wire feed contactor control...

  • Page 32: Stock Components

    ADIAL MOUNT system, enabling infinite rota- tional placement of the bore welder for clearance in tight spaces. The BW2600 radial mount also provides the means to use the adjustable base and the BW3000 radial mounts. Page 16 BW2600 Operating Manual...
  • Page 33 Swivel head assembly (P/N 35603) Designed for use with multiple torch heads, this ball-and-seat device performs the following functions: • Provides a fine diame- 2-8. S IGURE WIVEL HEAD ASSEMBLY ter adjustment for torches • Acts as a conductive path for weld current •...

  • Page 34: Accessories

    2-13. D BW2600 IGURE ETAIL OF CARRYING CASE 2.1.3 Accessories Accessories are not included with the basic BW2600 but are available for purchase. Contact CLIMAX for more information. Page 18 BW2600 Operating Manual...
  • Page 35 SHOWN WITH SWIVEL INSTALLED Remote operator pendant The remote operator pendant allows for control of the BW2600 while in close proximity to the weld process. The pendant allows the operator to control a limited number of bore welder functions. See Section 2.2...
  • Page 36 2-17. C IGURE OMPACT FACE TORCH The standard face torch is used with the adjustable base. Both face torches have a range of 1–20" (25–508 mm). 2-18. S IGURE TANDARD FACE TORCH Page 20 BW2600 Operating Manual...
  • Page 37 Adjustable base (P/N 29037) The adjustable base provides support, leveling, and centering adjustments for the BW2600. This is generally required when a boring bar interface is not available. The nonmagnetic base provides safe attachment and can be used on a variety of uneven surfaces.
  • Page 38 18-inch extension (P/N 29065) Extensions allow the torch and swivel mechanism to be installed farther away from the BW2600, providing greater reach. When reaching over 39" (991 mm), consider the use of the torch extension support kit (P/N 40877). Torch extension support kit (P/N...

  • Page 39: Controls

    ONTROLS This section explains control locations and functions. 2-23. BW2600 IGURE FRONT PANEL CONTROLS 2-1. BW2600 ABLE FRONT PANEL CONTROLS Item Control Action Purpose Notes Starts rotation and trig- Contactor control with power Starts and stops the bore MAIN ON...
  • Page 40 SKIP stop-start sections. rotation continues. Sets up to 180° of bore Welds within the cam detent The BW2600 must rotate fully to SKIP FILL to skip or fill, anywhere (fill) or outside the cam detent provide mechanical step, or else CAMS skip/fill is not applicable.

  • Page 41: Machine Specifications

    ACHINE SPECIFICATIONS Figure 2-25 shows the bore welder dimensions in inches. 2-25. BW2600 IGURE DIMENSIONS Machine specifications for the BW2600 are listed in Table 2-3. 2-3. BW2600 ABLE SPECIFICATIONS Welding process metal inert gas (MIG) Wire diameter range .030–.045"...

  • Page 42: Items Required But Not Supplied

    #0 Torch 28448 1.7–3.0" (46–76 mm) TEMS REQUIRED BUT NOT SUPPLIED The following items are required but not supplied in your CLIMAX product kit: • Wire feeder with burnback control • Welding power supply with 200-ampere minimum and 100% duty cycle •...

  • Page 43: Setup

    REPARING THE MACHINE FOR USE 3.1.1 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: 1.

  • Page 44: Assessing The Work Area

    NSTALLING THE BORE WELDER This section outlines the steps needed to get the BW2600 set up and ready to weld. The bore welder may be used in any position with the boring bar interface or the adjustable base.

  • Page 45: Mounting To A Boring Bar

    NOTICE The procedure for vertical bore welding is similar to the horizontal bore welding installation, with the addition of a locking collar to prevent the bore welder from slipping on the mounting rod. 3.3.1 Mounting to a boring bar BORE WELDER ADAPTER PLATE WELD HEAD SUPPORT ROD BORE WELDER...
  • Page 46 6. Remove the alignment tool. 7. Remove the boring bar. 8. Remove the cartridge bearing with the bearing removal tool. 9. Complete the final tightening on the bore welder adapter plate clamp. Page 30 BW2600 Operating Manual...

  • Page 47: Installing The Bore Welder Onto The Mounting Rod

    Installing the bore welder onto the mounting rod Do the following to install the bore welder onto the mounting rod: MOUNTING ROD 1. Slide the BW2600 radial mount over the nose col- BW2600 lar of the weld head RADIAL MOUNT...

  • Page 48: Installing The Torch And Torch Extensions

    2. Slide the BW2600 and radial mount halfway down the mounting rod (see Figure 3-6). 3. Hand-tighten the clamp to the mounting rod. 3-6. BW2600 IGURE AND RADIAL MOUNT ON MOUNTING ROD 3.3.1.2 Installing the torch and torch extensions Do the following to install the torch and torch extensions: 1.
  • Page 49 2. Assemble the torch and JAM NUT swivel assembly by doing the following: a) If liner is in the torch, insert the SWIVEL liner extending from ASSEMBLY the torch into the swivel assembly. TORCH b) Screw on the torch approximately half- way, or until the liner is flush with 3-7.
  • Page 50 Secure the liner with 3-9. J IGURE AM NUT TIGHTENED the set screw. f) Check that the liner is visible through the diffuser gas holes (see Figure 3-10). 3-10. L IGURE INER THROUGH DIFFUSER GAS HOLES Page 34 BW2600 Operating Manual...

  • Page 51: Setting The Bore Welder Stroke

    3. Install the extensions, torch, and swivel assem- bly onto the BW2600. 4. Check that all the connec- tions are tight in order to obtain good electrical 6 & 12 INCH TORCH EXTENSIO contact and gas seal. SWIVEL ASSEMBLY TORCH ADAPTER TORCH 3-11.

  • Page 52: Centering The Bore Welder

    Centering the bore welder Do the following to center the bore welder: 1. Connect the BW2600 to AC mains power with the provided power cord. 2. Rotate the bore welder spindle by connecting the AC mains cable (but not the wire feeder cable) and using the...
  • Page 53 3. Check the 3 o’clock and 9 o’clock positions (see Figure 3-14) using the torch as a guide, and “swing” the bore welder on the mounting rod to attain center (see Figure 3-15). 3-14. 3 ’ ’ IGURE CLOCK AND CLOCK POSITIONS 3-15.

  • Page 54: Installing The Bore Welder With An Adjustable Base

    3.3.2 Installing the bore welder with an adjustable base Do the following to install the BW2600 on the workpiece with an adjustable base: 1. Weld the mounting bolt of suitable length to a position approximately 11" (279 mm) from the center of the bore to be welded.
  • Page 55 The four spring washers and nut included with the adjustable base should be placed over the 0.5" (12 mm) bolt and finger tightened, plus a half turn with a wrench. See Figure 3-17. 3-17. A IGURE SSEMBLY ON ADJUSTABLE BASE 4.
  • Page 56 If a longer mounting rod is required, use the mounting rod extender to increase the length of the mounting rod without affecting stiffness. 6. Install the BW2600 onto the radial mount. 7. Attach the extensions to the BW2600 and reach through the hole to be welded for quick adjustment of the base (see Figure 3-19).

  • Page 57: Adjusting For Parallelism

    3.3.2.1 Adjusting for parallelism Do the following to adjust for parallelism: 1. For axis-to-bore alignment, swing the BW2600 over until the extension is close to the 3 o’clock or 9 o’clock position. 2. Adjust the two forward lev- eling jacks as a pair, while...

  • Page 58: Finishing The Installation

    4. Tighten the 0.5" (12.7 mm) hold-down nut to a torque of 15 ft-lb (20 Nm). 3.3.2.2 Achieving concentricity Do the following to achieve concentricity: 1. Articulate the BW2600 and extension to the approxi- mate bore center and lock the articulation joint (see Figure 3-22).
  • Page 59 2. Connect the power cord to the BW2600 (see Figure 3- 23). 3-23. P IGURE OWER CORD CONNECTION 3. Connect the wire feed con- duit to the BW2600 (see Figure 3-24) and tighten the set screw. 3-24. W IGURE IRE FEED CONDUIT CONNECTED P/N 85555, Rev.
  • Page 60 4. Connect the wire feed con- trol cable to the BW2600 (Figure 3-25). 3-25. W IGURE IRE FEED CONTROL CABLE CONNECTED 5. Connect the wire feed con- duit to the wire feeder (see Figure 3-26). 3-26. W IGURE IRE FEED CONDUIT CONNECTION 6.
  • Page 61 9. Once wire has exited the torch, clip the excess wire. NOTICE If there are issues feeding wire through the torch system, remove the torch system from the BW2600 and manually feed wire through the torch system. Then reinstall the torch onto the machine.

  • Page 62: Installing Accessories

    Setup of optional accessories are described in the following sections. 3.4.1 Standard torch adapter The standard torch adapter is designed to utilize standard CLIMAX BW3000 torches. Do the following to use the standard torch adapter: 1. Install the standard torch adapter onto the swivel.

  • Page 63: Torch #00 And #0

    Because these torches have non-insulated nozzles, clearance between the nozzle and the workpiece is crucial. If it is necessary to feed the wire through the BW2600 and swivel assembly with the torch detached, push the wire through the torch with pliers, and then re-attach the torch to the swivel head.

  • Page 64: Torch Extension Support Kit

    3.4.3 Torch extension support kit The torch extension support kit is ideal when the distance from the bore welder to the torch is great enough to make torch stability uncertain and alignment difficult. Page 48 BW2600 Operating Manual...
  • Page 65 Do the following to set up the torch extension support kit. 1. Slip the support body over an extension near the bore to be welded, at a position where the exten- sion support rod may be clamped or tack welded to provide support.
  • Page 66 This page intentionally left blank Page 50 BW2600 Operating Manual...

  • Page 67: Operation

    - - - - - - - - - - - - - - - - - - - - - - - - - -61 ELDING ON THE VERTICAL DOWNSIDE PERATION MODES The BW2600 is capable of welding any cylindrical workpiece, including bores, faces, and outsider diameters. Operation modes include: •...

  • Page 68: Principles Of Operation

    To avoid serious personal injury, keep clear of moving machinery during operation. The BW2600 often is used in dangerous locations (such as in elevated positions or near other operating equipment). The operator must perform a site-specific risk assessment (Section 4.3 and Section 1.6 on page 5) for each job before starting work.

  • Page 69: Preparing The Bore Welder For Welding

    REPARING THE BORE WELDER FOR WELDING 4.4.1 Setting the rotation speed Do the following to set the rotation speed: 1. Set the rotation speed of the torch to the desired linear travel speed along the bore surface. 2. Use Table 4-1 for approximate adjustments. 3.

  • Page 70: Setting The Wire Speed

    KNOB pendant. CAUTION Failure to disconnect the control cable in WIREFEED step 2 could result in CONTACTOR CONTACTOR unwanted weld CONTROL PORT activity. 4-1. C IGURE ONTROLS FOR CHECKING THE STEP SETTING Page 54 BW2600 Operating Manual...

  • Page 71: Attaching The Weld Ground Clamp

    4. Measure the length of feed in one rotation and set the STEP OPERATOR ADJUSTMENT ADJUSTMENT PENDANT PENDANT step knob to provide an KNOB PORT axial movement of 1/8". NOTICE Adjustments to step size and wire speed are necessary to attain the desired buildup.

  • Page 72: Welding

    #3 safety eyeglasses. This combination allows the operator to adjust the control while being protected from flash burn by the glasses. View the arc through the combination of the hand-held shield and the glasses, to observe accurate definition of wire location. Page 56 BW2600 Operating Manual...

  • Page 73: Weld Interrupt Options

    SKIP 8. Re-check the disc settings by rotating the spindle through the “interrupt” zone in the welding rotation direction. Filling oblong sections of the bore The BW2600 is capable of correcting moderately oblong bores. P/N 85555, Rev. 6 Page 57...

  • Page 74: Elding Pointers

    8. Re-check the disc settings by rotating the spindle through the “interrupt” zone in the welding rotation direction. NOTICE The BW2600 is limited in its capability of fixing oblong bores, as it must rotate 360°. Manual interrupt over grease holes...

  • Page 75: Using 0.035" Wire

    4.6.4 Wire and gas The BW2600 is designed for solid steel wire using the MIG welding process. The length of time that the bore welder may be used continuously depends on spatter build-up in the welding nozzle. When deciding the type of wire, gas, and power supply to use, select a combination that produces the smoothest arc action.

  • Page 76: Spindle Feed And Wire Location

    4.6.6.1 Welding on the vertical upside The BW2600 has no difficulty with lower and overhead (that is, 6 and 12 o’clock) positions of the bore. When the torch is welding in the vertical upside (the 9 o’clock position of the bore), the weld tends to run downward.

  • Page 77: If Welding Current Is Too High

    Do not increase gas flow. Instead, quickly solidify the weld metal in place with the following options (combine if necessary): • Speeding up the BW2600's rotational speed • Decreasing the welding current • Using a smaller wire size Another related problem is the arc playing on the molten metal rather than on the base metal, resulting in a lack of fusion to the base metal.
  • Page 78 This page intentionally left blank Page 62 BW2600 Operating Manual...

  • Page 79: Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING 5.1 O - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -63 VERVIEW 5.2 M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -64...

  • Page 80: Maintenance Intervals

    These parts require smooth surfaces for a gas seal. If it becomes difficult to insert the conduit into the BW2600, the O-ring may be dry or badly worn. If worn, replace with CLIMAX P/N 36379. It may be helpful to apply a small amount of O-ring grease to the ring, though the unit is shipped with a lubricated O-ring.

  • Page 81: Troubleshooting

    This procedure is helpful in assuring consistent wire feeding. Be careful not to over-tighten the setscrews that secure the liner. ROUBLESHOOTING This section is intended to help solve basic machine performance problems. Contact CLIMAX for serious maintenance or for questions on the following procedures. 5.5.1 If the feed will not work The feed will not work under the following conditions: •...

  • Page 82: If Weld Beads Are "Ropey

    / or interruption of continuous welding. The usual cause for too much spatter is that the arc voltage is too high. The arc should have an even sound that is not violent. A setting of 15.5–18 volts is normal. Page 66 BW2600 Operating Manual...

  • Page 83: If The Weld Is Porous

    5.5.6.2 Dirty bore surface Although the BW2600 usually handles these problems well, excessive oil or other organic compounds could cause porosity. These may be on the surface or embedded in crevices or grease holes. A thorough cleaning should be done prior to welding;...

  • Page 84: If Steel Weld Deposits Are Too Hard To Machine

    2. Position the wire conduit in such a way that the conduit makes only one continuous curve. The conduit should begin curving at its attachment point on top of the BW2600 and continue this curve for about 270°, then straighten out as it heads toward the wire feeder. This method works partic- ularly well with long conduits.

  • Page 85: If The Weld Voltage Is Hard To Control

    During the remainder of the buildup operation, graping should not be experienced within the current limits of the BW2600. If graping is experienced during the remainder of the buildup operation, the weld current probably is too high or the travel speed is too slow.

  • Page 86: Decommissioning

    While performing the buildups, the operator may vary each of the parameters to measure the effect on the buildup operation. Experimentation is a key element to building proficiency. ECOMMISSIONING To decommission the BW2600 before disposal, dispose or recycle machine parts according to local regulations. Page 70 BW2600 Operating Manual...

  • Page 87: Tool Kit

    WRENCH OPEN END 3/4 X 6.0 LONG 66861 WRENCH OPEN END 11/16 X 6-3/8 LONG 66862 WRENCH HEX L-KEY 1/8 X 2-5/16 LONG 67082 GLOVES WELDING CLIMAX BRANDED SIZE LARGE 67337 LUBRICANT 3 OZ WD-40 70176 CONSUMABLE PACKAGE BW1000 .035/.9MM TIPS (KB) 85555 MANUAL INSTRUCTION BW2600 P/N 85555, Rev.
  • Page 88 This page intentionally left blank Page 72 BW2600 Operating Manual...

  • Page 89: Storage And Shipping

    HIPPING TORAGE Proper storage of the BW2600 will extend its usefulness and prevent undue damage. Store the BW2600 in its original shipping container. Keep all packing materials for repackaging the machine. 6.1.1 Short-term storage Short term storage is defined as less than or equal to three months. For short-term storage: 1.
  • Page 90 TORCH EXTENSION 3" SWIVEL ASSEMBLY TORCH ADAPTER COLLAR CLAMP WELD HEAD ASSEMBLY TORCH EXTENSION 6" WELD HEAD SUPPORT ROD TORCH EXTENSION 12" ADJUSTABLE BASE ASSEMBLY PELICAN CASE 6-1. BW2600 S IGURE HIPPING CONTAINER WITH COMPONENTS PACKED Page 74 BW2600 Operating Manual...

  • Page 91: Appendix Aexploded Views And Parts Lists

    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 85555, Rev. 6 Page 75...

  • Page 92: Igure A-1. Bw2600 Assembly (P/N 91579)

    A-1. BW2600 (P/N 91579) IGURE ASSEMBLY Page 76 BW2600 Operating Manual...

  • Page 93: Igure A-2. Bw2600 Assembly Parts List 1 (P/N 91579)

    A-2. BW2600 1 (P/N 91579) IGURE ASSEMBLY PARTS LIST P/N 85555, Rev. 6 Page 77...

  • Page 94: Igure A-3. Bw2600 Assembly Parts List 2 (P/N 91579)

    A-3. BW2600 2 (P/N 91579) IGURE ASSEMBLY PARTS LIST Page 78 BW2600 Operating Manual...
  • Page 95 This page intentionally left blank P/N 85555, Rev. 6 Page 79...

  • Page 96: Igure A-4. Step Positioner Assembly (P/N 90590)

    A-4. S (P/N 90590) IGURE TEP POSITIONER ASSEMBLY Page 80 BW2600 Operating Manual...

  • Page 97: Igure A-5. Step Positioner Assembly Parts List (P/N 90590)

    A-5. S (P/N 90590) IGURE TEP POSITIONER ASSEMBLY PARTS LIST P/N 85555, Rev. 6 Page 81...

  • Page 98: Igure A-6. Radial Isolation Mount Assembly (P/N 85771)

    WASHER 1/2 FLTW SAE PLAIN FINISH 39179 SCREW 1/2-13 X 2 HHHCS GRADE 8 85769 MOUNT RADIAL 85770 SLEEVE MOUNT RADIAL ISOLATION 85773 SCREW 1/2-13 X 3-1/4 HHCS A-6. R (P/N 85771) IGURE ADIAL ISOLATION MOUNT ASSEMBLY Page 82 BW2600 Operating Manual...

  • Page 99: Igure A-7. Pelican Case Assembly (P/N 85771)

    CONDUIT ASSY TORCH HEAD PENDANT TORCH BODIES FOAM INSERTS BW2600 TUBE EXTENSIONS SLIDER BASE UNIT PELICAN CASE A-7. P (P/N 85771) IGURE ELICAN CASE ASSEMBLY P/N 85555, Rev. 6 Page 83...

  • Page 100: Igure A-8. Base Unit And Pelican Case Assembly (P/N 85824)

    SUPPORT ROD WELD HEAD 63596 CLAMP COLLAR 1 ID X 1-3/4 OD X 1/2 WIDE ONE PIECE 84425 ASSY WELD HEAD BW2600 120/220VAC CE 85731 CASE PELICAN ALL WEATHER B/BW2600 CUSTOM FOAM 1620NL 85771 SUB ASSY MOUNT RADIAL ISOLATION A-8. B (P/N 85824)
  • Page 101 SOCKET LOCATION 67482 POSITIONS 1 & 4 PLUG LOCATION 12941 POSITIONS 2 & 3 PARTS LIST ITEM P/N: DESCRIPTION 67057 CONNECTOR PLUG 11-4 METAL SHELL 67060 CABLE CLAMP LARGE SIZE 11 67280 CABLE POWER 2 CONDUCTOR 18 AWG 300 VAC RUBBER JACKET BLACK 67482 CONTACT SOCKET AWG 18-16 CRIMP 67734...
  • Page 102 67403 TERMINAL SNAP-PLUG MALE 22-18AWG HEAT-SHRINK 79219 SCREW M4 X 0.7 X 8MM BHSCS 85396 CONTACTOR BW2600 BLANK END W / 4 PIN ASSY 86557 RIVET RIBBED DIA .394 X .06 - .787 THICK NYLON BLK A-10. C (P/N 85435)

  • Page 103: Igure A-11. Power Supply For Switch Miller Assembly (P/N 85475)

    CABLE CLAMP LARGE SIZE 11 67155 TERMINAL PIN 18-16 AWG 67160 CONNECTOR PLUG 4 PIN REVERSE MALE/FEMALE SIZE 11 85396 CONTACTOR BW2600 BLANK END W / 4 PIN ASSY A-11. P (P/N 85475) IGURE OWER SUPPLY FOR SWITCH MILLER ASSEMBLY P/N 85555, Rev. 6...

  • Page 104: Igure A-12. Conduit Assembly For Miller (P/N 85476)

    SCREW 6-32 X 3/16 SSSCP 67333 BODY POWER PIN MILLER 67338 SUPPORT CABLE SPRING 67341 PLUG HOUSING EURO 67342 SUPPORT CABLE EURO BACK END 85475 SWITCH MILLER PWR SUPPLY BW2600 A-12. C (P/N 85476) IGURE ONDUIT ASSEMBLY FOR MILLER Page 88 BW2600 Operating Manual...

  • Page 105: Igure A-13. Conduit Power Assembly For Mig 225 Lincoln (P/N 85527)

    SCREW 6-32 X 3/16 SSSCP 67338 SUPPORT CABLE SPRING 67341 PLUG HOUSING EURO 67342 SUPPORT CABLE EURO BACK END 85475 SWITCH MILLER PWR SUPPLY BW2600 A-13. C MIG 225 L (P/N 85527) IGURE ONDUIT POWER ASSEMBLY FOR INCOLN P/N 85555, Rev. 6...

  • Page 106: Igure A-14. Contactor Assembly For Obart And Hermal Arc (P/N 85530)

    PARTS LIST ITEM P/N: DESCRIPTION 67050 CONNECTOR SOCKET DBL CRIMP 22-18 AWG .250 X .032 RED 85396 CONTACTOR BW2600 BLANK END W / 4 PIN ASSY A-14. C (P/N 85530) IGURE ONTACTOR ASSEMBLY FOR OBART AND HERMAL ARC Page 90...

  • Page 107: Igure A-15. Conduit Assembly For Obart And Hermal Arc Hefty Ii (P/N 85532)

    67338 SUPPORT CABLE SPRING 67341 PLUG HOUSING EURO 67342 SUPPORT CABLE EURO BACK END 85530 CONTACTOR ASSY HOBART & THERMAL ARC BW2600 A-15. C II (P/N 85532) IGURE ONDUIT ASSEMBLY FOR OBART AND HERMAL ARC HEFTY P/N 85555, Rev. 6...

  • Page 108: Igure A-16. Conduit Assembly For Tweco (P/N 85534)

    TERMINAL QUICK DISCONNECT DBL CRIMP MALE 22-18 AWG .250 X .032 RED 67338 SUPPORT CABLE SPRING 67341 PLUG HOUSING EURO 67342 SUPPORT CABLE EURO BACK END 85396 CONTACTOR BW2600 BLANK END W / 4 PIN ASSY A-16. C TWECO (P/N 85534) IGURE ONDUIT ASSEMBLY FOR Page 92 BW2600 Operating Manual...

  • Page 109: Igure A-17. Conduit Assembly For Incoln (P/N 85536)

    SUPPORT CABLE SPRING 67341 PLUG HOUSING EURO 67342 SUPPORT CABLE EURO BACK END 85540 CONTACTOR ASSY LINCOLN BW2600 86557 RIVET RIBBED DIA .394 X .06 - .787 THICK NYLON BLK 86565 SCREW M4 X 0.7 X 8MM PPHMS ZINC A-17. C...

  • Page 110: Igure A-18. Contactor Assembly For Incoln Pin (P/N 85540)

    CORD TYPE SOOW 18 AWG 5 COND 600V .325 OD UNSHIELDED GRAY JACKET 67482 CONTACT SOCKET AWG 18-16 CRIMP 67734 HEAT SHRINK TUBE 1/2 DIA BLACK A-18. C (P/N 85540) IGURE ONTACTOR ASSEMBLY FOR INCOLN Page 94 BW2600 Operating Manual...

  • Page 111: Appendix Bschematics

    APPENDIX B SCHEMATICS IN THIS CHAPTER: B-1. S (P/N 84635) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -97 IGURE CHEMATIC B-2.
  • Page 112 This page intentionally left blank Page 96 BW2600 Operating Manual...

  • Page 113: F (P/N 84635)

    B-3. C (P/N 84635) IGURE ONTROL ENCLOSURE SCHEMATIC P/N 85555, Rev. 6 Page 97...
  • Page 114 This page intentionally left blank Page 98 BW2600 Operating Manual...

  • Page 115: Igure B-2. Cable Assembly Rocker Switch (P/N 84898)

    B-2. C (P/N 84898) IGURE ABLE ASSEMBLY ROCKER SWITCH P/N 85555, Rev. 6 Page 99...

  • Page 116: Igure B-3. Connector Assembly Remote Pendant (P/N 85037)

    B-3. C (P/N 85037) IGURE ONNECTOR ASSEMBLY REMOTE PENDANT Page 100 BW2600 Operating Manual...

  • Page 117: Igure B-4. Pendant Assembly (P/N 85341)

    B-4. P (P/N 85341) IGURE ENDANT ASSEMBLY P/N 85555, Rev. 6 Page 101...

  • Page 118: Igure B-5. Power Entry Module Assembly (P/N 86514)

    B-5. P (P/N 86514) IGURE OWER ENTRY MODULE ASSEMBLY Page 102 BW2600 Operating Manual...

  • Page 119: Igure B-6. Power And Control Harness Assembly (P/N 86516)

    B-6. P (P/N 86516) IGURE OWER AND CONTROL HARNESS ASSEMBLY P/N 85555, Rev. 6 Page 103...

  • Page 120: Igure B-7. Potentiometer And Harness Assembly (P/N 86517)

    B-7. P (P/N 86517) IGURE OTENTIOMETER AND HARNESS ASSEMBLY Page 104 BW2600 Operating Manual...

  • Page 121: Igure B-8. Switch Rotation And Harness Assembly (P/N 86518)

    B-8. S (P/N 86518) IGURE WITCH ROTATION AND HARNESS ASSEMBLY P/N 85555, Rev. 6 Page 105...

  • Page 122: Igure B-9. Switch Auto Skip On Off Harness Assembly (P/N 86520)

    B-9. S (P/N 86520) IGURE WITCH AUTO SKIP ON OFF HARNESS ASSEMBLY Page 106 BW2600 Operating Manual...

  • Page 123: Igure B-10. Switch Skip Fill And Harness Assembly (P/N 86521)

    B-10. S (P/N 86521) IGURE WITCH SKIP FILL AND HARNESS ASSEMBLY P/N 85555, Rev. 6 Page 107...
  • Page 124 This page intentionally left blank Page 108 BW2600 Operating Manual...

Table of Contents