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Climax BB4500 Operating Manual Download Page 12

Page vi

BB4500-BB5000 Operating Manual

 LIST OF FIGURES (CONTINUED)

F

IGURE

P

AGE

A-4 Boring heads set 4–10 metric diameter assembly (P/N 43576) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  69
A-5 Boring heads set 4–10" diameter assembly (P/N 43575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  70
A-6 RDU 2nd gen assembly (P/N 53912) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  71
A-7 RDU 2nd gen assembly (P/N 53912) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  72
A-8 Hydraulic motor assembly (P/N 39848)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  73
A-9 Single-arm mount assembly (P/N 43262) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  74
A-10 Universal mount assembly (P/N 43267) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  75
A-11 Double-arm bearing mount assembly (P/N 43279). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76
A-12 Large and small set cones assembly (P/N 49060) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  77
A-13 Eibenstock motor assembly (P/N 88012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  78
A-14 Eibenstock motor assembly -- gen. 2 only  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  79
A-15 Eibenstock motor assembly parts list -- gen. 2 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  80
B-1 Axial feed unit assembly (P/N 28636) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  84
B-2 Axial feed unit assembly parts list (P/N 28636). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  85
B-3 HD axial feed unit assembly (P/N 91518) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  86
B-4 HD axial feed unit assembly parts list (P/N 91518). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  87
B-5 Air motor CE assembly (P/N 28697) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  88
B-6 Air motor CE assembly (P/N 28614) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  89
B-7 Pneumatic connection assembly (P/N 15088)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  90
B-8 Hydraulic motor assembly (P/N 39848)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  91
B-9 Setup cone assembly (P/N 26383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  92
B-10 Single-arm mount assembly (P/N 37472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  93
B-11 Double-arm mount assembly (P/N 37473) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  94
B-12 Air motor CE assembly (P/N 36959) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  95
B-13 ID bearing mount assembly (P/N 46293)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  96
B-14 Set cones setup assembly (P/N 49060) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  97
B-15 Servo drive 460 CE assembly (P/N 52876)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  98
B-16 Servo drive 460 CE assembly parts list (P/N 52876)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  99
B-17 RDU 12:1 assembly (P/N 53165) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  100
B-18 RDU 12:1 assembly parts list (P/N 53165) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  101
B-19 RDU no mount modified assembly (P/N 93090) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  102
B-20 RDU no mount modified assembly parts list (P/N 93090). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  103
B-21 Servo drive 230V CE assembly (P/N 54321)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  104
B-22 Servo drive 230V CE assembly (P/N 54321)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  105
B-23 Servo motor RDU adapter assembly (P/N 51536)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  106
B-24 Servo motor guard assembly (P/N 52937) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  107
B-25 Servo shroud fan assembly (P/N 56773)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  108
B-26 Servo drive motor 230V non-CE assembly (P/N 71071). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  109
B-27 Servo drive motor 460V non-CE assembly (P/N 71072). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  110
B-28 Eibenstock motor assembly -- gen. 2 only  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  111
B-29 Eibenstock motor assembly parts list -- gen. 2 only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  112
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
C-2 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz domestic assembly (P/N 88036 C00468)
121

Summary of Contents for BB4500

Page 1: ...BB4500 BB5000 BORING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS P N 92974 June 2019 Revision 1 BB4500 BB5000...

Page 2: ......

Page 3: ...ns about CLIMAX products or services please call CLIMAX or e mail info cpmt com For quick and accurate service please provide your representative with the following Your name Shipping address Telephon...

Page 4: ...Page B BB4500 BB5000 Operating Manual CLIMAX GLOBAL LOCATIONS...

Page 5: ...P N 92974 Rev 1 Page C CE DOCUMENTATION...

Page 6: ...its factory representative and return the part or repaired machine shipping pre paid to the factory CLIMAX will at its option either repair or replace the defective part and or correct any defect in...

Page 7: ...2 3 COMPONENTS 13 2 3 1 Rotational drive unit 13 2 3 2 Axial feed unit 14 2 3 3 Leadscrew 14 2 3 4 BB4500 tool heads 14 2 3 5 BB5000 tool heads 14 2 3 6 BB4500 boring bar 15 2 3 7 BB5000 boring bar 1...

Page 8: ...machines 46 3 5 4 Pneumatic machines 46 3 6 BB4500 BB5000 WITH SMALL DIAMETER BARS 47 4 OPERATION 51 4 1 PRE OPERATION CHECKS 51 4 2 TOOL BIT SELECTION 52 4 3 OPERATION 52 4 3 1 Starting the machine 5...

Page 9: ...ON PAGE 6 1 1 Short term storage 63 6 1 2 Long term storage 63 6 2 SHIPPING 63 6 3 DECOMMISSIONING 64 APPENDIX A BB4500 ASSEMBLY DRAWINGS 65 APPENDIX B BB5000 ASSEMBLY DRAWINGS 83 APPENDIX C SCHEMATIC...

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Page 11: ...Centering the spherical bearings 34 3 5 Positioning the spherical bearings 35 3 6 Aligning the bar 35 3 7 Inserting the tool bit 36 3 8 Tool head setup 36 3 9 Positioning the RDU 37 3 10 Positioning...

Page 12: ...assembly P N 26383 92 B 10 Single arm mount assembly P N 37472 93 B 11 Double arm mount assembly P N 37473 94 B 12 Air motor CE assembly P N 36959 95 B 13 ID bearing mount assembly P N 46293 96 B 14...

Page 13: ...en 120V CE 332P4W pin sleeve plug P N 88653 E00173 129 C 11 BB5000 Eibenstock power cable assembly 2nd gen 230V CE CEE7 7 Schuko plug P N 88654 E00174 130 C 12 BB5000 Eibenstock power cable assembly 2...

Page 14: ...Page viii BB4500 BB5000 Operating Manual This page intentionally left blank...

Page 15: ...ing bar dimension identification 27 2 18 Sub component mass 27 2 19 Boring specifications 27 2 20 Electrical specifications 28 3 1 Setup cone identification 33 3 2 Setup cone installation identificati...

Page 16: ...g Manual LIST OF TABLES CONTINUED TABLE PAGE A 1 BB4500 recommended spare parts 81 A 2 Tool kit 81 B 1 BB5000 recommended spare parts 114 B 2 Leadscrew spare parts 114 B 3 Hydraulic metric spare parts...

Page 17: ...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 1 2...

Page 18: ...he end user are responsible for conducting a risk assess ment of each job site before setting up and operating this machine Intended use Use this machine in accordance with the instructions and precau...

Page 19: ...hips during operation Always wear eye protection when operating the machine Sound level This machine produces potentially harmful sound levels Hearing protection is required when operating this machin...

Page 20: ...ly attach directly to the workpiece itself or to an adjacent struc ture and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and th...

Page 21: ...paths involved in lifting and rigging operations I have taken pre cautions to keep workers away from the identified fall path I considered how this machine operates and identified the best placement f...

Page 22: ...tely for replacements TABLE 1 4 BB4500 BB5000 LABELS P N 29154 Serial number plate P N 59037 Warning label read the operating manual P N 59044 Warning label read the operat ing manual P N 77568 ICE el...

Page 23: ...ement refer to the BB4500 exploded views in Appendix A on page 65 and the BB5000 exploded views in Appendix B on page 83 P N 78748 Warning label eye protection P N 78824 Warning label do not expose th...

Page 24: ...Page 8 BB4500 BB5000 Operating Manual FIGURE 1 1 AFU LABEL LOCATIONS 78735 78742 80510 80510 78735 78742...

Page 25: ...P N 92974 Rev 1 Page 9 FIGURE 1 2 RDU LABEL LOCATIONS...

Page 26: ...Page 10 BB4500 BB5000 Operating Manual This page intentionally left blank...

Page 27: ...MOUNTS 16 2 4 CONTROLS 17 2 4 1 HYDRAULIC POWER UNIT AND HYDRAULIC MOTORS 18 2 4 2 BB5000 SERVO MOTORS 19 2 4 3 ELECTRIC MOTOR 21 2 4 4 AIR MOTOR 24 2 4 5 PNEUMATIC CONDITIONING UNIT 24 2 5 DIMENSIONS...

Page 28: ...aintenance problems The BB4500 is designed for on site repair and servicing of heavy equipment at chemical plants public utilities mills mines power stations fluid transmission and distribution system...

Page 29: ...B5000 is a highly configurable machine with many options and accessories though this manual only covers the basic assembly components If a specific machine application requires accessories contact CLI...

Page 30: ...nts Contact CLIMAX for more information 2 3 4 BB4500 tool heads For the BB4500 the split body tool heads may be clamped anywhere along the bar The set of three tool heads bore 4 10 102 254 mm diameter...

Page 31: ...spacing patterns Do the following to determine the bar length required see Figure 2 14 on page 26 1 Determine the workpiece overall dimension stroke 27 686 mm 2 Round up to the next 24 610 mm incremen...

Page 32: ...he brackets in place These brackets are available in single arm double arm and universal styles The universal mount may also be turned into an inside diameter ID mount with the purchase of an optional...

Page 33: ...Hydraulic 10 hp HPU2 0 246 RPM at 60 Hz mains power 10 hp HPU 0 200 RPM at 50 Hz mains power 2 Hydraulic power unit HPU 10 hp 7 4 kW Section 2 4 1 on page 18 Electric 8 160 RPM 3 35 hp 2 5 kW Section...

Page 34: ...everse the bar rotation direction switch the hydraulic hoses at the motor or at the HPU Table 2 5 on page 18 shows the available HPUs and their specifications TABLE 2 5 AVAILABLE HPU SPECIFICATIONS If...

Page 35: ...PECIFICATIONS Motor capacity Maximum bar RPM Torque at bar Part number for motors with 60 series QD fittings Part number for motors with ISO 16028 QD fittings 8 36 gpm 31 5 L min 1 10 gpm 37 9 L min 2...

Page 36: ...are plugged in Do not unplug cables unless disconnected from mains power Servo drives for the BB5000 are available in 230V 16 amps or 460V 8 5 amps TABLE 2 7 BB5000 SERVO MOTOR SPECIFICATION Input po...

Page 37: ...k motor requires the fourth generation RDU 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 cu...

Page 38: ...from the supply outlet increases heavier gauge extension cords are required see Table 2 11 TABLE 2 9 POWER RATING 120V motor 3 35 hp 2 5 kW 20 Amps 60 Hz 230V motor 3 35 hp 2 5 kW 10 5 Amps 60 Hz TAB...

Page 39: ...sh Holder 2 85088 Carbon Brush 2 83591 Anti Parasite Condenser 1 85089 PCB Circuit Board 1 82699 Cap 1 90779 Stator Complete 1 83601 Grooved Ball Bearing 6201 LUZ 1 90780 Locking Ring 32x1 2 1 83602 S...

Page 40: ...lidating your warranty always route incoming air through the pneumatic conditioning unit PCU 2 4 5 Pneumatic conditioning unit The PCU shown in Figure 2 12 on page 25 provides clean dry air and lubric...

Page 41: ...ment valve 2 Pull the emergency stop button up 3 Press the START button repeat step 1 if necessary 2 5 DIMENSIONS Table 2 16 shows the BB4500 and BB5000 dimensions The following figures show the BB450...

Page 42: ...Page 26 BB4500 BB5000 Operating Manual FIGURE 2 13 BB4500 DIMENSIONS FIGURE 2 14 BB5000 DIMENSIONS 2 1 2 1 8 57 218 6 91 176 4 75 121...

Page 43: ...g HPU 10 HP 695 lbs 315 2 kg Machine total weight including single arm mounts setup cones and hydraulic motor 444 lbs 201 kg Approximate boring bar ship weight including the metal shipping container 1...

Page 44: ...with 1 second between Voltage dip brownout 20 of peak volts for 1 second maximum Voltage supplied from batteries 10 of nominal Voltage interruption DC 5 ms maximum Ambient temperature operating 41 10...

Page 45: ...2974 Rev 1 Page 29 2 7 ITEMS 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 work...

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Page 47: ...3 6 BB4500 BB5000 WITH SMALL DIAMETER BARS 47 This section describes the setup and assembly procedures for the BB4500 BB5000 boring machine 3 1 RECEIPT AND INSPECTION Your CLIMAX product was inspected...

Page 48: ...s Distance between the bores Distance between the bearings Style of bearings single arm double arm universal Contact CLIMAX for assistance with a custom application The BB4500 BB5000 s through bar des...

Page 49: ...ar in place until clamping or welds on tack plates are completed Then remove the cones and make precise adjustments to cen ter the bar Setup cones optional equipment Do the following to install the se...

Page 50: ...t head jacking screw Tighten the set screw in the setup cone to hold it securely in place 7 Repeat step 3 through step 6 until the cones are seated in the bores and there is no bar movement 8 Center t...

Page 51: ...cones 16 Carefully reinstall the bar through the mounting brackets If necessary precisely align the bar by doing the following 1 Loosen the hex bolts hold ing the bearing to the bracket 2 Attach a dia...

Page 52: ...it into the bar Do the following to insert the tool bit into the bar 1 Retract the set screw that is located 90 from the tool slot 2 Insert the tool bit into the tool slot so that it slides freely int...

Page 53: ...TIP Tool bits are either right handed or left handed This allows for feeding both directions with the same rotation direction 5 Use a dial indicator to set the tool bit to achieve the desired depth o...

Page 54: ...ng bracket 3 Install the RDU onto the bar positioning it against the spherical bearing bracket so that one of the spring pins engages one of the slots in the bearing mount 4 Tighten the clamp ring to...

Page 55: ...ews 9 Install the leadscrew into the AFU Check that the jam nut is on the other end of the leadscrew 10 Slide the AFU onto the bar if not already done so to position it between the mounting support br...

Page 56: ...4 1 Selecting the feed direction The feed direction has three positions Forward Neutral Reverse Pushing the three position feed shaft in on one side or the other will feed in the direction indicated...

Page 57: ...ched when the knob is approximately 0 625 16 mm away from the feed box Minimum feed is reached when the knob completely collapses the compression spring approximately 0 25 6 mm TABLE 3 6 AFU COMPONENT...

Page 58: ...al feed to stop Assemblies are included for stopping in either direction 2 Check that the stop arm is positioned to press against the feed stop screw assembly FIGURE 3 14 AUTOMATIC FEED STOP When the...

Page 59: ...it to mains power 5 After checking that all hydraulic hose quick coupler fittings are clean con nect the hydraulic hoses between the HPU and the hydraulic motor on the boring bar The hose connection m...

Page 60: ...ower examine all cables for damage Repair or replace the cable if neces sary 2 Connect the servo motor encoder cable power cable and cooling fan power cable 3 Connect the encoder and operator pendant...

Page 61: ...t Hold for three seconds to start the spindle rotation RPM Controls the rotational bar speed from 3 230 RPM Fault light Indicates that the servo drive has stopped due to a fault con dition such as the...

Page 62: ...e 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 br...

Page 63: ...X small bore kit P N 28698 NOTICE The small bore kit adapter collets fit into the existing collets Do not remove existing collets from the RDU and AFU The AFU collet is serrated on both ends and has n...

Page 64: ...re 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 FIGURE 3 20 SNAP RING REMOVAL KEYWAY KEY 2 1 TABLE 3 11 RDU COLLET...

Page 65: ...eplace the snap ring and install the 1 1 4 bar see Figure 3 22 on page 50 TABLE 3 12 SNAP RING REMOVAL IDENTIFICATION Number Component 1 AFU snap ring 2 RDU snap ring 3 Spherical bearing snap ring AFU...

Page 66: ...Manual FIGURE 3 22 SNAP RING REPLACEMENT AFU SNAP RING RDU SNAP RING SPHERICAL BEARING SNAP RING 2 3 1 TABLE 3 14 SNAP RING REPLACEMENT IDENTIFICATION Number Component 1 AFU snap ring 2 RDU snap ring...

Page 67: ...icator assembly before performing any troubleshooting 4 1 PRE OPERATION CHECKS Do the following checks before operating the machine 1 Complete the risk assessment checklist in Table 1 3 on page 5 2 Ch...

Page 68: ...ing carbide tool bits set the speed shift lever to HIGH These chips should be dark brown to blue 4 3 OPERATION 4 3 1 Starting the machine Check that the tool bit is installed so that as the boring bar...

Page 69: ...the controller CAUTION Brush wear depends on the load and RPM Regularly check both brushes for excessive wear and replace if necessary 4 3 1 3 Pneumatic drive Do the following to start the pneumatic...

Page 70: ...on direction 4 Press START To stop press the STOP button 4 4 SHUTDOWN To protect tool bits from chipping always place the feed box in neutral before stopping the bar rotation Do the following to shut...

Page 71: ...om the workpiece 4 5 DISASSEMBLY 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 dri...

Page 72: ...MPONENTS 5 Slide the AFU off the bar 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 ba...

Page 73: ...62 5 1 MAINTENANCE CHECKLIST Table 5 1 lists maintenance intervals and tasks TABLE 5 1 MAINTENANCE INTERVALS AND TASKS Interval Task Reference Before each use Inspect the power cord for damage and re...

Page 74: ...ery two years replace the hydraulic oil with AW 32 Fill to the sight glass Section 5 3 3 on page 59 Check both brushes for excessive wear and replace if necessary Section 5 3 4 on page 60 Check the ai...

Page 75: ...ks cuts or abrasions Dress the bar smooth if neces sary A bar with nicks or gouges can damage the bearing supports and RDU beyond repair Wipe the bar clean with solvent to remove dirt and chips 5 3 3...

Page 76: ...rush for excessive wear and replace if necessary WARNING Electrical equipment can shock or cause an explosion if used near wet or flammable materials Do not operate the motor if it is wet or exposed t...

Page 77: ...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...

Page 78: ...l clamps and hardware Provide additional support RDU will not rotate Check that the HPU is turned on Check that the HPU pump motor is rotating as indicated by the arrow on the pump body see Section 3...

Page 79: ...nal shipping container Keep all packing mate rials for repackaging the machine 6 1 1 Short term storage Do the following for short term storage three months or less 1 Remove the tooling 2 Lower and su...

Page 80: ...the boring machine before disposal remove the drive assembly from the RDU and dispose of the drive assembly separately from the rest of the machine components Refer to the BB4500 exploded views in Ap...

Page 81: ...RDU 2ND GEN ASSEMBLY P N 53912 71 FIGURE A 7 RDU 2ND GEN ASSEMBLY P N 53912 72 FIGURE A 8 HYDRAULIC MOTOR ASSEMBLY P N 39848 73 FIGURE A 9 SINGLE ARM MOUNT ASSEMBLY P N 43262 74 FIGURE A 10 UNIVERSAL...

Page 82: ...Page 66 BB4500 BB5000 Operating Manual FIGURE A 1 AXIAL FEED UNIT ASSEMBLY P N 43378 27 6 6 6...

Page 83: ...5 0 2 2 3 1 2 6 5 7 5867 2 5 6 2 635 1 203 2 5 21 67 1 66 67 50 5 7 7 6 7 86 1 5 9 635 1 3 81 5 7 25 5 52 5 87 6 2 0 3 5 1 61 3 9 3 81 5 386 7 1 5 1 02 187 90 5 66 0 81 7 286 1 5 83 2 5 21 6723 50 66...

Page 84: ...D METRIC 8 TO 10 DIA 1 3 4 BAR BB4500 43565 PARTS LIST DESCRIPTION P N QTY ITEM SCREW M8 X 1 25 X 12mm SSSCP 35214 2 1 SCREW M12 X 1 75 X 30mm SHCS 40697 2 2 PARTS LIST DESCRIPTION P N QTY ITEM SCREW...

Page 85: ...T 4 10 METRIC DIAMETER ASSEMBLY P N 43576 PARTS LIST DESCRIPTION P N QTY ITEM TOOL HEAD METRIC 4 TO 6 DIA 1 3 4 BAR BB4500 43563 1 1 TOOL HEAD METRIC 6 TO 8 DIA 1 3 4 BAR BB4500 43564 1 2 TOOL HEAD ME...

Page 86: ...al FIGURE A 5 BORING HEADS SET 4 10 DIAMETER ASSEMBLY P N 43575 PARTS LIST DESCRIPTION P N QTY ITEM TOOL HEAD 4 TO 6 DIA 1 3 4 BAR 43492 1 1 TOOL HEAD 6 TO 8 DIA 1 3 4 BAR BB4500 43493 1 2 TOOL HEAD 8...

Page 87: ...P N 92974 Rev 1 Page 71 FIGURE A 6 RDU 2ND GEN ASSEMBLY P N 53912 34 12 24 31 25 37 17 11 6 11 18 36 40 38 7 14 39 22 23 15 2 19 3 10 4 5 21 37 30 33 29 5 4 32 16 14 28 1 9 20 27 26 8 13 35...

Page 88: ...LUNGER HAND RETRACT 1 2 X 13 29207 2 20 SCREW 1 4 28 X 1 2 SHCS 45900 2 21 LABEL WARNING HOT SURFACE 46902 1 22 HOUSING RDU BB5000 4TH 49665 1 23 CAP WORM HOUSING BB5000 4TH GEN 49667 1 24 BRG BALL TH...

Page 89: ...CRIPTION MOTOR HYD P N 39837 MOTOR ASSY HYD 2 2 CU IN KEYED 1 2 FTG 27477 39843 MOTOR ASSY HYD 3 6 CU IN KEYED 1 2 FTG 20684 39844 MOTOR ASSY HYD 5 7 CU IN KEYED 1 2 FTG S SERIES 21530 39845 MOTOR ASS...

Page 90: ...ER 5 16 FLTW SAE 13489 8 1 SCREW 1 2 13 X 2 SHCS 14036 8 2 WASHER 1 2 FLTW HARDENED 1 1 8 OD X 3 16 THK 17145 8 3 SCREW 5 16 18 X 1 3 4 SSSFP 20174 8 4 MOUNT BRG SPHERICAL ARM BB45000 STD 43264 2 5 BR...

Page 91: ...X 2 SHCS 14036 4 4 WASHER 1 2 FLTW HARDENED 1 1 8 OD X 1 8 THK 22662 4 5 SCREW 1 2 20 X 3 4 SSSFP 27273 4 6 BEARING MOUNT RING 1 3 4 36962 1 7 EXTENSION ARM MOUNT 36965 4 8 TACK BLOCK 4 IN 36966 4 9 A...

Page 92: ...5 16 FLTW SAE 13489 4 1 SCREW 1 2 13 X 2 SHCS 14036 8 2 WASHER 1 2 FLTW HARDENED 1 1 8 OD X 3 16 THK 17145 8 3 SCREW 5 16 18 X 1 3 4 SSSFP 20174 4 4 MOUNT BRG SPHERICAL 1 3 4 ID W CLAM STD 43264 1 5 P...

Page 93: ...N STOP 29091 1 1 2 CONE SETUP BB4000 6 TO 10 42228 1 1 3 CLAMP COLLAR MODIFIED 1 3 4 ID 42508 1 2 CLAMP COLLAR MODIFIED 42508 1 2 1 SCREW 5 16 24 X 1 1 2 SHCS 17125 2 2 2 PARTS LIST DESCRIPTION P N QT...

Page 94: ...OPERATOR S MANUAL 1 5 DIA 59044 1 6 FLANGE MOTOR MTG ELEC RDU BB5000 75648 1 7 LABEL WARNING DO NOT EXPOSE TO WATER 78824 1 8 LABEL EIBENSTOCK RPM RANGES 84393 1 9 NFIS MOTOR ELECTRIC 4 SPEED REVERSI...

Page 95: ...P N 92974 Rev 1 Page 79 FIGURE A 14 EIBENSTOCK MOTOR ASSEMBLY GEN 2 ONLY...

Page 96: ...Page 80 BB4500 BB5000 Operating Manual FIGURE A 15 EIBENSTOCK MOTOR ASSEMBLY PARTS LIST GEN 2 ONLY...

Page 97: ...3 4 SSSCP 4 13356 Screw 5 8 11 X 2 1 2 SHCS 4 11691 Screw 1 2 13 X 1 5 SHCS 2 10191 Screw 3 8 16 X 1 SHCS 2 Spherical bearing mounting brackets 14036 Screw 1 2 13 x 2 SHCS 8 22662 Washer 8 26250 Scre...

Page 98: ...wrench 1 10601 5 16 Hex wrench 1 10600 5 32 Hex wrench 1 25710 Tool bit HSS 1 2 sq x 4 3 43697 Operating Manual 1 82949 Bag tool 14 x 5 5 x 6 polyester 1 39099 Filter element replacement 1 TABLE A 2...

Page 99: ...LY P N 52876 98 FIGURE B 16 SERVO DRIVE 460 CE ASSEMBLY PARTS LIST P N 52876 99 FIGURE B 17 RDU 12 1 ASSEMBLY P N 53165 100 FIGURE B 18 RDU 12 1 ASSEMBLY PARTS LIST P N 53165 101 FIGURE B 19 RDU NO MO...

Page 100: ...Page 84 BB4500 BB5000 Operating Manual FIGURE B 1 AXIAL FEED UNIT ASSEMBLY P N 28636 27 6 6 6 81 7 5 1 5 9...

Page 101: ...0 2 2 3 1 2 6 5 7 5867 2 5 6 2 635 1 203 2 5 21 67 1 66 67 2 7 8 5 50 5 7 7 6 7 86 1 5 9 635 1 3 81 5 7 25 5 52 5 87 6 2 0 3 5 1 61 3 9 3 81 5 386 7 1 5 1 02 187 90 5 66 0 81 7 286 1 5 83 2 5 21 6723...

Page 102: ...6 BB4500 BB5000 Operating Manual FIGURE B 3 HD AXIAL FEED UNIT ASSEMBLY P N 91518 14 15 24 22 6 7 7 28 5 9 24 8 28 26 12 10 19 31 1 2 19 4 18 3 29 5 20 21 14 21 29 4 18 3 20 27 2 1 9 26 8 15 22 25 13...

Page 103: ...CAL AXIAL FEED BB5000 27198 1 13 BRG CUP 2 328 OD x 470 WIDE 27203 2 14 BRG CONE 1 3775 ID X 66 WIDE 27204 2 15 NOT SHOWN STOP ARM ASSY 27222 1 16 NOT SHOWN BLOCK TACKWELD BB5000 28756 1 17 RING SNAP...

Page 104: ...ASSEMBLED PARTS LIST DESCRIPTION P N QTY ITEM SCREW 5 16 18 X 3 4 FHSCS 10516 6 1 MOTOR AIR 3HP 475 RPM FS 228 RPM MAX 93TQ 15087 1 2 WRENCH HEX 3 8 SHORT ARM BONDHUS BALLDRIVER 26845 1 3 SCREW 1 2 13...

Page 105: ...S LIST DESCRIPTION P N QTY ITEM SCREW 5 16 18 X 3 4 FHSCS 10516 6 1 MOTOR AIR 3 2HP 975 RPM FS 485 RPM MAX 47 3TQ 15109 1 2 WRENCH HEX 3 8 SHORT ARM BONDHUS BALLDRIVER 26845 1 3 SCREW 1 2 13 X 1 1 4 S...

Page 106: ...1 2 NPTM X 1 2 NPTF OVAL HANDLE 35667 1 9 FTG ELBOW 1 2 NPTM X 1 2 NPTF ST 90 DEG BRASS 35692 1 10 FTG QUICK COUPLER 1B 1 NPTF FEMALE AIR BRASS 55800 1 11 FTG QUICK COUPLER 1B 1 NPTM MALE AIR NON VAL...

Page 107: ...CRIPTION MOTOR HYD P N 39837 MOTOR ASSY HYD 2 2 CU IN KEYED 1 2 FTG 27477 39843 MOTOR ASSY HYD 3 6 CU IN KEYED 1 2 FTG 20684 39844 MOTOR ASSY HYD 5 7 CU IN KEYED 1 2 FTG S SERIES 21530 39845 MOTOR ASS...

Page 108: ...83 26507 SET CONE SETUP 2 75 TO 8 37 DIA BB5000 PARTS LIST DESCRIPTION P N QTY ITEM CONE SETUP 2 75 TO 8 37 BB5000 26380 1 1 SCREW MOD 3 8 24 X 1 3 16 SSSFD 29092 1 1 1 PIN STOP 29091 1 1 2 CLAMP COLL...

Page 109: ...4036 4 1 WASHER 1 2 FLTW HARDENED 1 1 8 OD X 3 16 THK 17145 4 2 PLATE SPACER TACK WELD MTG 19869 1 3 WASHER 5 16 FLTW HARDENED 21798 8 4 ASSY BRG SPHERICAL 2 1 4 ID W CLAMP COLLAR 26248 1 5 BRACKET MT...

Page 110: ...SHCS 14036 8 1 WASHER 1 2 FLTW HARDENED 1 1 8 OD X 3 16 THK 17145 8 2 PLATE SPACER TACK WELD MTG 19869 2 3 WASHER 5 16 FLTW HARDENED 21798 8 4 ASSY BRG SPHERICAL 2 1 4 ID W CLAMP COLLAR 26248 1 5 SCRE...

Page 111: ...4 Rev 1 Page 95 FIGURE B 12 AIR MOTOR CE ASSEMBLY P N 36959 PARTS LIST DESCRIPTION P N QTY ITEM ASSY BRG SPHERICAL 2 1 4 ID W CLAMP COLLAR 26248 1 1 MOUNT UNIVERSAL BORING BARS BB5000 NO BEARING 41514...

Page 112: ...IA X 1 1 2 35600 4 3 BOLT JACKING 1 ID BRG MOUNT 37618 4 4 BOLT JACKING 1 2 20 X 1 1 2 ID BEARING MOUNT 37619 4 5 30 DEGREE SLIDE 46216 4 6 PLATE FACE ADJUST 46218 1 7 HOUSING MOUNT ID BRG BB5000 4621...

Page 113: ...P 29091 1 1 2 CONE SETUP BB4000 6 TO 10 42228 1 1 3 CLAMP COLLAR MODIFIED 1 3 4 ID 42508 1 2 CLAMP COLLAR MODIFIED 42508 1 2 1 SCREW 5 16 24 X 1 1 2 SHCS 17125 2 2 2 PARTS LIST DESCRIPTION P N QTY ITE...

Page 114: ...Page 98 BB4500 BB5000 Operating Manual FIGURE B 15 SERVO DRIVE 460 CE ASSEMBLY P N 52876...

Page 115: ...02725 02 65 N 530 9 6 7 66 1 2 5 6 592 5 9 0 21 66 21752 5 6 592 5 9 5 1 66 1 6 592 5 9 1 21 127 6 2 1 0 18 16758 7 21 25 1 5 3 576 67 1 1 7 0 47 3 1 6 5 37 21 127 6 2 1 5 1 6 257 50 21 86 21 86 5 9...

Page 116: ...BB4500 BB5000 Operating Manual FIGURE B 17 RDU 12 1 ASSEMBLY P N 53165 37 11 36 33 38 40 39 26 45 10 6 10 17 32 7 14 23 43 22 15 31 2 19 30 18 44 3 9 4 5 21 45 24 35 27 5 4 34 16 14 25 1 25 29 28 20 8...

Page 117: ...1 LABEL WARNING HOT SURFACE GRAPHIC 1 13 TALL 46902 1 22 HOUSING RDU BB5000 4TH GEN 49665 1 23 KEY MAIN DRIVE BB5000 4TH GEN 49666 1 24 CLAMP RING RDU MOUNT BB5000 4TH 52303 1 25 BRG BALL THRUST 40 MM...

Page 118: ...ge 102 BB4500 BB5000 Operating Manual FIGURE B 19 RDU NO MOUNT MODIFIED ASSEMBLY P N 93090 ASSEMBLED 14 4 5 23 12 25 13 9 6 9 32 22 10 33 31 35 11 18 34 16 19 20 29 27 21 24 5 17 26 15 12 7 8 4 1 36 2...

Page 119: ...REW 1 4 28 X 1 2 SHCS 45900 2 17 LABEL WARNING HOT SURFACE GRAPHIC 1 13 TALL 46902 1 18 HOUSING RDU BB5000 4TH 49665 1 19 KEY MAIN DRIVE BB5000 4TH GEN 49666 1 20 CAP WORM HOUSING BB5000 4TH GEN 49667...

Page 120: ...Page 104 BB4500 BB5000 Operating Manual FIGURE B 21 SERVO DRIVE 230V CE ASSEMBLY P N 54321...

Page 121: ...5 6 7 6 592 1 20 1 32 5 211 21 1 1 6 592 02725 02 65 N 530 9 6 7 66 21752 5 6 592 5 9 5 1 127 6 2 1 0 18 16758 7 21 25 1 5 3 576 67 1 1 7 0 47 3 1 6 5 37 21 127 6 2 1 5 1 6 257 50 21 86 21 86 5 9 5 12...

Page 122: ...SCREW 1 2 13 X 1 1 4 SHCS 12646 2 2 SCREW 1 2 13 X 1 3 4 SHCS 20534 4 3 BRG BALL 1 9685 ID X 3 1496 OD X 6299 22575 1 4 RING SNAP 3 149 ID 80mm SPIRAL MED DUTY 39131 1 5 KEY 1 4 X 1 4 X 1 00 RAD BOTH...

Page 123: ...CRIPTION P N QTY ITEM SCREW 1 4 20 X 3 4 SHCS 10160 2 1 GUARD SERVO MOTOR REAR PLATE 52916 1 2 SCREW M8 X 1 25 X 80MM SHCS 52936 4 3 HANDLE PULL 1 4 CBORE MTG 2 0 X 5 12 X 1 02W PLASTIC COATED 53462 1...

Page 124: ...5 DIA BLACK 22800 2 IN 5 NUT 8 32 LOCKING STAR WASHER 28617 4 6 HANDLE PULL 1 4 CBORE MTG 2 0 X 5 12 X 1 02W PLASTIC COATED 53462 1 7 SHROUD FAN BB5000 RDU SERVO 56587 1 8 RECEPTACLE MICROFAST 3 POLE...

Page 125: ...o ITEM ADAPTER BB5000 RDU TO SERVO MOTOR 51536 1 GUARD ASSY BB5000 SERVO MOTOR 52937 2 LABEL WARNING HOT HAND 53464 3 LABEL WARNING VOLTAGE 53482 4 LABEL WARNING VOLTAGE CABLE 53483 5 SHROUD FAN BB500...

Page 126: ...N PART No ITEM ADAPTER BB5000 RDU TO SERVO MOTOR 51536 1 GUARD ASSY BB5000 SERVO MOTOR 52937 2 LABEL WARNING HOT HAND 53464 3 LABEL WARNING VOLTAGE 53482 4 LABEL WARNING VOLTAGE CABLE 53483 5 SHROUD F...

Page 127: ...P N 92974 Rev 1 Page 111 FIGURE B 28 EIBENSTOCK MOTOR ASSEMBLY GEN 2 ONLY...

Page 128: ...Page 112 BB4500 BB5000 Operating Manual FIGURE B 29 EIBENSTOCK MOTOR ASSEMBLY PARTS LIST GEN 2 ONLY...

Page 129: ...P N 92974 Rev 1 Page 113 FIGURE B 30 LEADSCREW ASSEMBLY P N 28654...

Page 130: ...3 4 SSSCP 4 13356 SCREW 5 8 11 X 2 1 2 SHCS 4 Electric Motor Assembly 20273 KEY 1 4 SQ X 1 00 SQ BOTH ENDS 1 26845 WRENCH HEX 3 8 SHORT ARM BONDHUS BALL DRIVER 1 82698 SP BRUSH CARBON PAIR FOR EIBENST...

Page 131: ...CRANK MODIFIED 1 27015 SP PIN DOWEL MODIFIED 187 DIA X 75 GROOVED 2 27197 LEAD NUT BB4500 BB5000 AXIAL FEED 2 92494 SCREW ASSY FEED STOP GEN 2 2 27356 NUT 1 5 ACME 7 8 TALL 1 1 2 HEX FINISHED 2 29207...

Page 132: ...9 WRENCH HEX SET 050 3 8 BONDHUS BALL END 25550 WRENCH HEX 5 16 X 11 4 BALLDRIVER T HANDLE 54033 VIDEO BB5000 SETUP AND OPERATION DVD 34578 BIT TOOL HSS 12MM X 1 8 LH ROUGHING SINGLE 29660 WRENCH HEX...

Page 133: ...Page 117 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 TABLE B 4 BB5000 TOOL KIT CONTINUED Part numb...

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Page 135: ...LY 2ND GEN 120V DOMESTIC L5 30P PLUG P N 88652 E00172 128 FIGURE C 10 BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 120V CE 332P4W PIN SLEEVE PLUG P N 88653 E00173 129 FIGURE C 11 BB5000 EIBENSTOCK P...

Page 136: ...Page 120 BB4500 BB5000 Operating Manual FIGURE C 1 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50 60 HZ CE SCHEMATIC P N 88035 C00467...

Page 137: ...P N 92974 Rev 1 Page 121 FIGURE C 2 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50 60 HZ DOMESTIC ASSEMBLY P N 88036 C00468...

Page 138: ...Page 122 BB4500 BB5000 Operating Manual FIGURE C 3 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY P N 88037 C00465...

Page 139: ...P N 92974 Rev 1 Page 123 FIGURE C 4 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V CE ASSEMBLY P N 88038 C00466...

Page 140: ...Page 124 BB4500 BB5000 Operating Manual FIGURE C 5 BB5000 MOTOR 230V AND 460V FAN ASSEMBLY P N 91811 E00034...

Page 141: ...P N 92974 Rev 1 Page 125 FIGURE C 6 BB5000 SERVO MOTOR 230VAC AND 460VAC POWER CABLE ASSEMBLY P N 91811 E00048...

Page 142: ...Page 126 BB4500 BB5000 Operating Manual FIGURE C 7 BB5000 EIBENSTOCK MOTOR CABLE ASSEMBLY 2ND GEN 120V 12AWG SCHEMATIC P N 88649 E00170...

Page 143: ...P N 92974 Rev 1 Page 127 FIGURE C 8 BB5000 EIBENSTOCK MOTOR CABLE ASSEMBLY 2ND GEN 230V 14AWG SCHEMATIC P N 88650 E00171...

Page 144: ...Page 128 BB4500 BB5000 Operating Manual FIGURE C 9 BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 120V DOMESTIC L5 30P PLUG P N 88652 E00172...

Page 145: ...P N 92974 Rev 1 Page 129 FIGURE C 10 BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 120V CE 332P4W PIN SLEEVE PLUG P N 88653 E00173...

Page 146: ...Page 130 BB4500 BB5000 Operating Manual FIGURE C 11 BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 230V CE CEE7 7 SCHUKO PLUG P N 88654 E00174...

Page 147: ...P N 92974 Rev 1 Page 131 FIGURE C 12 BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 230V DOMESTIC L6 15P PLUG P N 88655 E00175...

Page 148: ...Page 132 BB4500 BB5000 Operating Manual FIGURE C 13 PNEUMATIC CONDITIONING UNIT SCHEMATIC P N 59248 4 5 5 4 4 2 2 4 1 1 3 3 5 5 3 3 E STOP E STOP 2 2 1 1 XP XP START START V1 V1 3 3 1 1 2 2 SHUTOFF...

Page 149: ...P N 92974 Rev 1 Page 133 FIGURE C 14 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50 60 HZ CE ASSEMBLY P N 88035 B00367...

Page 150: ...Page 134 BB4500 BB5000 Operating Manual FIGURE C 15 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50 60 HZ DOMESTIC ASSEMBLY P N 88036 B00368...

Page 151: ...P N 92974 Rev 1 Page 135 FIGURE C 16 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY P N 88037 B00365...

Page 152: ...Page 136 BB4500 BB5000 Operating Manual FIGURE C 17 BB4500 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V CE ASSEMBLY P N 88038 B00366...

Page 153: ...P N 92974 Rev 1 Page 137 FIGURE C 18 BB5000 SERVO CONTROLLER 3RD GEN 460VAC CE ASSEMBLY P N A00099...

Page 154: ...Page 138 BB4500 BB5000 Operating Manual FIGURE C 19 BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY P N A00100...

Page 155: ...P N 92974 Rev 1 Page 139 FIGURE C 20 BB5000 SERVO PENDANT ASSEMBLY P N B00024...

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Page 157: ...ndant 6 Reduce speed to zero by turning the knob fully counter clockwise 7 Open the cover to access the function keys on the servo amp See Figure D 1 8 Press the mode button repeatedly until the displ...

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Page 159: ...P N 92974 Rev 1 Page 143 APPENDIX E SDS Contact CLIMAX for the current Safety Data Sheets...

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