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Climax BW2600 Operating Manual Download Page 11

P/N 85555, Rev. 6

Page v

 LIST OF FIGURES

F

IGURE

P

AGE

1-1 Top label locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  8
1-2 Bottom label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  8
1-3 Side label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9
2-1 BW2600 controls and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12
2-2 BW2600 Skip or fill controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13
2-3 Step amount indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14
2-4 Drag brake adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  14
2-5 BW2600 Control features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15
2-6 Conduit assembly (Miller example shown)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16
2-7 BW2600 Radial mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16
2-8 Swivel head assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
2-9 Swivel assembly and torch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
2-10 Torch sizes #1 and #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  17
2-11 6" and 12" extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
2-12 Detail of mounting rod P/N 30773 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
2-13 Detail of BW2600 carrying case  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
2-14 Torch sizes #00 and #0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
2-15 Standard torch adapter kit (shown with swivel installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
2-16 Remote operator pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
2-17 Compact face torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20
2-18 Standard face torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20
2-19 BW2600 adjustable base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  21
2-20 BW2600 Radial mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  21
2-21 Mounting rod extender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  21
2-22 BW2600 torch extension support  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22
2-23 BW2600 front panel controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  23
2-24 Remote pendant controller  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  24
2-25 BW2600 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
3-1 Detail of installing the boring bar adapter kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29
3-2 Set screws in adapter plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30
3-3 Alignment tool over the mounting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  30
3-4 Tightening the set screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
3-5 BW2600 assembly components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31
3-6 BW2600 and radial mount on mounting rod  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  32
3-7 Torch and swivel assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  33
3-8 Torch aligned with the travel slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  33
3-9 Jam nut tightened  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  34
3-10 Liner through diffuser gas holes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  34
3-11 Torch extension assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  35
3-12 BW2600 controls side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  35
3-13 BW2600 axial stroke distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  36
3-14 3 o’clock and 9 o’clock positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37
3-15 Swinging the bore welder to attain center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37
3-16 Supporting the bore welder for sag adjustment (extensions not shown). . . . . . . . . . . . . . . . . . . . . . .  38

Summary of Contents for BW2600

Page 1: ...BW2600 AUTOBOREWELDER BW2600 OPERATING MANUAL ORIGINAL INSTRUCTIONS P N 85555 January 2019 Revision 6...

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 BW2600 Operating Manual CLIMAX GLOBAL LOCATIONS...

Page 5: ...P N 85555 Rev 6 Page C CE DOCUMENTATION...

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

Page 7: ...FICATIONS 25 2 4 ITEMS REQUIRED BUT NOT SUPPLIED 26 3 SETUP 27 3 1 PREPARING THE MACHINE FOR USE 27 3 1 1 Inspecting the machine 27 3 1 2 Assessing the work area 28 3 2 LIFTING AND RIGGING 28 3 3 INST...

Page 8: ...E AND TROUBLESHOOTING 63 5 1 OVERVIEW 63 5 2 MAINTENANCE INTERVALS 64 5 3 MAINTENANCE TASKS 64 5 4 REPLACING LINERS 64 5 5 TROUBLESHOOTING 65 5 5 1 If the feed will not work 65 5 5 2 If there is a lac...

Page 9: ...P N 85555 Rev 6 Page iii TABLE OF CONTENTS CONTINUED CHAPTER SECTION PAGE 6 1 2 Long term storage 73 6 2 SHIPPING 73 APPENDIX A EXPLODED VIEWS AND PARTS LISTS 75 APPENDIX B SCHEMATICS 95...

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Page 11: ...0 2 18 Standard face torch 20 2 19 BW2600 adjustable base 21 2 20 BW2600 Radial mount 21 2 21 Mounting rod extender 21 2 22 BW2600 torch extension support 22 2 23 BW2600 front panel controls 23 2 24 R...

Page 12: ...pping container with components packed 74 A 1 BW2600 assembly P N 91579 76 A 2 BW2600 assembly parts list 1 P N 91579 77 A 3 BW2600 assembly parts list 2 P N 91579 78 A 4 Step positioner assembly P N...

Page 13: ...y P N 86514 102 B 6 Power and control harness assembly P N 86516 103 B 7 Potentiometer and harness assembly P N 86517 104 B 8 Switch rotation and harness assembly P N 86518 105 B 9 Switch auto skip on...

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Page 15: ...set up 5 1 4 Labels 6 2 1 BW2600 front panel controls 23 2 2 Remote pendant controls 24 2 3 BW2600 specifications 25 2 4 Buildup diameters per swivel head 26 2 5 Optional torch diameter ranges 26 3 1...

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Page 17: ...or operate the machine The first page of each chapter includes a list of the chapter contents to help you locate specific information The appendices contain supplemental product information to aid in...

Page 18: ...this or any machine tool you should receive instruction from a qualified trainer Contact CLIMAX for machine specific training information Risk assessment Working with and around this machine poses ris...

Page 19: ...els and avoid contact with bare skin until the machine has cooled 1 4 MACHINE SPECIFIC SAFETY PRECAUTIONS Hazardous environments Do not operate the machine in environments where explosive materials to...

Page 20: ...ly to the work piece itself or to an adjacent structure The design intent is that the portable welding tool and the structure to which it is attached become one complete machine during the welding pro...

Page 21: ...cabling and the operator I have assessed for additional risks unique to this application of the Portable Welding tool TABLE 1 3 RISK ASSESSMENT CHECKLIST AFTER SET UP After Set up I checked that the m...

Page 22: ...for replacements TABLE 1 4 LABELS P N 29154 Serial number plate P N 37576 Warning label electri cal shock danger P N 46902 Warning label hot surface P N 59044 Read the owner s manual P N 63504 Warnin...

Page 23: ...P N 85555 Rev 6 Page 7 P N 86158 BW2600 label P N 90487 Run position label P N 90627 Step indicator label TABLE 1 4 LABELS...

Page 24: ...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 FIGURE 1 1 TOP LABEL LOCATIONS Label P N 86036 86158...

Page 25: ...P N 85555 Rev 6 Page 9 FIGURE 1 3 SIDE LABEL LOCATIONS Label P N 46902 90487...

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Page 27: ...e full range of torches The range can be extended to 10 254 mm by carefully monitoring the step func tion If step problems develop push the axial feed knob in and pull it out again This cycle resets t...

Page 28: ...gger control described on page 15 Reversible rotation described on page 15 Axial adjustment described on page 13 FIGURE 2 1 BW2600 CONTROLS AND COMPONENTS DRAG BRAKE ADJUSTMENT STEP ADJUSTMENT KNOB AX...

Page 29: ...age 58 for how to set the detent for the SKIP or FILL feature Variable mechanical step Variable mechanical step an infinitely variable mechanical step ranging 0 060 0 175 1 52 4 5 mm The amount of ste...

Page 30: ...ontrol of axial placement of the spindle at any time when the feed is disengaged When the feed is engaged axial adjustment can only be done in the spindle retract direction Feed drag brake adjustment...

Page 31: ...factures many interface kits for use with world wide suppliers of MIG welding units The customer s wire feed system connects to the BW2600 at the wire feed contactor control port as seen in Figure 2 5...

Page 32: ...Conduit Switch Assembly Lincoln PowerMig P N 85527 Conduit Switch Assembly Lincoln Tweco Style with 5 pin Amphe nol P N 86046 BW2600 radial mount P N 85771 The radial mount was designed for use betwe...

Page 33: ...anges of the 7 16 20 stem of up to 10 degrees off center may be accommodated The swivel head has a locking nut on the brass stem that can be loosened to remove the torch Upon re installation the torch...

Page 34: ...se is provided for the protection and storage of the bore welder Quick change torch Torches may be changed easily with the torch connection system allowing for fast changes between torch sizes The tor...

Page 35: ...torch P N 29063 and the 0 torch P N 28448 enabling bore welding range capability down to 0 87 22 mm diameter Remote operator pendant The remote operator pendant allows for control of the BW2600 while...

Page 36: ...the bore welder is interfacing with the BB5000 Boring Bar A minimum of 6 152 mm swing in 6 152 mm axial clearance is necessary to use the compact face torch The standard face torch is used with the a...

Page 37: ...on with the adjustable base option only They provide support articulation and add distance from the mounting rod to the bore welder spindle for larger jobs It is commonly used with the standard face t...

Page 38: ...ing 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 40877 The torch extension support kit is used for extension...

Page 39: ...and trig gers the wire feeder system Starts and stops the bore welding process Contactor control with power switch is still operative when the AC mains are not connected 2 WIRE FEEDER CONTROL PORT Pro...

Page 40: ...IP FILL ON OFF Enables or disables skip and fill function Disables the switch from reading the cams Useful for situations where cams are preset but the operator needs to disable or enable during weld...

Page 41: ...riggers the wire feeder system to weld Starts the bore welding pro cess To use the pendant turn ON the panel MAIN ON OFF switch 13 WELD STOP Stops rotation and the wire feeder system Stops the bore we...

Page 42: ...elding lead Personal protective equipment Diagonal cutters CLIMAX offers a wire feeder for purchase Contact CLIMAX for more information Maximum continuous welding current 175 amps BW2600 power 120v or...

Page 43: ...42 3 4 INSTALLING ACCESSORIES 46 3 4 1 STANDARD TORCH ADAPTER 46 3 4 2 TORCH 00 AND 0 47 3 4 3 TORCH EXTENSION SUPPORT KIT 48 This chapter explains how to set up the machine for operation 3 1 PREPARI...

Page 44: ...e and each time before you operate the machine 3 2 LIFTING AND RIGGING There are no special rigging and lifting instructions for the BW2600 CAUTION Use caution and follow all site procedures such as a...

Page 45: ...e welder from slipping on the mounting rod 3 3 1 Mounting to a boring bar FIGURE 3 1 DETAIL OF INSTALLING THE BORING BAR ADAPTER KIT Do the following to install the boring bar adapter kit 1 Screw the...

Page 46: ...Align the mounting rod to the boring bar by sliding the alignment tool back and forth then tighten the inter face plate clamp screw enough to prevent move ment NOTICE Completing the tightening of the...

Page 47: ...ng rod Do the following to install the bore welder onto the mounting rod 1 Slide the BW2600 radial mount over the nose col lar of the weld head assembly and hand tighten the clamp bolt see Figure 3 5...

Page 48: ...ecessary extensions for the bore size using Table 3 1 NOTICE All the torches in Table 3 1 except for the swivel torch heads require a standard torch adapter to use with the swivel head FIGURE 3 6 BW26...

Page 49: ...om the torch into the swivel assembly b Screw on the torch approximately half way or until the liner is flush with the back of the swivel assembly c Align the torch with the travel direction of the sw...

Page 50: ...ollow ing i Install the liner into the torch and swivel assembly ii Cut the liner flush at the male 3 4 10 fitting iii Secure the liner with the set screw f Check that the liner is visible through the...

Page 51: ...at the axial stroke of the machine is set to pro vide full coverage maxi mum of 9 229 mm of the bore At full spindle extension the torch should start at the end of the bore farthest away from the mach...

Page 52: ...76 152 305 457 mm FIGURE 3 13 BW2600 AXIAL STROKE DISTANCE 3 3 1 4 Centering the bore welder Do the following to center the bore welder 1 Connect the BW2600 to AC mains power with the provided power c...

Page 53: ...re welder on the mounting rod to attain center see Figure 3 15 NOTICE The use of extensions installed as a mandrel reaching through the bore can facilitate quick centering of the machine Use a scale o...

Page 54: ...following to set the torch offset 1 Set the torch nozzle approximately 1 8 3 2 mm away from the surface to be welded 2 Check that the swivel nut in the swivel assembly is as tight as possible by hand...

Page 55: ...cluded 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 4 Screw the mounting rod into the slider hole on the adjust...

Page 56: ...se a 10 254 mm radial mount BW3000 radial mounts can be joined together if required If a longer mounting rod is required use the mounting rod extender to increase the length of the mounting rod withou...

Page 57: ...the extension at the 6 o clock position and adjust the rear leveling jack until the extension appears parallel to the bore surface In this way the rear jack makes the base pivot on the forward jacks...

Page 58: ...h in the X axis NOTICE The torch and spindle may be rotated manually or by using the controls WARNING When using the panel controls unplug the wire feeder cable or the wire feed circuit will be active...

Page 59: ...43 2 Connect the power cord to the BW2600 see Figure 3 23 3 Connect the wire feed con duit to the BW2600 see Figure 3 24 and tighten the set screw FIGURE 3 23 POWER CORD CONNECTION FIGURE 3 24 WIRE FE...

Page 60: ...it to the wire feeder see Figure 3 26 6 Connect the wire feed con trol cable to the wire feeder see Figure 3 27 7 Stage the wire into the feed rollers and clamp the feed rolls FIGURE 3 25 WIRE FEED CO...

Page 61: ...If your wire feeder does not have a WIRE JOG function and does not easily disconnect the weld power remove the weld ground connection before placing the BW2600 in weld mode 9 Once wire has exited the...

Page 62: ...propriate for your application NOTICE With MIG welding the wire speed bears a direct relationship to the weld current 3 4 INSTALLING ACCESSORIES Setup of optional accessories are described in the foll...

Page 63: ...0 These torches are used to build up bores ranging in diameter from 0 88 1 7 22 44 mm and 1 7 3 44 76 mm respectively They are used with the standard torch adapter described in Section 3 4 1 CAUTION...

Page 64: ...P Because the wire is curved when exiting the tip the point of contact with the work is higher than might otherwise be expected Therefore position the tip slightly toward the end of the nozzle After r...

Page 65: ...at right angles to the extension string 3 Obtain concentricity of the support body with the bore 4 Attach the extension sup port rod to the foundation determined in step 1 5 Continue with the set up a...

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Page 67: ...ARC VOLTAGE 58 4 6 2 USING 0 035 WIRE 59 4 6 3 SHIELDING GAS 59 4 6 4 WIRE AND GAS 59 4 6 5 SPINDLE FEED AND WIRE LOCATION 60 4 6 6 WELDING IN THE HORIZONTAL AXIS 60 4 6 6 1 WELDING ON THE VERTICAL UP...

Page 68: ...4 3 and Section 1 6 on page 5 for each job before starting work The BW2600 has an optional remote operation pendant that allows the operator to choose the best location to operate the machine 4 3 PRE...

Page 69: ...to get the total seconds per rotation of the spindle at 18 in min 457 mm min linear travel speed Optimum travel speed for MIG welding is 20 in min 508 mm min With vertical bore welder axis welding tra...

Page 70: ...he bead size is approximately 0 115 in depth 4 4 4 Checking the step setting Do the following to check the step setting 1 Check that the bore welder is clear of rotational obstructions 2 Disconnect th...

Page 71: ...wire speed 4 4 5 Attaching the weld ground clamp Attach the power supply ground clamp to the part to be welded The surface to which the clamp is attached should be clean bare metal and located with a...

Page 72: ...s weld deposition is cru cial Adjust the wire speed to place the bead at intersection of previous bead and the base metal or slightly above If the step is too small increase the step by unscrewing the...

Page 73: ...itch falls into the low area 6 Rotate the torch as in step 3 to the end of the interrupt area 7 Hold the first disc where it was set in step 5 Then move the other disc until the SKIP switch actuates 8...

Page 74: ...ng 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 hol...

Page 75: ...bstructed gas flow from the diffuser If wind is a problem make a shield from leather or other avail able non conductive materials 4 6 4 Wire and gas The BW2600 is designed for solid steel wire using t...

Page 76: ...rected slightly above the intersection point between the base metal and the previous bead The first step ending the first revolution should be made slightly smaller than those that follow An alternati...

Page 77: ...If the deposited metal does not solidify quickly enough it will follow or even run ahead of the arc and in the process use up all its de oxidizers the welding wire contains elements to cleanse the wel...

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Page 79: ...IENCING WIRE FLIP 67 5 5 8 IF STEEL WELD DEPOSITS ARE TOO HARD TO MACHINE 68 5 5 9 IF THE WELD IS GRAPING IN THE HORIZONTAL AXIS 68 5 5 10 IF THE WELD VOLTAGE IS HARD TO CONTROL 69 5 6 TRAINING 69 5 7...

Page 80: ...ease to the ring though the unit is shipped with a lubricated O ring The needle bearings that support the spindle are greased for the life of the machine 5 4 REPLACING LINERS When a liner needs replac...

Page 81: ...s the cam follower up against the cam or if something is jamming the cam follower arm 5 5 2 If there is a lack of fusion to the bore surface Lack of fusion in MIG welding occurs when the weld metal la...

Page 82: ...pread out the weld puddle NOTICE As the inductance is changed the arc voltage will need to be adjusted to compensate for the variation in inductance If the power supply does not have an inductance con...

Page 83: ...shielded from the atmosphere the oxygen and nitrogen will react with the weld metal causing porosity 5 5 6 2 Dirty bore surface Although the BW2600 usually handles these problems well excessive oil o...

Page 84: ...nd that once the weld bead is hardened it can be annealed to soften it For this to happen the weld must be allowed to cool below about 400 F and then reheated to about 950 1 250 F 510 676 C The weldin...

Page 85: ...tage is difficult to stabilize i e the process is stubbing or spray never settling into a stable short arc mode no matter what adjustments are made to voltage and wire speed In this case look for issu...

Page 86: ...Bore coupons to check for proper fusion Perform multi layered build ups Measure and record the step size rotation time and wire speed Then the operator may compare the data with Section 4 4 1 on page...

Page 87: ...64 SHORT ARM 1 40424 SP LINER STAINLESS STEEL 065 ID X 144 OD X 16 FT FOR 023 045 WIRE KB 1 66860 WRENCH OPEN END 3 4 X 6 0 LONG 1 66861 WRENCH OPEN END 11 16 X 6 3 8 LONG 1 66862 WRENCH HEX L KEY 1 8...

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Page 89: ...grease metal chips and moisture 2 Package the machine in its shipping container as shown in Figure 6 1 6 1 2 Long term storage Long term storage is defined as longer than three months For long term s...

Page 90: ...TH COMPONENTS PACKED CONDUIT ASSY TORC CH 2 TORCH 1 TORCH 0 WELD HEAD SUPPORT ROD TORCH EXTENSION 12 TORCH EXTENSION 6 ADJUSTABLE BASE ASSEMBLY Y TORCH 00 TORCH EXTENSION 3 TORCH ADAPTER SWIVEL ASSEMB...

Page 91: ...BLY WITH EURO CONNECTOR P N 85435 86 FIGURE A 11 POWER SUPPLY FOR SWITCH MILLER ASSEMBLY P N 85475 87 FIGURE A 12 CONDUIT ASSEMBLY FOR MILLER P N 85476 88 FIGURE A 13 CONDUIT POWER ASSEMBLY FOR MIG 22...

Page 92: ...Page 76 BW2600 Operating Manual FIGURE A 1 BW2600 ASSEMBLY P N 91579...

Page 93: ...1 1 02817 3 2 0 6 5 5281 866 32 233 5 57 86 3 9 03 5 7 9 63 1 5 9 725 37 5 63 1 62 725 725 1 63 1 78 6 5 666 33 86 1 62 725 6 9 1 21 6 02 211 725 2685 3 25 0 0 51 1 27 685 5 3 7 6 5 33 676 6 7 33 1 2...

Page 94: ...1 17 211 725 66 5 5 6 5 PP PP 2 PP 2 3 7 872 6 3 7 2 02725 2 02725 02817 250 5 5 7 02725 5 9 6833257 67 1 2 0 0 21 187 62 7 3 2 51 1 1 3 1 029 1 3 576 5 3 7 257 2 2 66 32 5 175 02 8 66 51 66 32 5 1 2...

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Page 96: ...Page 80 BW2600 Operating Manual FIGURE A 4 STEP POSITIONER ASSEMBLY P N 90590...

Page 97: ...51 61 3 7 86 1 5 2 3 1 52 5 52 5 87 2 86 1 2 7 2 3 1 2 187 81 36 3 81 5 1 21 3 7 635 1 7 2 5 21 5 7 21 6 35 2 5 1 87 6 67 3 59 6 5 6 6 187 1 21 16 57 2 1 5 2 352 6 5 635 1 9 2 7 6 5 635 1 9 2 7 6 5 66...

Page 98: ...Y P N 85771 PARTS LIST DESCRIPTION P N QTY ITEM NUT 1 2 13 STDN 10849 2 1 WASHER 1 2 FLTW SAE PLAIN FINISH 11779 2 2 SCREW 1 2 13 X 2 HHHCS GRADE 8 39179 1 4 MOUNT RADIAL 85769 1 5 SLEEVE MOUNT RADIAL...

Page 99: ...P N 85555 Rev 6 Page 83 FIGURE A 7 PELICAN CASE ASSEMBLY P N 85771 CONDUIT ASSY PENDANT TORCH BODIES TORCH HEAD BW2600 SLIDER BASE UNIT TUBE EXTENSIONS FOAM INSERTS PELICAN CASE...

Page 100: ...MM 3 29038 1 1 TORCH EXTENSION 152MM 6 29039 1 2 TORCH EXTENSION 305MM 12 29040 1 3 SUPPORT ROD WELD HEAD 30773 1 4 CLAMP COLLAR 1 ID X 1 3 4 OD X 1 2 WIDE ONE PIECE 63596 1 5 ASSY WELD HEAD BW2600 12...

Page 101: ...941 POSITIONS 2 3 PARTS LIST DESCRIPTION P N QTY ITEM CONNECTOR PLUG 11 4 METAL SHELL 67057 1 2 CABLE CLAMP LARGE SIZE 11 67060 1 3 CABLE POWER 2 CONDUCTOR 18 AWG 300 VAC RUBBER JACKET BLACK 67280 1 4...

Page 102: ...023 045 WIRE X 15 FT LONG 48552 1 5 SCREW 6 32 X 3 16 SSSCP 66872 1 6 SUPPORT CABLE LARGE 67307 1 7 NUT EURO 174X 2 67336 1 8 SUPPORT CABLE SPRING 67338 1 9 PLUG HOUSING EURO 67341 1 10 SUPPORT CABLE...

Page 103: ...MBLY P N 85475 PIN LOCATION 67155 POSITION 1 2 PARTS LIST DESCRIPTION P N QTY ITEM CABLE CLAMP LARGE SIZE 11 67060 1 1 TERMINAL PIN 18 16 AWG 67155 2 2 CONNECTOR PLUG 4 PIN REVERSE MALE FEMALE SIZE 11...

Page 104: ...SHCS 35910 1 2 FTG QUICK COUPLER MALE 41003 1 3 CABLE ASSY 8FT 41006 1 4 LINER TWECO 023 045 WIRE X 15 FT LONG 48552 1 5 NUT POWER PIN 66853 1 6 SCREW 6 32 X 3 16 SSSCP 66872 1 7 BODY POWER PIN MILLER...

Page 105: ...1 SCREW M4 X 0 7 X 8MM SHCS 35910 1 2 FTG QUICK COUPLER MALE 41003 1 3 CABLE ASSY 8FT 41006 1 4 SP END TWECO 41008 1 5 LINER TWECO 023 045 WIRE X 15 FT LONG 48552 1 6 SCREW 6 32 X 3 16 SSSCP 66872 1...

Page 106: ...g Manual FIGURE A 14 CONTACTOR ASSEMBLY FOR HOBART AND THERMAL ARC P N 85530 PARTS LIST DESCRIPTION P N QTY ITEM CONNECTOR SOCKET DBL CRIMP 22 18 AWG 250 X 032 RED 67050 2 1 CONTACTOR BW2600 BLANK END...

Page 107: ...HCS 35910 1 2 FTG QUICK COUPLER MALE 41003 1 3 HEAT SHRINK TUBE 1 1 2 DIA BLACK 41005 1 4 CABLE ASSY 8FT 41006 1 5 SP END TWECO 41008 1 6 LINER TWECO 023 045 WIRE X 15 FT LONG 48552 1 7 SCREW 6 32 X 3...

Page 108: ...COUPLER MALE 41003 1 3 CABLE ASSY 8FT 41006 1 4 SP END TWECO 41008 1 5 LINER TWECO 023 045 WIRE X 15 FT LONG 48552 1 6 SCREW 6 32 X 3 16 SSSCP 66872 1 7 TERMINAL QUICK DISCONNECT DBL CRIMP MALE 22 18...

Page 109: ...TWECO 023 045 WIRE X 15 FT LONG 48552 1 7 NUT SIZE B INERT GAS 48939 1 8 NIPPLE BARBED FOR A 41009 64119 1 9 SCREW 6 32 X 3 16 SSSCP 66872 1 10 FTG NIPPLE INERT GAS B SIZE 1 4 HOSE 67033 1 11 CLAMP HO...

Page 110: ...4 METAL SHELL 67057 1 2 CABLE CLAMP LARGE SIZE 11 67060 1 3 CONNECTOR CABLE CLAMP MS3057A SIZE 18 67138 1 4 CONNECTOR STRAIGHT PLUG SIZE 18 5 PIN 67147 1 5 RUBBER BUSHING FOR MS3057A CABLE CLAMP 312 I...

Page 111: ...FIGURE B 4 PENDANT ASSEMBLY P N 85341 101 FIGURE B 5 POWER ENTRY MODULE ASSEMBLY P N 86514 102 FIGURE B 6 POWER AND CONTROL HARNESS ASSEMBLY P N 86516 103 FIGURE B 7 POTENTIOMETER AND HARNESS ASSEMBL...

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Page 113: ...P N 85555 Rev 6 Page 97 FIGURE B 3 CONTROL ENCLOSURE SCHEMATIC P N 84635...

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Page 115: ...P N 85555 Rev 6 Page 99 FIGURE B 2 CABLE ASSEMBLY ROCKER SWITCH P N 84898...

Page 116: ...Page 100 BW2600 Operating Manual FIGURE B 3 CONNECTOR ASSEMBLY REMOTE PENDANT P N 85037...

Page 117: ...P N 85555 Rev 6 Page 101 FIGURE B 4 PENDANT ASSEMBLY P N 85341...

Page 118: ...Page 102 BW2600 Operating Manual FIGURE B 5 POWER ENTRY MODULE ASSEMBLY P N 86514...

Page 119: ...P N 85555 Rev 6 Page 103 FIGURE B 6 POWER AND CONTROL HARNESS ASSEMBLY P N 86516...

Page 120: ...Page 104 BW2600 Operating Manual FIGURE B 7 POTENTIOMETER AND HARNESS ASSEMBLY P N 86517...

Page 121: ...P N 85555 Rev 6 Page 105 FIGURE B 8 SWITCH ROTATION AND HARNESS ASSEMBLY P N 86518...

Page 122: ...Page 106 BW2600 Operating Manual FIGURE B 9 SWITCH AUTO SKIP ON OFF HARNESS ASSEMBLY P N 86520...

Page 123: ...P N 85555 Rev 6 Page 107 FIGURE B 10 SWITCH SKIP FILL AND HARNESS ASSEMBLY P N 86521...

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