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BB7100 Operating Manual

RISK ASSESSMENT AND HAZARD MITIGATION

Machine Tools are specifically designed to perform precise material-removal
operations.

Stationary Machine Tools include lathes and milling machines and are typically
found in a machine shop. They are mounted in a fixed location during operation
and are considered to be a complete, self-contained machine. Stationary Machine
Tools achieve the rigidity needed to accomplish material-removal operations from
the structure that is an integral part of the machine tool.

In contrast, Portable Machine Tools are designed for on-site machining
applications. They typically attach directly to the workpiece itself, or to an
adjacent structure, and achieve their rigidity from the structure to which it is
attached. The design intent is that the Portable Machine Tool and the structure to
which it is attached become one complete machine during the material-removal
process.

To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, set-up, and operation practices that are unique
to Portable Machine Tools.

The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of portable machining applications,
identifying one or more hazards that must be addressed is typical.

When performing the on-site risk assessment, it is important to consider the
Portable Machine Tool and the workpiece as a whole.

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Содержание BB7100

Страница 1: ...PN 55769 March 2019 Revision 4 BB7100 BORINGMACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS ...

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Страница 3: ...ons 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 Telephone number Machine model Serial number if applicable Date of purchase CLIMAX World Headquarters 2712 East 2nd Street Newberg Oregon 97132 USA Telephone worldwide 1 503 538 2815 Toll free North America ...

Страница 4: ...Page B BB7100 Operating Manual CLIMAX WORLDWIDE LOCATIONS ...

Страница 5: ...ctory 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 the labor performed both at no charge and return the part or repaired machine shipping prepaid These warranties do not apply to the following Damage after the date of shipment not caused by defects in materi...

Страница 6: ...Page D BB7100 Operating Manual This page is intentionally left blank ...

Страница 7: ... the Electric Feed 17 To mount the electric feed to the bar 17 ATTACHING THE MECHANICAL RAPID FEED OPTIONAL EQUIPMENT 18 ROTATIONAL DRIVE SETUP 19 TO SETUP THE ROTATIONAL DRIVE 19 INSTALLING THE FACING AND BORING ARMS TO THE BORING BAR 21 To mount the tool carrier 21 To lock the tool carrier on the bar for other operations 21 To remove the brass nut 22 INSTALL THE SLIDE ARM ONTO THE TOOL CARRIER 2...

Страница 8: ...E DISASSEMBLY 33 To remove the bearings before removing the bar 33 MAINTENANCE 35 RECOMMENDED LUBRICANTS 35 BORING BAR AND LEAD SCREW 35 AXIAL FEED 35 ROTATIONAL DRIVE 36 BEARING SUPPORT 37 End mount bearing support assemblies 37 ID mount bearing support assemblies 37 BORING HEAD 37 MECHANICAL FACING HEAD 37 AXIAL TOOL CARRIER 37 STORAGE 38 SPARE PARTS 39 TOOL KIT 40 EXPLODED PARTS AND VIEWS 41 SC...

Страница 9: ... heed warnings could result in injury or even be fatal Proper care is your responsibility Contact CLIMAX immediately for replacement manuals or safety decals Intended Use Use this machine according to the instructions in this operating manual Do not use this machine for any purpose other than its intended use as described in this manual Stay Clear of Moving Parts Keep clear of the machine during o...

Страница 10: ...n matching sets and must be used to secure the bar when the machine is in the vertical orientation Torque these collars to 46 ft lbs Use the clamp collars to prevent over tightening of the bearings Clamp collars should be positioned ABOVE at least 2 support bearings when installed in a vertical orientation Clamp collars should be shouldered against the bearing when in use Metal Fragment Hazard The...

Страница 11: ...ions to reduce the risk of hazards and serious injury DANGER Indicates a hazardous situation that could be fatal or cause serious injury WARNING Indicates a potentially hazardous situation that could be fatal or cause serious injury CAUTION Indicates a potentially hazardous situation that could result in minor to moderate injury damage to the machine or interruption of an important process IMPORTA...

Страница 12: ...tach directly to the workpiece itself or to an adjacent structure and achieve their rigidity from the structure to which it is attached The design intent is that the Portable Machine Tool and the structure to which it is attached become one complete machine during the material removal process To achieve the intended results and to promote safety the operator must under stand and follow the design ...

Страница 13: ... 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 for the controls cabling and the operator I evaluated and mitigated any other potential risks specific to my work area TABLE 1 2 RISK ASSESSMENT CHECKLIST AFTER SET UP After set up I checked that the machine is safely ...

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Страница 15: ...N This manual describes how to use your Model BB7100 Portable Boring Machine Every part meets CLIMAX s strict quality standards For maximum safety and performance read the entire Operating Manual before using the portable boring machine ...

Страница 16: ...included invoice to ensure that all components have been shipped 3 Inspect all components for damage IMPORTANT Contact CLIMAX immediately to report damaged or missing components This is a highly configurable machine with many options and accessories This manual covers the use and operation of all of those possible options The machine configuration purchased by a customer may not contain all of the...

Страница 17: ...onsistently can crash the machine into the work piece damaging the tool DANGER A machine swinging or falling out of control can cause serious injury or even be fatal Make sure all crane hoist operators are trained on the proper use of the machines Also make sure the lifting devices are secure and properly rated for the load CAUTION To prevent damage to the machine always use the lifting eyes provi...

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Страница 19: ...P N 55769 Rev 4 Page 11 ...

Страница 20: ...t bearings in a vertical orientation DANGER To prevent the bar from sliding through the support bearings or falling use the 2 clamp collars provided in the tool kit when using the boring bar in a vertical orientation Torque to 46 ft lbs End mount bearing support setup Even though the end mount bearing support attaches to the outside of the work piece it can be placed anywhere along the boring bar ...

Страница 21: ...bar into the bore s to be machined Placement of the Boring Bar in the bore 8 Slide bearing supports onto each end of the bar Attaching bearing supports 9 Using a hoist hold the bar and bearings in the center of the bore 10 Align within 0 6 15 mm ...

Страница 22: ...iece to align with slots in the spiders 5 Mount one bearing to the end of the work piece 6 Slide the boring bar through the bearing support 7 If you need to mount the rotational drive between the supports do it now 8 If mounting another end mount bearing support repeat previous steps 9 Slide the boring bar through all bearing assemblies 10 Lock the bar in place by tightening the bearing cartridge ...

Страница 23: ...nd the boring bar 14 While holding the strap wrench in place tighten the bearing nut using the bearing nut wrench 15 Remove the bearing key tool P N 55572 from the boring bar 16 Precisely align the boring bar 17 Position a dial indicator to measure the concentricity between the boring bar and the bore 18 Adjust the screws in the bearing support adjusting blocks until the bar is centered TIP CLIMAX...

Страница 24: ... the bar end cap turn the feed unit output shaft until the hexes fit together 3 Secure the axial feed unit with the two screws provided 4 Secure the trip rod to a fixed object to engage the feed mechanism WARNING A loose trip rod can cause damage and injury Secure the trip rod to a fixed object Setting axial feed direction The lever for axial feed direction is on the flat base of the axial feed To...

Страница 25: ...f both the HPU and the axial feed drive The full load of the axial feed drive is 10 amps at 460 volts Refer to the electrical schematics for the HPU to determine the full load amps of the HPU and axial feed drive To mount the electric feed to the bar 1 Connect the power supply cable 2 Slide the leadscrew coupling onto the gearbox output shaft 3 Mount the adapter plate with two 3 8 16 and one 10 ca...

Страница 26: ...y and the end of the boring bar It has a side port for a standard 7 16 drill socket used to rapid advance the feed The lever engages and disengages the rapid feed system When engaged access to the drill socket port is available When the servo is engaged the drill socket will not fit into the port Drawings P N 81709 are found in the Exploded Parts and Views on page 41 ...

Страница 27: ...mounting bolts are tight Mounting the hydraulic motor and torque arms on the RDU 4 Loosen the bar drive lock ring clamp screws Push out both lock rings by screwing in the jacking screws 5 Slide the rotational drive unit over the boring bar 6 Remove the socket head cap screws from one bar drive lock ring Slide the ring away from the rotational drive along the bar 7 Be sure key slots in the boring b...

Страница 28: ...lide the bar drive lock ring back into place in the rotational drive 10 Tighten the clamping screws on both lock rings WARNING Weak tie down failure or loose torque arms can allow the torque arms to swing uncontrollably seriously injuring the operator and damaging the machine Secure the torque arms to a stationary object strong enough to withstand the full torque 11 Connect the hydraulic lines bet...

Страница 29: ...rier with the four 3 4 10 x 2 SHCS screws P N 28757 6 Insert the removable drive key P N 53523 inside the tool carrier onto the leadscrew Tighten the mounting screws P N 22496 to 96 in lbs 10 85 N m IMPORTANT The bar can rotate in either direction Be sure the rotation is correct for the carbide cartridges TIP Precision bores are best achieved with multiple roughing cuts then one or two finishing c...

Страница 30: ...BB7100 Operating Manual To remove the brass nut 1 Do not remove all the screws 2 Remove the screws on each end of the brass nut 3 If there is too much play in the brass nut the center set screw can be tightened ...

Страница 31: ...r is equipped with four set screws that allow you to adjust the slide arm perpendicularity if required Feedbox Assembly Mount and secure the feedbox with adapter plate P N 46879 as shown below Feedbox Trip Arm Set up Install the Counterweight Arm onto the Tool Carrier 1 Rotate the tool carrier on the bar to allow the counterweight arm to be mounted on the receiving surface of the tool carrier 2 At...

Страница 32: ...ecessary to re adjust them These set screws have Vibratite VC3 in order to avoid losing tension during vibration The lock also has this compound and it might be necessary to re apply some every once in a while if necessary The BB7100 micro adjustment boring head comes with a 3 4 square shank tool holder A bolt on shim is provided the 3 4 tool holder so that it can be easily converted to a 1 2 tool...

Страница 33: ...rts using the Boring head tool range table 2 Using the drawing as a guide assemble the stack up blocks on to the tool carrier symmetrically on both sides of the tool carrier from tallest to shortest 3 Mount the boring head and the counterweight on the stack up blocks ...

Страница 34: ...66 7 768 3 0 0 1 30 25 34 25 768 3 870 1 0 1 34 25 38 25 870 971 5 0 1 1 38 25 42 25 971 5 1073 1 1 1 1 42 25 46 25 1073 1 1174 7 0 0 2 46 25 50 25 1174 7 1276 3 1 0 2 50 25 54 25 1276 3 1378 0 1 2 54 25 58 25 1378 1479 5 1 1 2 BB 7100 SOLID TOOLING BORING HEAD TOOL RANGE TABLE 12 9 61 4 DIAMETER BORE RANGE DIAMETER INCH MM NUMBER OF SPACER BLOCKS REQUIRED 75 BLOCK 2 BLOCK 4 BLOCK 8 BLOCK 12 9 15 ...

Страница 35: ...9 734 06 810 26 0 0 0 1 30 4 33 4 772 16 848 36 1 0 0 1 32 9 35 9 835 66 911 86 0 1 0 1 34 4 37 4 873 76 949 96 1 1 0 1 36 9 39 9 937 26 1013 46 0 0 1 1 38 4 41 4 975 36 1051 56 1 0 1 1 40 9 43 9 1038 86 1115 06 0 1 1 1 42 4 45 4 1076 96 1153 16 1 1 1 1 44 9 47 9 1140 46 1216 66 0 0 0 2 46 4 49 4 1178 56 1254 76 1 0 0 2 48 9 51 9 1242 06 1318 26 0 1 0 2 50 4 53 4 1280 16 1356 36 1 1 0 2 52 9 55 9 ...

Страница 36: ...the hydraulic motor as described in the power unit instruction manual 8 Plug the power unit into a grounded outlet CAUTION Operating this hydraulic power unit for extended periods of time without connecting the hydraulic motor will overheat the system and may damage the pump WARNING To avoid injury by flying chips or loud noise wear personal protective equipment while operating the machine Jog the...

Страница 37: ...e hydraulic power unit wiring matches the electric power source Plug the power unit into a grounded outlet 8 Check the hydraulic power unit reservoir level Fill the reservoir to above the red bar with Mobil DTE 24 anti wear hydraulic oil or equivalent Check that the power unit is on a level surface 9 Clean the hydraulic hoses and fittings before connecting them 10 Check that the hydraulic power un...

Страница 38: ...letely stopped use a brush to remove chips CAUTION To avoid personal injury from flying chips do not use compressed air to remove chips Repetitive Machining To set the machine up for repetitive machining 1 Reverse the axial feed tool head direction 2 Manually or automatically feed the tool head back to where it started cutting 3 Sharpen the tool bit or replace the carbide inserts if necessary 4 Us...

Страница 39: ...ate potentiometer and runs the axial power feed at maximum rate regardless of the potentiometer setting Feed Fwd Rev A 3 position selector switch that determines the direction of axial feed In neutral power feed is disengaged The feed rate can be adjuted or reversed during operation Speed The Feed potentiometer controls the axial feed rate Counterclockwise decreases the feed rate clockwise increas...

Страница 40: ...ring bar When disengaged a hand drill can be installed for manual rapid operation When the gear box is in the manual override position the pendant functions are not active CAUTION Do not force the shift lever to engage Forceful engagement can damage the mechanical override mechanism To move the tool carrier rapidly shift the feed lever on the top of the gearbox to the back position With a socket o...

Страница 41: ...he bearing cartridges 14 Remove the boring bar 15 Remove the bearing support s from the work piece Alternative disassembly To remove the bearings before removing the bar 1 Turn off and lock out the hydraulic power unit 2 Disconnect the hydraulic hoses from the motor 3 Remove the tool bit or carbide cartridge from the tool head 4 Remove the tool head and tool carrier 5 Securely support the boring b...

Страница 42: ...rive key 13 Carefully slide the rotational drive off the bar 14 Loosen the bearing cartridges 15 Place a clean wooden crib in the bottom of the bore 16 Remove the bearing support s from the work piece 17 Slide the bar out of the bore using the crib ...

Страница 43: ...4 anti wear hydraulic oil Hydraulic power unit and motor CAUTION To avoid damage only use specified lubricants Boring bar and lead screw Clean the lead screw and boring bar frequently during operation Keep chips away from the lead screw threads Lubricate the lead screw periodically with light oil to ensure smooth travel of the rotational drive Before storage lightly oil the bar to prevent rusting ...

Страница 44: ... Aero Lube SAE 90 gear oil or equivalent To fill the gear box 1 Using the lifting eye set the gear box upright Secure the gearbox so it cannot move 2 Remove the fill plug and the level plug Filling the gearbox with oil 3 Fill the gearbox through the fill hole until oil comes out the level hole 4 Replace the level plug 5 Add one more quart of oil 6 Replace the fill plug ...

Страница 45: ...d grease the worm gears inside the blocks Periodically grease the bearing cartridge Boring head Lightly oil all parts to prevent rusting Mechanical facing head Before and frequently during operation lubricate the tool head carrier with way oil through the grease fitting Brush chips from the lead screw to prevent thread damage Lightly oil the lead screw periodically to ensure smooth travel of the t...

Страница 46: ...Before storing the machine clean it using solvent to remove grease metal chips and moisture Spray the machine with a moisture protective coating LPS1 or LPS2 for short term storage LPS 3 for long term storage to prevent rusting Store the machine in the boxes provided Place desiccant bags or vapor wrap around the machine to absorb moisture ...

Страница 47: ...e carbide inserts Adjust the feed rate Increase or decrease the hydraulic motor speed Change the cutter depth PART NO DESCRIPTION QTY WHERE USED 15549 Lead screw bearing adjustment nut 2 Boring bar 15173 Thrust washer 4 12446 Thrust bearing 2 15172 Needle bearing 2 15555 Bar Drive Key 1 15754 Trip rod 1 Mechanical axial feed 15608 Seal 2 Rotational drive 15768 Seal 2 18432 Extension spring 3 Facin...

Страница 48: ...261 WRENCH SOCKET 3 8 6 PT X 3 8 DRIVE 1 Piece 19700 CONTAINER SHIPPING FLAT ROOF 20 X 8 75 X 10 5 1 Piece 20869 WRENCH HEX SET 5 64 TO 3 4 15 PIECES 1 Piece 21406 SCREW 3 4 10 X 2 HHCS 2 Piece 24751 WRENCH RATCHET 3 8 DRIVE 1 Piece 29661 WRENCH HINGE HANDLE 1 2 DRIVE 17 IN HANDLE KB 1 Piece 33999 WRENCH HEX SET 050 3 8 BONDHUS BALL END KB 1 Piece 42792 CLAMP COLLAR 5 ID X 6 1 4 OD X 7 8 2 PIECE 2...

Страница 49: ...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 Portable Machining Welding Systems to perform service on the machine ...

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Страница 83: ...P N 55769 Rev 4 Page 75 SCHEMATICS ...

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Страница 87: ...P N 55769 Rev 4 Page 79 SPECIFICATIONS ...

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