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Page 54

BB8100 Operating Manual

Troubleshooting

SYMPTOM

SOLUTION

Axial feed unit will not
advance the bar

Check the feed direction is set to the desired setting.

Clean the leadscrew.

Check that the feed rate is not too low.

Check that the axial feed unit is securely mounted to the
end of the bar.

Chatter

Re-sharpen the tool bit or replace the carbide inserts.

Adjust the feed rate.

Increase or decrease the hydraulic motor speed.

Change the cutter depth.

Machine is unstable

Tighten all clamps and hardware.

Provide additional support.

Rotational drive unit
will not rotate

Check that the hydraulic power unit is turned on.

Check that the pump motor is turning in the correct
direction.

Check the oil level in the power unit.

Check that the speed control is open.

Check the hydraulic hose connections.

Feeds in wrong
direction

Check the handle position on the axial feed unit.

Hydraulic power unit
fails to deliver fluid

Check the fluid level. Add more fluid if necessary.

Check that the pump motor is turning in the correct
direction.

Check hydraulic connections for plugs or leaks.

Hydraulic power unit
motor does not run

Check that the power unit and electrical supply are
compatible.

Check that the power unit is plugged in.

Check for faulty wiring.

Содержание BB8100

Страница 1: ...PN 57064 June 2019 Revision 5 BB8100 BORING MACHINE OPERATING MANUAL ORIGINAL INSTRUCTIONS...

Страница 2: ......

Страница 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...

Страница 4: ...Page B BB8100 Operating Manual CLIMAX WORLDWIDE LOCATIONS...

Страница 5: ...tory 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 labo...

Страница 6: ...Page D BB8100 Operating Manual CE INFORMATION...

Страница 7: ...y without spider 12 CLAMP COLLARS 12 BORING BAR AND LEADSCREW ASSEMBLY 13 AXIAL TOOL CARRIER 13 MANUAL BORING HEAD ASSEMBLY 13 FACING HEAD ASSEMBLY 13 SETUP 15 BORING BAR AND BEARING SUPPORT ASSEMBLY...

Страница 8: ...5 USING THE REMOTE PENDANTS 46 Feed pendant 46 HPU PENDANT 47 MANUAL OVERRIDE ELECTRICAL FEED ONLY 47 CLAMP COLLARS 47 STARTING THE MACHINE 48 STOPPING THE MACHINE 48 REPETITIVE MACHINING 49 DISASSEMB...

Страница 9: ...P N 57064 Rev 5 Page iii SCHEMATICS 95 SDS 99...

Страница 10: ...Page iv BB8100 Operating Manual This page is intentionally left blank...

Страница 11: ...of product safety signs and labels is to increase the level of awareness to possible dangers Safety Alert Symbols indicate DANGER WARNING or CAUTION These symbols may be used in conjunction with other...

Страница 12: ...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...

Страница 13: ...hine HAZARDOUS ENVIRONMENTS Do not use the machine in a hazardous environment such as near explosive chemicals toxic fumes or a radiation hazard RADIATION HAZARDS There are no systems or components on...

Страница 14: ...ach 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 struc...

Страница 15: ...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 ca...

Страница 16: ...against the included invoice to make sure that all components have been shipped 3 Inspect all components for damage IMPORTANT Contact CLIMAX immediately to report damaged or missing components This i...

Страница 17: ...P N 57064 Rev 5 Page 7 Basic Components Figure 1 Components...

Страница 18: ...Page 8 BB8100 Operating Manual This page is intentionally left blank...

Страница 19: ...ial feed assembly CAUTION If the mechanical axial feed unit is moved to the other end of the bar the machine will feed in the opposite direction Check the feed direction before operating the machine T...

Страница 20: ...t fittings A multi function pendant controls the power unit and the machine Several hydraulic power units are available Obtain more information by calling CLIMAX CAUTION To avoid damaging the power un...

Страница 21: ...assembly with spider The end mount bearing support assembly mounts to the end of the work piece through a slotted spider The bar is held in place by a self aligning bearing which can compensate for ba...

Страница 22: ...Figure 8 Non self aligning ID mount with spider 48 5 77 1 232 1 956 mm Non self aligning bearing assembly without spider The bearing assembly does not include a spider it mounts to any existing suppor...

Страница 23: ...carrier with screws and if necessary spacers The tool carrier includes a brass nut and drive key Manual boring head assembly The boring head assembly includes spacers leading and trailing cartridge h...

Страница 24: ...oth the number of spacers used and the stroke of the facing head Feed rate is variable from 0 003 0 025 0 076 0 635 mm per revolution The facing head uses 1 square inch tool bits Figure 11 Available f...

Страница 25: ...place each assembly on the bar Because the rotational drive and tool head assemblies can be anywhere along the bar make sure to provide room for them when setting up the machine Boring bar and bearing...

Страница 26: ...Bearings placed too far apart allow the bar to deflect reducing bore accuracy 1 Clean the bore of the work with solvent to remove grease oil and dirt 2 Check the bar for nicks or cuts Dress the bar s...

Страница 27: ...f you want to mount the rotational drive assembly between the supports do it now See the Rotational drive assembly setup on page 21 for mounting information 11 If mounting another end mount bearing su...

Страница 28: ...ess it smooth if necessary A bar with nicks or gouges can damage mating parts including the tool carrier assembly and rotational drive unit beyond repair Clean the bar with solvent to remove dirt and...

Страница 29: ...ructions 8 If mounting another ID mount bearing repeat Steps 3 through 7 If mounting an end mount bearing support assembly see End mount bearing support assembly setup on page 16 CAUTION Bearings plac...

Страница 30: ...327 2 1422 4 1 4 6 B 56 0 59 75 1422 4 1517 7 1 4 7 A 59 75 63 5 1517 7 1612 9 1 4 7 B 62 75 66 5 1593 9 1689 1 1 4 5 6 C 5 66 5 70 25 1689 1 1784 4 1 4 5 6 D 6 70 25 74 0 1784 4 1879 6 1 4 5 7 C 7 74...

Страница 31: ...ng the boring bar 5 Remove one of the locking rings to gain access to the RDU keyway 6 Insert the drive key into the boring bar leadscrew groove Check that the key meshes with the leadscrew 7 Slide th...

Страница 32: ...on the power unit Mounting the axial feed assembly to the bar The mechanical axial feed unit can be mounted to either end of the boring bar 1 Place the axial feed unit in NEUTRAL so the leadscrew dri...

Страница 33: ...rapid feed system When engaged access to the drill socket port is available Access to this drill socket port opens and closes when the lever is switched between servo and rapid feed mode This prevent...

Страница 34: ...x assembly to CLIMAX 3 5 5 6 and 8 88 9 127 152 4 and 203 2 mm boring bars Adapters are also available for competitive boring systems P N 43735 Electric Feed Assembly for BB6000 BB6100 3 5 88 9 mm dia...

Страница 35: ...bar using the 10 cap screw and two 13 cap screws 2 Mount the mechanical override assembly to the adaptor plate Make sure the hex in the mechanical override is aligned with the hex on the lead screw 3...

Страница 36: ...To set the feed to NEUTRAL position the shifter knob half way between FORWARD and REVERSE NOTE The higher the feed rate the faster the axial feed unit will engage Setting feed direction when the bar i...

Страница 37: ...dial on the axial feed unit shows the feed speed when the bar is rotating Tooling setup Tool carrier setup Tool head assemblies require a tool carrier to mount to the boring bar Do the following to m...

Страница 38: ...rier on the bar for other operations 1 Loosen the setscrew on the side of the tool carrier 2 Tighten or loosen the adjustment screw 3 Tighten the setscrew to keep the adjustment screw in position Figu...

Страница 39: ...boring head assembly setup The manual boring assembly requires the tool carrier to mount it to the boring bar NOTE The bar can rotate either direction Check that the tooling faces the correct directi...

Страница 40: ...lock the middle dove tail set screw with the provided T handle hex drive Each division in the dial screw resolves in 0 001 0 025 mm change in diameter The dove tail adjustment set screws are set to th...

Страница 41: ...DIAMETER BORE RANGE DIAMETER NUMBER OF SPACER BLOCKS REQUIRED 2 95 76 mm block 5 9 150 mm block 11 8 300 mm block 14 5 21 5 368 546 mm 1 0 0 0 20 4 27 4 518 696 mm 1 0 0 26 3 33 3 668 846 mm 0 1 0 32...

Страница 42: ...8 300 mm block 14 5 22 5 368 572 mm 2 0 0 0 20 4 28 4 518 721 mm 1 0 0 26 3 34 3 668 871 mm 0 1 0 32 2 40 2 818 1 021 mm 1 1 0 38 1 46 1 968 1 171 mm 0 0 1 44 52 1 118 1 321 mm 1 0 1 49 9 57 9 1 267 1...

Страница 43: ...in Table 2 on page 31 and Table 3 on page 32 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 shortes...

Страница 44: ...40 and Table 7 on page 41 depending on the travel head size 5 Mount the spacers if necessary to the tool carrier CLIMAX recommends using the same number of spacers on both sides of the tool carrier to...

Страница 45: ...based on the desired range as specified in Table 5 on page 39 2 Select the appropriate feed tools based on the following a If no spacers are being used see Figure 22 use the straight crank handle and...

Страница 46: ...tool in toward the center of the bar At the maximum recommended torque rod angle of 15 the automatic radial feed is infinitely variable up to 0 008 0 2 mm per trip NOTE If the facing head is assemble...

Страница 47: ...chet provide a trip mechanism for the steel rod Set the trip to move the rod no more than 15 If a radial feed of more than 0 008 0 2 mm per revolution is desired use multiple trip mechanisms NOTE CLIM...

Страница 48: ...principles When the feed trip arm is oriented away from the boring bar operate the bar in the counter clockwise direction feed is radially in to out When the feed trip arm is oriented toward the borin...

Страница 49: ...75 mm 5 9 150 mm 11 8 300 mm 20 8 30 8 528 32 782 32 mm 0 0 0 No 26 7 36 7 678 18 932 18 mm 1 0 0 Yes 32 6 42 6 828 04 1 082 04 mm 0 1 0 No 38 5 48 5 977 9 1 231 9 mm 1 1 0 Yes 44 4 54 4 1 127 76 1 3...

Страница 50: ...95 75 mm 5 9 150 mm 11 8 300 mm 20 8 36 8 528 32 934 72 mm 0 0 0 No 26 7 42 7 678 18 1 084 58 mm 1 0 0 Yes 32 6 48 6 828 04 1 234 44 mm 0 1 0 No 38 5 54 5 977 9 1 384 3 mm 1 1 0 Yes 44 4 60 4 1 127 7...

Страница 51: ...75 mm 5 9 150 mm 11 8 300 mm 20 8 44 8 528 32 1 137 92 mm 0 0 0 No 26 7 50 7 678 18 1 287 78 mm 1 0 0 Yes 32 6 56 6 828 04 1 437 64 mm 0 1 0 No 38 5 62 5 977 9 1 587 5 mm 1 1 0 Yes 44 4 68 4 1 127 76...

Страница 52: ...1 Using a device such as a crane place arm onto tool carrier flush with carrier surface as shown important Always use the lifting eyes when lifting the arms The rotating lifting eyes provide the flexi...

Страница 53: ...rm 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 Attach the lifting eye onto counterweight arm...

Страница 54: ...Connect the hydraulic lines from the hydraulic motor to the power unit 4 Jog the motor to see which direction the bar is rotating Do the following to reverse the bar rotation a Turn off the hydraulic...

Страница 55: ...Check that moving parts move freely 4 Check that the hydraulic power unit is OFF 5 Check that the power unit wiring matches the electric power source Plug the power unit into a grounded outlet 6 Check...

Страница 56: ...te 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...

Страница 57: ...rive from the boring 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 n...

Страница 58: ...etting the feed rate on page 27 If facing a Set the feed direction on the axial feed assembly to NEUTRAL See Setting the feed direction b Adjust the automatic trip mechanism on the facing head See Fac...

Страница 59: ...rdened To prevent damage to the bar do not strike it against the bearing supports or the work piece Standard disassembly 1 Turn off and lock out the hydraulic power unit 2 Unplug electrical cords and...

Страница 60: ...ol carrier 6 Securely support the boring bar bearing supports and rotational drive assembly with hoists 7 Remove the axial feed assembly from the bar 8 If the rotational drive assembly is between the...

Страница 61: ...e leadscrew periodically with light oil to ensure smooth travel of the rotational drive assembly Before storage lightly oil the bar to prevent rusting Lightly grease the leadscrew Do not grease areas...

Страница 62: ...way oil to the dovetail ways Tool carrier Lightly oil all parts with JET LUBE 550 to prevent rusting Hydraulic power unit and motor General hydraulic system After 72 hours of operation do the followi...

Страница 63: ...the oil becomes contaminated When the power unit is operated at high temperatures for a long time Every two years Hydraulic fluid level should not drop below the red bar on the fluid level temperature...

Страница 64: ...nal support Rotational drive unit will not rotate Check that the hydraulic power unit is turned on Check that the pump motor is turning in the correct direction Check the oil level in the power unit C...

Страница 65: ...ore storing wipe the machine down with solvent to remove grease metal chips and moisture 2 To prevent rusting spray with a moisture displacement material such as Jet Lube 550 for short term storage LP...

Страница 66: ...Page 56 BB8100 Operating Manual SPECIFICATIONS...

Страница 67: ...P N 57064 Rev 5 Page 57 Figure 35 Dimensions of the self aligning bearing assembly without spider Figure 36 Dimensions of the non aligning bearing assembly without spider...

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Страница 76: ...2 Piece 57064 MANUAL INSTRUCTION BB8100 1 Piece 71726 SP PLM WRENCH TENTHSET DEPTH ADJUSTING SIZE 10 1 Piece 71727 WRENCH TENTHSET COMPRESSION ADJUSTING SIZE 10 1 Piece 71729 WRENCH HEX 3 32 3 25 T H...

Страница 77: ...ring 1 11739 Thrust washer 1 11158 5 8 Lifting eye 1 End mount bearing assembly 15208 5 8 Flat Washer 12 20390 Screw 5 8 11 x 6 SHCS 4 11696 Screw 1 2 13 x 3 SHCS 8 26100 Screw 3 8 24 x 2 HHCS 8 26101...

Страница 78: ...r clutch 1 22357 Carbide insert SPU 20 23046 Chip breaker 6 25807 Filter element 1 Hydraulic power unit 14420 Hydraulic fluid 5 gal 23662 Axial feed bar fuse 1 Mechanical Unit Axial feed assembly Elec...

Страница 79: ...TS 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 writi...

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Страница 109: ...P N 57064 Rev 5 Page 99 SDS Contact CLIMAX for the current Safety Data Sheets...

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