BB6100 57017 RFS
BB6100 57017 RFS
BB6100 57017 RFS
BORING BAR
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
DANGER
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, WILL result in injury or loss of life.
WARNING
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, COULD result in injury or loss of life.
CAUTION
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, could result in minor or moderate injury.
NOTICE
concerns a condition, procedure, or practice worthy of special
attention.
TIP:
A tip provides additional information that can aid in completion of a
task.
Number Component
1 Boring/facing counterweight arm
2 ID bearing mount
3 Micro-adjust boring head
4 Hydraulic motor
5 Net fit tool carrier
6 Boring/facing arm
7 Three-arm bearing mount
NOTICE
Contact CLIMAX immediately to report damaged or missing
components.
TIP:
A suitable lifting device is critical in the safe setup of the machine.
Whenever possible, use a crane or hoist that provides smooth
control and fine adjustment such as a hydraulic lift or two-stage
winch. A device that is unstable, erratic, or difficult to maneuver
can be awkward and consequently put the operator and equipment
at risk.
TIP:
In many applications, the machine is effectively set-up using only
common measuring devices such as a steel rule or tape measure.
On those occasions when more precise alignment and accurate
machining is called for, plan to have the following additional tools
on hand:
DANGER
To prevent the bar from sliding through the support bearings, or
falling, use the two clamp collars provided in the tool kit when using
the boring bar in a vertical orientation. Torque to 25 ft.-lbs (34 mm).
5. Using a hoist, hold the bar and bearings in the approximate center of the bore.
Alignment within 1/8" (3 mm) is sufficient.
1/8” (3 mm)
off-center okay
WARNING
Uncontrolled swinging or falling machinery can cause serious
injury. Securely wrap the hoist around the bar and/or bearings
before lifting the machine.
P/N: 57017, Rev. 4 Page 17
6. Use existing holes if they align with slots in the spider bearing supports.
Otherwise, drill and tap new holes or weld to work piece. If holes are to be drilled
and tapped, with the spider against the work, and mark their alignment.
7. Pull the bearing supports from the boring bar. Remove the boring bar from the
work piece.
8. If necessary, drill and tap suitable mounting holes in the end of the work piece to
align with slots in the spider bearing supports.
9. Mount one bearing support to the end of the work piece.
10. Slide the boring bar through the bearing support.
11. If the RDU is to be mounted between supports, mount it now.
12. Make sure the RDU shaft collars are on the drive hub. See Section 3.6 on page 24
for mounting information.
13. For mounting another end-mount bearing support, repeat steps #8 through #10. If
using an ID-mount bearing assembly, see Section 3.4 on page 19. CLIMAX
recommends no fewer than two support assemblies to obtain adequate machine
stability. The maximum recommended unsupported bar length is 5 feet (1.5 m).
See Section 3.2 on page 15.
14. Slide the boring bar through all bearing assemblies and position axially. Use an
additional bar clamp as necessary when the bar is in a vertical orientation (see
Section 3.1 on page 15).
15. Do the following to clamp the bearing support onto the bar:
a. Align two setscrews in the bearing with the indentation in the bearing
ring.
b. Adjust the bearing ring (and screws) so it is 90° to the lead screw in the
bar.
c. Tighten the setscrews evenly until the bar is held firmly.
Number Component
1 Plate check
2 Chuck body
FIGURE 2. ID-MOUNT BEARING COMPONENT
3 Modified bearing
4 Short jacking bolt
5 Long jacking bolt
6 3.5" (90 mm) jaw
7 5.5" (140 mm) jaw
8 7.5" (190 mm) jaw
9 9.5" (240 mm) jaw
10 1" (25 mm) spacer
b. Loosely mount the bearing to the plate using the spring washers, flat washers, and screws (if
necessary).
If using the large chuck body, do the following before moving on to step 5:
a. Loosely mount the jaw clamping plates to the chuck body. Check that the stop plates on the
end of the clamping plates face toward the center of the chuck and toward the leg slot.
Number Component
1 Jacking screw stop
2 Jaw clamping plate
3 Large chuck body
Number Component
1 1" (25 mm) spacer
2 Leg
3 Jacking screw
c. Slide jacking screw assemblies into the slots in the chuck body. The legs should fit up
against the stop block on the back of the jaw clamping plates.
CAUTION
Bearings placed too far apart allow the bar to deform, reducing
bore precision. To keep the bar from deflecting, do not space the
bearing supports more than 5 feet (1.5 m) apart.
FIGURE 5. ID-MOUNT BEARING SUPPORT ASSEMBLY (LEFT) AND HINGED CLAMP COLLAR (RIGHT)
3. Mount the hinged clamp collar to the bar and tighten it.
4. Slide the bar through the bearing assemblies until the collar is against the
bearings.
5. Tightly clamp the modified collar onto the bar on opposite side (either outside or
inside).
6. Tighten the collar tensioning screws until there is slight resistance on the screws.
7. Rotate the bar by hand and check for resistance. If the bar will not rotate, back off
the screws in the hinged clamp collar.
CAUTION
The boring bar is not hardened. To prevent damage to the bar, do
not strike it against the bearing supports or the work piece.
FIGURE 6. ALIGN THE DRIVE HUB SLOT WITH THE LEAD SCREW
1. Inside the torque arms are mounted to (radial direction is optional) RDU housing.
2. Mount the hydraulic motor to the RDU.
3. Slide the RDU onto the boring bar.
4. Make sure the key slots in the boring bar and the RDU drive hub are aligned.
5. Push the bar drive key into the key slot.
CAUTION
The rotational drive key must be in place before operating the
boring bar. Failure to do so may damage the machine.
6. Adjust the shaft collars into place in the RDU. Tighten the clamping screws to
lock the shaft collars to the boring bar.
7. Secure the torque arms to insure the RDU does not rotate when energized.
WARNING
Loose torque arms can seriously injure the operator and damage
the machine. Secure the torque arms to a stationary structure
strong enough to withstand the full torque of the RDU.
8. Connect the hydraulic lines to the hydraulic power unit. See the Hydraulic power
section on page 43 for preparation and how to connect the lines.
CAUTION
To avoid damage to the hydraulic power unit pump, connect the
motor to the power unit before plugging in and turning it on.
TIP:
If the axial feed unit is moved to the opposite end of the bar, the
feed direction will be reversed. Check the feed direction before
operating the machine.
CAUTION
To avoid permanent damage to the axial feed unit, do not leave the
wrench in the lead screw dial.
Number Component
1 Feed adjustment knob
2 To feed unit
3 Neutral
4 From feed unit
CAUTION
To avoid internal damage to the feed box, do not force the feed
adjustment knob.
NOTICE
If the axial feed unit is moved to the opposite end of the bar, the
feed direction will reverse. Check feed direction before operating
the machine.
Number Component
1 Lead screw nut
2 Oil hole
3 Rod scraper
6. Lightly oil the boring bar and lead screw so the tool carrier will move freely.
Number Component
1 Tool carrier assembly
2 Tool holder
3 1" (25.4 mm) spacer
4 Leading tool holder
5 Trailing tool holder
6 2" (50.18 mm) spacer with slot
7 2" (50.18 mm) spacer no slot
8 6" (152.4 mm) spacer with slot
9 6" (152.4 mm) spacer no slot
10-13 Socket head cap screws (different sizes)
To set the tool to the desired diameter, simply feed the dial screw until reaching it
and then 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 the correct load by CLIMAX and
should not be necessary 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 it occasionally, if necessary.
The BB6100 micro-adjust boring head comes with a 3/4" (19 mm) 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" (13 mm) tool holder.
To set up leading and trailing, simply shift the boring heads against the mounting
screws in opposite directions.
There is a small set screw that stops the tool carriage from being removed from its
holder, and the boring head should never be operated without it on.
Proper maintenance would involve cleaning and lubricating the dove tail surfaces and
the dial screw threads and groove, and if the lock set screw feels loose after a while,
applying the provided Vibrative VC-3.
TIP:
The bar can rotate in either direction. Be sure the tool bits face the
correct direction.
Number Component
1 Stack-up blocks
2 Boring head
3 Tool carrier
4 Counterweight
TIP:
Geometry shown is for a left-hand tool.
5. Secure the tool bit in the tool holder. Using a dial indicator, adjust the tool
cutting depth. The maximum recommended cut is 0.125" (3 mm).
TIP:
Precision bores are best achieved by several roughing cuts and
one or more shallow finishing cuts.
NOTICE
Always use the lifting eyes when lifting the arms. The rotating lifting
eyes provide the flexibility and safety during setup operations.
2. Secure arm with clamp bar (P/N 53074) with 1/2-20 x 1-3/4 screws (P/N 18225), four per
clamp bar, and torque to 100 ft-lb. (135 N-m).
NOTICE
Always use the lifting eyes when lifting the arms. The rotating lifting
eyes provide the flexibility and safety during setup operations.
3. Using a lifting device such as a crane, lift the counterweight assembly to the arm. Fasten the
counterweight assembly to the arm using the fasteners shown in the exploded views.
Note that you can position the counterweight itself anywhere along the arm as needed to balance the
assembly.
Number Component
1 Feed trip
2 Facing head
3 Set screws
4 Tool bit
5 Cutting depth setting screw
6 Rotation
7 Tool carrier
8 Boring bar
Number Component
1 Tool carrier
2 Facing head
3 Counterweight
4-5 Spacers (different sizes)
6-8 Socket head cap screws (different sizes)
TIP:
The counterweight mounts on the side of the tool carrier opposite
of the facing head. The components figure shows spacers for one
side only. Use an identical spacer stack for each side.
CAUTION
Connect the hydraulic motor to the power unit pump prior to turning
on the power unit. Failure to do so will damage the pump and void
all warranties.
The hydraulic motor mounts to the rotational drive unit. Hydraulic hoses with quick
disconnect fittings connect to hydraulic power unit and the hydraulic motor. Before
connecting or disconnecting the hoses, turn off the power unit.
The return and pressure lines are interchangeable. If you switch these lines, the
boring bar will rotate in the opposite direction.
Do the following to reverse bar rotation:
1. Turn off the hydraulic power unit
2. Switch the hoses at the motor end.
The control pendant's START/STOP push buttons run the hydraulic power unit. The
20-foot (6 meter) cable allows remote operation of the motor.
Make sure to check the direction of bar rotation and tool head feeding before
operating the boring bar. Check that the electrical supply matches the requirements of
the power unit.
CAUTION
The bar rotation and the axial feed are independent of each other.
Be sure the feed is OFF when the bar is not running.
CAUTION
Damage to the cutter, the boring machine and your work piece may
occur if the bar rotation is stopped while the power feed is engaged
and the cutting tool is in contact with the work piece.
NOTICE
Additional information about the HPU function, construction, and
maintenance schedule can be found in the HPU manual.
Feature Description
Run/Jog
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 on the hexagon shaft, run with an electric drill or speed
wrench. To re-engage the feed, remove the socket, turn the feed on slow, and shift
the feed lever to the forward position.
4.5 Disassembly
Hydraulic power
NA See the HPU operator manual. NA
unit
PART DESCRIPTION