BB6100 57017 RFS

BB6100
BORING BAR
OPERATING MANUAL
ORIGINAL INSTRUCTIONS
PN: 57017 October 2020 Revision 4

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P/N: 57017, Rev. 4 Page A

CLIMAX WORLDWIDE LOCATIONS
Page B BB6100 Operating Manual

CE DOCUMENTATION
P/N: 57017, Rev. 4 Page C

This page is intentionally left blank
Page D BB6100 Operating Manual

TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................... 1
1.1 Limited Warranty....................................................................................................................................... 1
1.2 Alerts ......................................................................................................................................................... 2
1.3 Safety Precautions ..................................................................................................................................... 2
1.4 Machine Specific Safety Practices ............................................................................................................. 3
1.5 Risk Assessment and Hazard Mitigation ................................................................................................... 5
1.6 Risk Assessment Checklist ........................................................................................................................ 6
2 OVERVIEW ............................................................................................................................ 7
2.1 About this manual ...................................................................................................................................... 8
2.1.1 Recommended tools .............................................................................................................................. 8
2.2 Receipt and inspection ............................................................................................................................... 8
2.3 Specifications and Dimensions .................................................................................................................. 9
2.4 Axial Feed Assembly ................................................................................................................................. 14
3 SETUP .................................................................................................................................. 15
3.1 Clamp collars ............................................................................................................................................. 15
3.2 About Boring Machine Support................................................................................................................. 15
3.3 Installing End-mount Bearing Support ...................................................................................................... 16
3.3.1 To install the end-mount bearing support ............................................................................................ 16
3.3.2 Clamping the bearing assembly to the bar ........................................................................................... 19
3.4 ID-mount bearing support.......................................................................................................................... 19
3.4.1 If mounting an end-mount bearing ...................................................................................................... 23
3.4.2 Clamping the bearing assembly to the bar ........................................................................................... 23
3.5 Preload bearing kit ..................................................................................................................................... 23
3.6 RDU Setup ................................................................................................................................................. 24
3.7 Mounting the Mechanical Axial Feed Unit ............................................................................................... 26
3.7.1 Setting feed direction and rate ............................................................................................................. 27
3.7.2 Neutral (no feed) .................................................................................................................................. 27
3.7.3 Feed away from the axial feed unit...................................................................................................... 27
3.7.4 Feed toward the axial feed unit............................................................................................................ 28
3.7.5 Disengaging the feed under load ......................................................................................................... 28
3.7.6 Setting the feed rate ............................................................................................................................. 28
3.7.7 Stopping the feed ................................................................................................................................. 29
3.8 Mounting the Electric Axial Feed Assembly ............................................................................................. 29
3.8.1 Setting the Axial Feed Rate ................................................................................................................. 31
3.9 Tool Head Setup ........................................................................................................................................ 31
3.9.1 Small bore tool carrier setup ................................................................................................................ 31
3.9.2 Small bore tool carrier boring head setup ............................................................................................ 32
3.10 Micro-adjust boring head ........................................................................................................................... 33
3.11 Boring head setup ...................................................................................................................................... 36
3.11.1 To lock the tool carrier on the bar for other operations ....................................................................... 38
3.11.2 Do the following to remove the brass nut:........................................................................................... 38
3.12 Install the slide arm onto the tool carrier ................................................................................................... 39
3.13 Adjusting the tool carrier for perpendicularity .......................................................................................... 40
3.14 Feedbox assembly ...................................................................................................................................... 40
3.15 Feedbox and trip arm set-up ...................................................................................................................... 40
3.16 Mechanical facing head setup .................................................................................................................... 40
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3.17 Hydraulic power preparation and connection ............................................................................................ 43
4 OPERATION ........................................................................................................................ 45
4.1 Using the remote pendants ........................................................................................................................ 45
4.1.1 Feed pendant ....................................................................................................................................... 45
4.2 HPU pendant ............................................................................................................................................. 46
4.3 Manual override (electrical feed only) ...................................................................................................... 46
4.4 Pre-startup checks...................................................................................................................................... 47
4.4.1 Running the machine ........................................................................................................................... 47
4.4.2 Stopping the machine .......................................................................................................................... 47
4.4.3 Repetitive machining........................................................................................................................... 47
4.5 Disassembly............................................................................................................................................... 48
4.5.1 Standard disassembly .......................................................................................................................... 48
4.5.2 Optional disassembly .......................................................................................................................... 48
5 MAINTENANCE ................................................................................................................... 49
5.1 Recommended lubricants .......................................................................................................................... 49
5.2 Boring bar/lead screw assembly ................................................................................................................ 49
5.3 Axial feed unit ........................................................................................................................................... 49
5.4 Rotational drive unit .................................................................................................................................. 49
5.5 Bearing support assembly.......................................................................................................................... 49
5.6 Tool head assembly ................................................................................................................................... 49
5.6.1 Boring head assembly ......................................................................................................................... 49
5.6.2 Mechanical facing head assembly ....................................................................................................... 50
5.6.3 Tool carrier maintenance ..................................................................................................................... 50
5.7 Hydraulic power unit and motor................................................................................................................ 50
6 STORAGE ............................................................................................................................ 51
6.1 Tool kit ...................................................................................................................................................... 51
6.2 Spare Parts ................................................................................................................................................. 53
7 EXPLODED VIEWS AND PARTS LISTS............................................................................. 55
8 SCHEMATICS ...................................................................................................................... 93
9 SDS ...................................................................................................................................... 97
Page ii BB6100 Operating Manual

1 INTRODUCTION
1.1 Limited Warranty

Climax Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants
that all new machines are free from defects in materials and workmanship. This
warranty is available to the original purchaser for a period of one year after delivery.
If the original purchaser finds any defect in materials or workmanship within the
warranty period, the original purchaser should contact its factory representative and
return the entire machine, shipping prepaid, to the factory. CLIMAX will, at its
option, either repair or replace the defective machine at no charge and will return the
machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship,
and that all labor has been performed properly. This warranty is available to the
customer purchasing parts or labor for a period of 90 days after delivery of the part or
repaired machine or 180 days on used machines and components. If the customer
purchasing parts or labor finds any defect in materials or workmanship within the
warranty period, the purchaser should contact 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 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 materials or
workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties
of merchantability and fitness for a particular purpose are disclaimed and excluded.
Terms of Sale
Be sure to review the terms of sale which appear on the reverse side of your invoice.
These terms control and limit your rights with respect to the goods purchased from
CLIMAX.
About This Manual
CLIMAX provides the contents of this manual in good faith as a guideline to the
operator. CLIMAX cannot guarantee that the information contained in this manual is
correct for applications other than the application described in this manual. Product
specifications are subject to change without notice.
P/N: 57017, Rev. 4 Page 1

1.2 Alerts
Pay careful attention to the alerts appearing in this manual. Alert types are defined in
the following examples.
DANGER
concerns a condition, procedure, or practice that, if not avoided or
strictly observed, WILL result in injury or loss of life.
WARNING
strictly observed, COULD result in injury or loss of life.
CAUTION
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.
1.3 Safety Precautions

CLIMAX leads the way in promoting the safe use of portable machine tools. Safety
is a joint effort. You, the machine operator, must do your part by being aware of your
work environment and closely following the operating procedures and safety
precautions contained in this manual, as well as your employer’s safety guidelines.
Observe the following safety precautions when operating or working around the
machine.
Training – Before operating 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 risks to your
safety. You, the end user, are responsible for conducting a risk assessment of each
job site before setting up and operating this machine.
Page 2 BB6100 Operating Manual

Intended Use – Use this machine in accordance with the instructions and
precautions in this manual. Do not use this machine for any purpose other than its
intended use as described in this manual.
Personal Protective Equipment – Always wear the appropriate personal
protective gear when operating this or any other machine tool. Eye and ear protection
are required when operating or working around the machine. Flame-resistant clothing
with long sleeves and legs is recommended when operating the machine, as hot
flying chips from the workpiece may burn or cut bare skin.
Work Area – Keep the work area around the machine clear of clutter. Keep all cords
and hoses away from the work area when operating the machine.
Lifting – Many CLIMAX machine components are very heavy. Whenever possible,
lift the machine or its components using proper hoisting equipment and rigging.
Always use designated lifting points on the machine. Follow all lifting instructions in
the setup procedures of this manual.
Lock Out/Tag Out – Lock out and tag out the machine before doing maintenance.
Moving Parts – CLIMAX machines have numerous exposed moving parts and
interfaces that can cause severe impact, pinching, cutting, and other injuries. Except
for operating controls, avoid contact with moving parts by hands or tools during
machine operation. Secure hair, clothing, jewelry, and pocket items to prevent them
from becoming entangled in moving parts.
Sharp Edges – Cutting tools and workpieces have sharp edges that can easily cut
skin. Wear protective gloves and exercise caution when handling a cutting tool or
workpiece.
Hot Surfaces – During operation, motors, some housings, and cutting tools can
generate enough heat to cause severe burns. Pay attention to hot surface labels, and
avoid contact with bare skin until the machine has cooled.
1.4 Machine Specific Safety Practices

This list includes safety practices applicable to CLIMAX Portable Machines.
All aspects of the machine have been designed with safety in mind. Warning signs
are affixed to the machine to warn of residual hazards associated with machine
relating to operation, setup, whether or not it is in use.
Machine safety features—Never attempt to defeat or override the safety features
designed into the machine.
Securing the machine—Never attempt to run the machine without first securing
it to a stable work piece.
Personal Protection—Wear safety glasses, earplugs, and safety shoes while
operating the machine. Gloves are not a form of protection and should not be worn
while operating the machine. Metal chips and debris created by the machine should
be disposed using a dust pan and broom.
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Keeping clean—Maintain your machine according to the procedures described in
this manual to maximize safety and machine longevity.
Keep clear—Keep clear of the machine during operation. Never lean or reach into
the machine to remove chips or to adjust the machine while it is running. Doing so
can cause serious injury or death.
Controls—Operator controls are located outside the danger zone of the machine.
All controls perform a one-to-one action. The machine is not supplied with a power
unit and, therefore, does not have an E-stop.
Machine setup and disassembly—With a modular design, the machine can be
broken down into components to ease setup.
Machine guards—There are no guards used on this machine.
Clamp Collars—To prevent the bar from sliding through the support bearings, or
falling, use P/N 25010 – The collars are used to secure the bar when the machine is
in the vertical orientation. Torque these collars to 25 ft-lbs (34 Nm). 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.
Electrical emissions—There are no electrical components used on this machine.
Operator station—Due to the nature of portable machinery, no designated
operator’s station exists.
Moving parts—The operator is not exposed to the cutter head when the work piece
is being machined. Keep all cords and hoses away from moving parts during
operation. If the cords become tangled in the machinery the operator could be
seriously injured and the machine extensively damaged.
Fluids—Cutting fluids are required for machine operation. The machine itself does
not emit any fluids.
Lifting—When lifting the machine for setup or disassembly, a conventional sling-
type lift is suggested for convenience and safety of the operator. Use designated
lifting eyes. Do not lift the machine by the turning bar.
Repetitive motion—Individuals can be susceptible to disorders of the hands and
arms when exposed to tasks that involve highly repetitive motions and/or vibration.
To reduce the likelihood of these disorders, follow these guidelines:
• Use minimum hand grip force
• Keep wrists straight
• Avoid exposure to continue vibration
• Avoid repeated bending of wrists and hands
• Keep hands and arms warm and dry

1.5 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 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.
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 attached to it become one complete
machine during the material-removal process.
To achieve the intended results and to promote safety, the operator must understand
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.
P/N: 57017, Rev. 4 Page 5

1.6 Risk Assessment Checklist
Use these checklists as part of your risk assessment:
TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

Before Set-up
 I took note of all the warning labels on the machine.
I removed or mitigated all identified risks (such as tripping, cutting, crushing,

entanglement, shearing, or falling objects).
I considered the need for personnel safety guarding and installed any necessary

guards.
 I read the Setup section on page 15.
I created a lift plan, including identifying the proper rigging, for each of the setup lifts

required during the setup of the support structure and machine.
I located the fall paths involved in lifting and rigging operations. I have taken

precautions to keep workers away from the identified fall path.
I considered how this machine operates and the best placement for the controls,

cabling, and the operator.
 I evaluated and mitigated any other potential risks specific to my work area.
TABLE 2. RISK ASSESSMENT CHECKLIST AFTER SET-UP

After Set-up
I checked that the machine is safely installed (according to the Setup section) and the
 potential fall path is clear. If the machine is elevated, I checked that the machine is
safeguarded against falling.
I identified all possible pinch points, such as those caused by rotating parts, and

informed the affected personnel.
 I planned for containment of any chips or swarf produced by the machine.
 I followed the Maintenance section with the recommended lubricants on page 49.
I checked that all affected personnel have the recommended personal protective

equipment, as well as any equipment required by the site or other regulations.
 I checked that all affected personnel understand the danger zone and are clear of it.
 I evaluated and mitigated any other potential risks specific to my work area.

2 OVERVIEW
Machining range from 8.8–38" (224–965 mm) diameter and faces from 7.5–42.1"
(191–1,069 mm) are quickly restored to original condition with the CLIMAX
BB6100 Portable Boring Machine.
This modular machine tool shown in Figure 2-1 is dedicated to on-site restoration of
worn internal diameters to precise roundness and dimensional accuracy ready to
accept new bearings, sleeves, shafts, or similar mating parts.
FIGURE 2-1. BB6100 COMPONENTS
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
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2.1 About this manual
This manual describes the most effective setup and operation of your Model BB6100
Portable Boring Machine. All parts meet CLIMAX’s strict quality standards. For
maximum safety and performance, read the entire manual before operating this
machine.
2.1.1 Recommended tools

CLIMAX includes a general tool kit with the machine. You may require additional
equipment specific to your worksite and particular setup. Please contact CLIMAX
for accessories.
2.2 Receipt and inspection

Your CLIMAX product was inspected and tested before shipment and was packaged
for normal shipment conditions. CLIMAX does not guarantee the condition of your
machine upon delivery. When you receive your CLIMAX product, perform the
following receipt checks.
• Inspect the shipping containers for damage.
• Check the contents of the shipping containers against the included invoice to
ensure that all components have been shipped.
• Inspect all components for damage.
NOTICE
Contact CLIMAX immediately to report damaged or missing
components.

2.3 Specifications and Dimensions
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2.4 Axial Feed Assembly

3 SETUP
Before proceeding with set-up of the BB6100, determine the best placement of each
module on the bar. The RDU and tool head assemblies can be located anywhere
along the bar. Make sure to allow space for them while planning your set-up.
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:
• Magnetic base dial indicator

• Machinist’s precision level
• Dial or digital slide calipers
3.1 Clamp collars

The clamp collars (P/N 25010) must be used to secure the bar when the machine is in
the vertical orientation.
This will prevent the bar from sliding through the support bearings or falling.
To prevent over tightening of the bearings, the clamp collars should be placed above
at least two support bearings in a vertical orientation. ID mounted bearings (P/N
54355, 92850) should not be used to support the boring bar in the axial direction.
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).
3.2 About Boring Machine Support

At least two bearing supports are required to obtain machine stability.
P/N: 57017, Rev. 4 Page 15

CAUTION
Bearings spaced too far apart allow extreme deflection of the bar
and will decrease bore accuracy. Avoid spacing bearing supports
more than 5 feet (1.5 m) apart.
3.3 Installing End-mount Bearing Support

Though the end-mount bearing support attaches to the outside of the work piece, it
can be positioned anywhere on the boring bar.
3.3.1 To install the end-mount bearing support

1. Clean the bore with solvent to remove grease, oil, and dirt.
2. Inspect the bar for nicks or cuts. Dress the bar smooth with a honing stone if
necessary. Clean the bar with solvent to remove dirt and chips. A bar with nicks
or gouges can severely damage mating parts, including the tool carrier and RDU.

3. Slide the boring bar into the workpiece.
4. Slide the bearing supports onto the ends of the bar.
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.
FIGURE 1. LEAD SCREW (TOP) AND BEARING RING (RIGHT)
16. Do the following to precisely align the boring bar:

a. Use a dial indicator and four adjusting screws to center the boring bar in
the bore.
b. Tighten the four locking screws.

3.3.2 Clamping the bearing assembly to the bar
Do the following to clamp the bearing assembly to the bar:
1. Remove the screws holding the lock plate.
2. Slide the lock plate away from the lock nut.
3. Rotate the lock nut using both hands until it is snug. This is the zero reference
point.
4. Mark or note the angular position of the lock nut.
5. Use the offset spanner wrench in the tool kit to rotate the lock nut approximately
1.25—1.5 additional turns.
6. Reapply the lock plate. If necessary, additionally tighten the lock nut until a slot
in the lock plate is aligned with the retaining screw holes.
7. Reinstall the retaining screws.
3.4 ID-mount bearing support

The ID-mount bearing support assembly can be placed inside of the workpiece at any
position along the bar.
1. Clean the bore with solvent to remove grease, oil, and dirt.
2. Examine the bar for nicks or cuts. Dress the bar smooth if necessary. A bar with
nicks or gouges can severely damage mating parts, including the tool carrier
assembly and RDU. Clean the bar with solvent to remove dirt and chips.
3. Measure the diameter of the bore into which the bearing is to fit.
4. Use the following table to select components required.
P/N: 57017, Rev. 4 Page 19

ID-Mount Bearing Assembly Bore Diameter Table
Bore Range Components
Inch (mm) required
12.0 - 14.53 (304.8 - 369.1) 1,3,4
14.53 - 16.53 (369.1 - 419.9) 2, 3, 6, 4
16.53 - 18.53 (419.9 - 470.7) 2, 3, 5, 6
18.53 - 20.53 (470.7 - 521.5) 2, 3, 4, 7
20.53 - 22.53 (521.5 - 572.3) 2, 3, 5, 7
22.53 - 24.53 (572.3 - 623.1) 2, 3, 5, 7, 10
24.53 - 27.53 (623.1 - 699.3) 2, 3, 4, 8
27.53 - 29.53 (699.3 - 750.1) 2, 3, 5, 8
29.53 - 31.53 (750.1 - 800.9) 2, 3, 5, 8, 10
31.53 - 33.53 (800.9 - 851.7) 2, 3, 4, 9
33.53 - 35.53 (851.7 - 902.5 2, 3, 5, 9
35.53 - 37.53 (902.5 - 953.3) 2, 3, 5, 9, 10
TABLE 3. ID-MOUNT BEARING COMPONENT FIGURE IDENTIFICATION
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

If using the small plate chuck, do the following before moving on to step 5:
a. Screw short or long jacking bolts into the sides of the plate chuck.
FIGURE 3. SMALL PLATE CHUCK (LEFT) AND JACKING SCREW (RIGHT)
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
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b. Screw the jacking screws into the legs. When spacers are being used, attach them to the other
end of the legs.
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.
FIGURE 4. SLIDE JAWS IN AGAINST THE STOP BLOCK
d. Tighten the jaw clamping screws.

e. Mount the bearing to the chuck body using spring washers, flat washers, and screws.
5. Slide one bearing support assembly onto the boring bar.

6. Position the bearing in the bore.
7. Use a dial indicator to precisely align the boring bar to the bearing.

8. Center the bar by evenly adjusting the jacking screws then tighten the hex-head
cap screws.
9. Slide the bar and bearing support into the work piece.
10. Using a dial indicator and the jacking screws, center the bar inside the work
piece. Tighten the jacking screw against the inside of the bore. Do not exceed 22
ft-lbs (30 Nm) of torque.
11. If mounting the RDU between the bearing supports, do so now. See Section 3.6
on page 24 for instructions.
12. If mounting another ID-mount bearing, repeat the above steps.
3.4.1 If mounting an end-mount bearing

Do the following to set up an end-mount bearing support assembly:
1. Re-check the bar for center by sweeping a dial indicator inside the bore.
2. Adjust the jacking screws, if necessary.
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.
3.4.2 Clamping the bearing assembly to the bar

Do the following to clamp the bearing assembly to the bar:
1. Remove the screws holding the lock plate.
2. Slide the lock plate away from the lock nut.
3. Rotate the lock nut using both hands until it is snug. This is the zero reference
point.
4. Mark or note the angular position of the lock nut.
5. Use the offset spanner wrench in the tool kit to rotate the lock nut approximately
1.25—1.5 additional turns.
6. Reapply the lock plate. If necessary, additionally tighten the lock nut until a slot
in the lock plate is aligned with the retaining screw holes.
7. Reinstall the retaining screws.
3.5 Preload bearing kit

The preload bearing kit is only used on bearing assemblies using the bearing
cartridge P/N 23570. It is appropriate in those applications demanding greater
machine stability, especially facing operations. The kit contains a pair of 3.5" (89
mm) hinged clamp collars, one standard and the other with tensioning screws. This
kit can be used in either the vertical or horizontal positions.
P/N: 57017, Rev. 4 Page 23

Do the following:
1. Determine if the hinged clamp collars are to be mounted to the inside or outside
of the bearing supports. Both collars must be either inside or outside the mount
bearings.
2. Set up the bar and bearings as described. See Section 3.3 on page 16.
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.
3.6 RDU Setup

The RDU can be placed anywhere along the boring bar.
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.

TIP:
When mounting the RDU, the slot in the drive hub must align with
the lead screw slot in the bar.
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.
P/N: 57017, Rev. 4 Page 25

Number Component
1 Secure key between the lead screw and hub
2 Tie down the torque arms before operating
3 Tighten collars over hub and bar
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.
3.7 Mounting the Mechanical Axial Feed Unit

The axial feed unit can be mounted to either end of the boring bar. The hexagon hole
in the output shaft fits onto the hexagon end of the bar lead screw.
1. Place the axial feed unit in NEUTRAL so the lead screw drive can rotate in either
direction. See Section 3.7.1 on page 27.
2. While holding the axial feed unit against the bar end cap, turn the output shaft
until the hexagons fit together.
3. Tighten the mounting cap screws.
4. Secure the stop rod to a stationary object to engage the feed mechanism.
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.

WARNING
A loose trip rod can cause damage and injury. Secure the trip rod
to a fixed object.
3.7.1 Setting feed direction and rate

Feed direction and feed rate are set using the feed adjustment knob. Axial feed rate is
variable from 0.003–0.020" (0.076–0.508 mm) per revolution.
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
3.7.2 Neutral (no feed)

In neutral, the lead screw can turn in either direction. To verify this, insert a hex
wrench into the lead screw dial and turn the dial. If the machine is in neutral, the
wrench will turn freely in either direction.
3.7.3 Feed away from the axial feed unit

Engage the feed by pushing the feed adjustment knob with one hand and slightly
turning the lead screw dial with a wrench until you feel the unit engage. When the
feed unit engages, the dial will turn counter-clockwise only.
P/N: 57017, Rev. 4 Page 27

FIGURE 7. STOP ROD (LEFT) AND FEED DIAL (RIGHT)
3.7.4 Feed toward the axial feed unit

Engage the feed by pulling the feed adjustment knob with one hand and slightly
turning the lead screw dial with a wrench until you feel the unit engage. When the
feed unit engages, the dial will turn clockwise only.
3.7.5 Disengaging the feed under load

If the machine is stopped while the feed box is under load, it may be difficult to
disengage the feed.
CAUTION
To avoid internal damage to the feed box, do not force the feed
adjustment knob.
To disengage a feed box under load:

1. Insert a wrench into the dial socket.
2. Turn the wrench in the direction the lead screw was turning while pushing or
pulling the feed adjustment knob.
Upon disengagement, the feed box will rotate freely in either direction.
If the feed box does not disengage:
1. Unbolt the feed box from the end of the bar.
2. Shift the feed into NEUTRAL.
3. Re-install the feed box.
3.7.6 Setting the feed rate

To reduce the rate of feed, pull the plunger and lock in the out position then turn the
adjustment knob clockwise. To increase the feed rate, pull the plunger and lock in
position then turn the adjustment knob counterclockwise. The feed is adjustable
while the machine is running.

FIGURE 8. MINIMUM FEED (LEFT) AND MAXIMUM FEED (RIGHT)
3.7.7 Stopping the feed

To quickly stop the boring head from feeding, pull the stop rod out of the torque hub
on the axial feed unit. This is helpful when cutting up to a shoulder.
3.8 Mounting the Electric Axial Feed Assembly

The electric feed unit consists of the adaptor plate, manual override, electric motor
assembly, and remote pendant control.
The axial feed unit can be mounted to either end of the boring bar. The locating nose
and hex nut hole of the feed unit fit into the locating nose seat and protruding hex
shaft of the boring bar end cap.
1. Mount the adapter plate to the end of the bar using the ¾-10 cap screw and two
½-13 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. Mount the electric axial feed assembly to the back of the mechanical override
with four cap screws.
4. Make sure to align the key way in the coupling.
5. Attach the pendant electrical cable to the rear of the electric axial feed.
P/N: 57017, Rev. 4 Page 29

Number Component
1 Electrical axial feed assembly
2 Mechanical override assembly
3 Adapter plate
4 Bar end cap
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.

3.8.1 Setting the Axial Feed Rate
The feed potentiometer controls the axial feed rate. Turning the knob
counterclockwise decreases the feed rate; turning the knob clockwise increases the
feed rate.
Axial feed rate is adjustable and variable from 0.010–0.500" (0.25–13 mm) per
minute.
3.9 Tool Head Setup

Do the following:
1. Check for lead screw endplay (loose axial lead screw nuts)
2. Attach carrier assembly, lifting eyes + drive key to boring bar
3. Adjust brass shoes for 0.001-0.002 clearance. (Note: Adjust for contact of each
pad against the boring bar, and back off 10 degrees for 0.0015 clearances).
4. Spray with antirust lubricant.
The boring and facing heads require a tool carrier to mount them to the boring bar.
3.9.1 Small bore tool carrier setup

Do the following to mount the tool carrier:
1. Check the bar for nicks, burrs, or cuts. Smooth the bar if necessary. A bar with
nicks, cuts or gouges can damage mating parts, including the tool carrier and
RDU, beyond repair. Clean the bar with solvent to remove dirt and chips.
2. Mount the axial lead screw nut to the top of the tool carrier. Tighten the mounting
screws.
3. Be sure the scraper halves are mounted securely to the ends of the tool carrier.
4. Mount the tool carrier onto the boring bar. Be sure the lead screw nut engages the
lead screw.
5. Tighten the socket-head cap screws.
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.
P/N: 57017, Rev. 4 Page 31

3.9.2 Small bore tool carrier boring head setup
The boring head requires a tool carrier. See “Tool carrier setup” on page 31 for
information.
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)

3.10 Micro-adjust boring head
The micro-adjust boring head offers the possibility to micro-adjust readily available
off-the-shelf square shank tooling for boring. The micro-adjust travel is 0.5" (13
mm), and the ability to slide the tool without having to change the setup provides a
total tool travel of more than 2" (51 mm) per setup.
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.
P/N: 57017, Rev. 4 Page 33

BB6100 Micro adjust boring head tool range table
8.8–40.8" (224–1,036 mm) diameter
Bore range diameter Number of spacer blocks required
2" (51 mm) 4" (102 mm) 8" (203 mm)
block block block
8.8–12.8" (224–325 mm) 0 0 0
12.8–16.8" (325–427 mm) 1 0 0
16.8–20.8" (427–528 mm) 0 1 0
20.8–24.8" (528–630 mm) 1 1 0
24.8–28.8" (623–732 mm) 0 0 1
28.8–32.8" (732–833 mm) 1 0 1
32.8–36.8" (833–935 mm) 0 1 1
36.8–40.8" (935–1036 mm) 1 1 1
TIP:
The bar can rotate in either direction. Be sure the tool bits face the
correct direction.

BB6100 Solid tooling boring head tool range table
9.7–42.2" (246–1,072 mm) diameter
Number of spacer blocks required
Bore range diameter 0.75" (19 2" (51 mm) 4" (102 8" (203 mm)
mm) block block mm) block block
9.7–12.7" (246–323 mm) 0 0 0 0
11.2–14.2" (285–361 mm) 1 0 0 0
13.7–16.7" (348–424 mm) 0 1 0 0
15.2–18.2" (386–462 mm) 1 1 0 0
17.7–20.7" (450–526 mm) 0 0 1 0
19.2–22.2" (488–564 mm) 1 0 1 0
21.7–24.7" (551–627 mm) 0 1 1 0
23.2–26.2" (589–665 mm) 1 1 1 0
25.7–28.7" (653–729 mm) 0 0 0 1
27.2–30.2" (691–767 mm) 1 0 0 1
29.7–32.7" (754–831 mm) 0 1 0 1
31.2–34.2" (792–869 mm) 1 1 0 1
33.7–36.7" (856–932 mm) 0 0 1 1
35.2–38.2" (894–970 mm) 1 0 1 1
39.2–42.2" (996–1,072 mm) 1 1 1 1
P/N: 57017, Rev. 4 Page 35

3.11 Boring head setup
1. Select the required parts 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.
Number Component
1 Stack-up blocks
2 Boring head
3 Tool carrier
4 Counterweight

P/N: 57017, Rev. 4 Page 37
3.11.1 To lock the tool carrier on the bar for other operations
1. Loosen the lock screw on the side of the tool carrier.
2. Tighten or loosen the adjustment screw.
3. Tighten the lock screw to keep the adjustment screw in position.
FIGURE 9. ADJUSTMENT SCREW (LEFT) AND LOCK SCREW (RIGHT)
3.11.2 Do the following to remove the brass nut:

1. Do not remove all the screws.
2. Remove the screws on each end of the brass nut.
(If there is too much play in the brass nut, the center set screw can be tightened.)
FIGURE 10. REMOVING THE BRASS NUT

3. Using the previous boring head tool range table, select the required spacers and
screws. Clamp all parts tightly to the tool carrier.
4. Grind a 1/2" square HSS tool bit (see following illustration) or install inserted
carbide tool holder with insert.
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.
3.12 Install the slide arm onto the tool carrier

1. Using a device such as a crane, place arm onto tool carrier flush with carrier surface as
shown.
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).
P/N: 57017, Rev. 4 Page 39

DANGER
Failure to properly torque the four ½-20 x 1-1/4 SHCS (P/N 18225)
to 100 ft-lb (135 Nm) can result in unexpected slippage of the tool
arm which can result in injury or be fatal.
3.13 Adjusting the tool carrier for perpendicularity

The tool carrier is equipped with four set screws that allow you to adjust the slide
arm perpendicularity if required.
3.14 Feedbox assembly

Mount and secure the feedbox (see Section 7 on page 55).
3.15 Feedbox and 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. Attach the lifting eye onto counterweight arm and install arm.
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.
3.16 Mechanical facing head setup

The mechanical facing head assembly requires either a one-piece or the two-piece
tool carrier.
1. Assemble the facing head as necessary. (See the following Facing Head Tool
Range Table and Mechanical Facing Head exploded view drawing to see how the
parts fit together).
2. Mount the facing head onto the tool carrier.
3. Secure a sharpened tool bit in the tool carrier.

CAUTION
The facing head is operational in only one direction. Check that the
bar rotates in the correct direction the tool bit faces appropriately.
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
4. Set the depth of cut by adjusting the screw.

5. Engage the automatic feed trip. The trip mechanism produces radial feed from 0
(no trip) to 0.010" (0.254 mm). The farther down the trip rod catches on the trip,
the greater the feed. Multiple trip rods increase the rate of feed.
P/N: 57017, Rev. 4 Page 41

Facing head tool range table for 4" (102 mm) model
Face diameter range Components required
10.5–22.5" (267–572 mm) 1, 2, 3, 7
16.5–28.5" (419.1–724 mm) 1, 2, 3, 5, 6, 7
24–36" (610–914 mm) 1, 2, 3, 4, 5, 5, 6, 8
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.
The facing head can bore diameters as small as 23.25" (590.55

mm).

3.17 Hydraulic power preparation and connection
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.
P/N: 57017, Rev. 4 Page 43


4 OPERATION
4.1 Using the remote pendants

Operator controls for the machine are located on the remote pendants, described
below.
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.
4.1.1 Feed pendant

The following is a description of the feed pendant controls:
Symbol Feature Description
Feed speed A momentary button which

override overrides the feed rate
potentiometer and runs the axial
power feed at maximum rate,
regardless of the potentiometer
setting.
Feed A 3-position switch that

direction determines the direction of the
axial or radial feed. In the STOP
position, the motor will not move
under power from the pendant.
Feed direction may be changed
FEEDBOX PENDANT during operation.
Speed The Feed potentiometer controls

the axial feed rate.
Counterclockwise decreases the
feed rate; clockwise increases
the feed rate.
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.
P/N: 57017, Rev. 4 Page 45

4.2 HPU pendant
NOTICE
Additional information about the HPU function, construction, and
maintenance schedule can be found in the HPU manual.
The hydraulic power unit comes with a standard control pendant.
Feature Description
Run/Jog
RPM Increases or decreases the

rotational speed.
Bar Off Turns off the hydraulic power unit

(red)
Bar On Turns on the hydraulic power unit

(green)
Off (red) Turns off the electric motor
On (blue) Turns on the electric motor
4.3 Manual override (electrical feed only)

The manual override consists of 2-position gear lever that disengages the electric
drive 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 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.

4.4 Pre-startup checks
Do the following before operating the boring bar:
1. Tie down the RDU torque arms and the axial feed unit stop rod.
2. Use only properly sharpened tool bits.
3. Secure all machine parts, including the bearing assemblies, the tool carrier, and
the boring head. See that moving parts move freely.
4. Check that electric cords and cables are in good condition and correctly
connected.
5. Turn the hydraulic power unit OFF.
6. Check that the power unit wiring matches the electric source. Plug the power unit
into a grounded outlet.
7. Check that the reservoir level is filled above the red bar with UNAX AW32
hydraulic oil or equivalent.
8. Check that the power unit is set level.
9. Clean the hydraulic hoses and fittings before connecting them.
10. Check that the electric pump motor on the hydraulic power unit is turning as
indicated by the arrow on the case.
11. If using the boring bar in a vertical orientation, check that the two clamp collars
are in place to secure the bar (see Section 3.1 on page 15).
4.4.1 Running the machine

1. Set the feed direction and feed rate on the axial feed unit (see Section 3.7.1 on
page 27).
2. Press START on the hydraulic power unit pendant.
3. Adjust the bar rotation using the speed control hand wheel on the hydraulic power
unit or the knob on pendant.
4. As cutting begins, lubricate the work piece and cutting tool with plenty of cutting
oil. Apply cutting oil with a squirt can.
4.4.2 Stopping the machine

1. Press STOP on the pendant to stop the power unit.
2. After all parts of the machine have stopped, use a brush to remove chips.
3. If you will be machining the work piece again, see Section 4.4.4. If you are done
machining, see Section 4.5.
4.4.3 Repetitive machining

4. Reverse the boring head feed direction.
5. Manually or automatically feed the boring head back to where it started cutting.
P/N 57017, Rev. 4 Page 47

6. Sharpen the tool bit, if necessary.
7. Use a dial indicator to reset the tool bit cutting depth. The maximum
recommended cutting depth is 0.125" (3 mm).
8. Operate the boring bar as described in Section 4.4.2.
4.5 Disassembly
4.5.1 Standard disassembly

1. Turn off and unplug the hydraulic power unit.
2. Disconnect the hydraulic lines from the motor.
3. Remove the tool bit.
4. Remove the tool head and tool carrier.
5. Remove the axial feed unit from the bar.
6. Support the boring bar, bearing supports, and RDU with hoists.
7. If the RDU is between the bearing support assemblies, loosen one support first.
Remove that support from the work piece and bar.
8. Secure the RDU with a hoist. Loosen the shaft collars. Remove the drive key.
Carefully slide the RDU off the bar.
9. Loosen the remaining bearing support assemblies. Remove the boring bar.
10. Remove the bearing supports from the work piece.
4.5.2 Optional disassembly

In some cases, it is better to remove the bearings before removing the bar.
1. Turn off and unplug the hydraulic power unit.
2. Disconnect the hydraulic lines from the motor.
3. Remove the tool bit.
4. Remove the tool head and tool carrier.
5. Securely support the boring bar, bearing supports, and RDU with hoists.
6. Remove the axial feed unit from the bar.
7. If the RDU is between the bearing support assemblies, remove one support first.
Remove the support from the work piece and bar.
8. Secure the RDU with a hoist. Loosen the shaft collars. Remove the drive key and
carefully slide the RDU off the bar.
9. Loosen the bearing support jacking screws.
10. Place a wooden support in the bottom of the bore to support the bar.
11. Remove the bearing supports from the work piece.
12. Slide the bar out of the bore using the wooden support.

5 MAINTENANCE
5.1 Recommended lubricants

Lubricant Brand Where used
Gear grease Polytac EP #2 Rotational drive, axial feed units
Light Oil LPS 2 Unpainted surfaces
Cutting oil UNOCAL KOOLKUT Tool bits, work pieces
Hydraulic oil Union UNAX AW32 Hydraulic motor

Anti-wear hydraulic oil
Anti-seize lubricant Moly Grade Anti-seize Jacking bolts
5.2 Boring bar/lead screw assembly

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 tool carrier assembly. Before storage, lightly oil the bar to
prevent rusting. Do not grease the leadscrew.
5.3 Axial feed unit

Under normal conditions, the mechanical axial feed unit is maintenance free.
5.4 Rotational drive unit

The RDU has sealed lubrication. Under normal use, it is maintenance free.
5.5 Bearing support assembly

Before using the boring bar and periodically during long machining operations,
grease the bearings. Add grease slowly while the bar is rotating until a slight bead of
grease forms at the seals.
Periodically apply anti-seize to jacking bolts of the ID-mounting bearing.
5.6 Tool head assembly
5.6.1 Boring head assembly

Lightly oil all parts to prevent rusting.
P/N 57017, Rev. 4 Page 49

5.6.2 Mechanical facing head assembly
Before machining and frequently during operation, lubricate the tool head carrier at
the grease fitting. Brush chips from the lead screw frequently to prevent thread
damage. Lightly oil the lead screw.
5.6.3 Tool carrier maintenance

Before operating the boring bar, pump light oil into the oiler in the side of the carrier.
Be careful not to damage the scrapers.
Before storage, lightly oil all parts to prevent rusting.
5.7 Hydraulic power unit and motor

See the HPU manufacturer’s documentation for information about your HPU and its
maintenance.

6 STORAGE
Proper storage of the portable boring bar will prevent undue deterioration or damage.
Before storing, wipe the machine down with solvent to remove grease, metal chips,
and moisture.
To prevent rusting, spray with a moisture-displacement material such as JET-LUBE
550 for short-term storage, LPS 3 for long-term storage.
Store the machine in the container provided.
Place desiccant bags or vapor wrap around the machine to absorb moisture.
6.1 Tool kit

TABLE 4 . BB6100 TOOL KIT (P/N 54262)
P/N DESCRIPTION QTY UOM
10855 WRENCH EXTENSION 3/8 DRIVE X 6 1 Piece
11856 WASHER 5/8 FLTW 4 Piece
12339 WASHER 3/4 FLTW 2 Piece
12800 WRENCH END 15/16 1 Piece
12835 WRENCH END 1-1/8 COMBINATION LONG (KB) 1 Piece
14735 WRENCH EXTENSION 1/2 DRIVE X 10 1 Piece
14818 WRENCH RATCHET 1/2 DRIVE 1 Piece
15367 WRENCH STRAP 1-3/4 WIDE X 48 LONG 1 Piece
15781 WRENCH HEX BIT SOCKET 3/8 X 3/8 (KB) 1 Piece
16792 WRENCH END 3/8 COMBINATION 1 Piece
17378 SCREW 5/8-11 X 2-1/4 HHCS 4 Piece
19261 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
P/N 57017, Rev. 4 Page 51

P/N DESCRIPTION QTY UOM
23659 FUSE AXIAL FEED 3-1/2 BAR 1 Piece
24751 WRENCH RATCHET 3/8 DRIVE 1 Piece
25010 CLAMP COLLAR SPLIT HINGED 3-1/2ID 2 Piece
29661 WRENCH HINGE HANDLE 1/2 DRIVE 17 IN HANDLE (KB) 1 Piece
54411 STANDOFF RDU 6IN 1 Piece
54412 STANDOFF RDU 6.5IN 1 Piece
54717 TOOL BEARING BB6100 1 Piece
WRENCH SPANNER FOR 3.5 DIA DODGE IMPERIAL BRG

56734 1 Piece
OFFSET 1 IN
57017 MANUAL INSTRUCTION BB6100 BORING BAR 1 Piece

6.2 Spare Parts
Parts listed below include items most frequently required due to wear, loss, or
damage. To avoid unscheduled down time you may want to stock any or all of the
parts listed.
TABLE 5. SPARE PARTS KIT
Where used P/N DESCRIPTION QTY
22143 NUT LEADSCREW BRG ADJUSTING 3/4 DIA 2
22403 KEY DRIVE 3-1/2 BORING BAR 1

Boring bar
assembly HOIST RING 3/4-10 X 1-1/2 1-3/4 ID 3-1/4 OD 6-
22814 1
3/8 OAL 5000 LBS SWIVEL
22815 SPACER BOLT EYE 1/2 THK 1
22409 DIAL FEED 1

Mechanical axial
feed assembly
14303 ROD STOP 1
54217 SHOE ADJUSTABLE TOOL CARRIER BB6100 1
SET NUT AXIAL LEAD SCREW 3/4-5 ACME

Net fit tool carrier 54221 2
BB6100
14771 SCREW 5/16-18 X 3/4 BHSCS 4
22205 NUT AXIAL LEADSCREW 1

Small bore tool
22384 WIPER ROD 3.5 ID MOLYTHANE 2
carrier
10453 SCREW 3/8-16 X 1-1/4 SHCS 6
45691 ASSY FEEDBOX REVERSE CLUTCH INPUT 1
Boring/facing arms 54178 NUT HALF FACING HEAD BB7100 1
55094 TRIP ARM STEEL 3 INCH 1
Hydraulic power
NA See the HPU operator manual. NA
unit
BORING HEAD MICRO ADJUST 3/4 INCH

Tooling 79020 1
TOOLING (1/2 INCH READY) LARGE BB
P/N 57017, Rev. 4 Page 53

Where used P/N DESCRIPTION QTY
BIT TOOL HSS 1/2 X 4.0 LH FINISHING

31859 1
SINGLE TC
BIT TOOL HSS 1/2 X 4.0 LH ROUGHING

31868 1
SINGLE
HOLDER INSERT 3/4 SQ SHANK NEG RAKE

33996 1
RIGHT HAND
HOLDER INSERT 3/4 SQ SHANK NEG RAKE

33997 1
LEFT HAND
INSERT CARBIDE 80 DEG 1/2 IC 1/64 NOSE

41407 10
RADIUS KC5010
INSERT CARBIDE 80 DEG 3/8 IC 1/64 NOSE

50741 10
RADIUS CPGM-3251 KC5010

7 EXPLODED VIEWS AND PARTS LISTS
The following diagrams and parts 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 to perform service on the machine.
P/N 57017, Rev. 4 Page 55

FIGURE 11. 4-JAW CHUCK FACE ADJUSTING 3.5 ID BEARING ASSEMBLY (P/N 92850)

FIGURE 12. 4-JAW CHUCK FACE ADJUSTING 3.5 ID BEARING ASSEMBLY PARTS LIST (P/N 92850)
P/N 57017, Rev. 4 Page 57
FIGURE 13. ID-MOUNT BEARING ASSEMBLY (P/N 54355)

FIGURE 14. ID MOUNT BEARING ASSEMBLY AND HOUSING (P/N 97049)
P/N 57017, Rev. 4 Page 59

FIGURE 15. OD MOUNT BEARING ASSEMBLY AND HOUSING (P/N 53691)

FIGURE 16. SPIDER BEARING ASSEMBLY END SUPPORT (P/N 53710)
P/N 57017, Rev. 4 Page 61

FIGURE 17. SPIDER BEARING THREE-ARM END SUPPORT ASSEMBLY (P/N 53840)

FIGURE 18. 4-ARM END MOUNT BEARING ASSEMBLY (P/N 22091)
P/N 57017, Rev. 4 Page 63

FIGURE 19. BORING BAR CHART ASSEMBLY (P/N 71618)
FIGURE 20. BORING BAR CHART ASSEMBLY PARTS LIST (P/N 71618)
P/N 57017, Rev. 4 Page 65

FIGURE 21. MECHANICAL AXIAL FEED UNIT ASSEMBLY (P/N 23299)

FIGURE 22. MECHANICAL AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 23299)
P/N 57017, Rev. 4 Page 67

FIGURE 23. ELECTRIC AXIAL FEED ASSEMBLY (P/N 41062)

FIGURE 24. ELECTRIC AXIAL FEED ASSEMBLY PARTS LIST (P/N 41062)
P/N 57017, Rev. 4 Page 69

FIGURE 25. ELECTRIC AXIAL FEED ASSEMBLY (P/N 86681)

FIGURE 26. MECHANICAL FEED ASSEMBLY FOR ELECTRIC AXIAL FEED (P/N 41064)
P/N 57017, Rev. 4 Page 71

FIGURE 27. MECHANICAL FEED ASSEMBLY PARTS LIST FOR ELECTRIC AXIAL FEED (P/N 41064)

FIGURE 28. ROTATIONAL DRIVE ASSEMBLY (P/N 22221)
P/N 57017, Rev. 4 Page 73

FIGURE 29. ROTATIONAL DRIVE ASSEMBLY PARTS LIST (P/N 22221)

FIGURE 30. FACING HEAD CHART ASSEMBLY (P/N 75682)
P/N 57017, Rev. 4 Page 75

FIGURE 31. FACING HEAD CHART ASSEMBLY PARTS LIST (P/N 75682)
FIGURE 32. BORING/FACING SLIDE ARM SET ASSEMBLY (P/N 81561)
P/N 57017, Rev. 4 Page 77

FIGURE 33. BORING/FACING SLIDE ARM SET ASSEMBLY PARTS LIST (P/N 81561)

FIGURE 34. BORING/FACING TOOL ARM CHART ASSEMBLY (P/N 86638)
P/N 57017, Rev. 4 Page 79

FIGURE 35. BORING/FACING TOOL ARM CHART ASSEMBLY PARTS LIST (P/N 86638)

FIGURE 36. TOOL CARRIER ASSEMBLY (P/N 54224)
P/N 57017, Rev. 4 Page 81

FIGURE 37. ADJUSTABLE AXIAL NUT LEAD SCREW ASSEMBLY (P/N 54223)

FIGURE 38. BORING HEAD SOLID TOOLING (P/N 81246)
P/N 57017, Rev. 4 Page 83

FIGURE 39. BORING HEAD SET SUPPLEMENTAL SOLID TOOLING HOLDERS (P/N 60382)

FIGURE 40. MICRO ADJUST BORING HEAD ASSEMBLY (P/N 79325)
P/N 57017, Rev. 4 Page 85

FIGURE 41. MICRO ADJUST BORING HEAD ASSEMBLY PARTS LIST (P/N 79325)

FIGURE 42. BORING DIAMETER RANGE STACK-UP BLOCKS ASSEMBLY (P/N 81249)
P/N 57017, Rev. 4 Page 87

FIGURE 43. BORING DIAMETER RANGE STACK-UP BLOCKS ASSEMBLY PARTS LIST (P/N 81249)

FIGURE 44. TOOL CARRIER ASSEMBLY (P/N 22377)
P/N 57017, Rev. 4 Page 89

FIGURE 45. TORQUE ARM ASSEMBLY (P/N 22604)

FIGURE 46. SCREW ASSEMBLY (P/N 55564)
P/N 57017, Rev. 4 Page 91

TABLE 6. HYDRAULIC MOTORS
PART DESCRIPTION
43438 Hydraulic, 3.6 CIR 60 SERIES QD
43444 Hydraulic, 17.9 CIR
84278 Hydraulic, 3.6 CIR ISO 16028 QD

8 SCHEMATICS
P/N 57017, Rev. 4 Page 93

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FIGURE 47. ELECTRIC FEED CONTROLLER ASSEMBLY (P/N 42368)
P/N 57017, Rev. 4 Page 95
This page intentionally left blank

9 SDS
Contact CLIMAX for the current list of Safety Data Sheets.
P/N 57017, Rev. 4 Page 97


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BB6100

PN: 57017 October 2020 Revision 4

P/N: 57017, Rev. 4 Page A

Page B BB6100 Operating Manual

P/N: 57017, Rev. 4 Page C

Page D BB6100 Operating Manual

Page ii BB6100 Operating Manual

1.1 Limited Warranty

P/N: 57017, Rev. 4 Page 1

1.3 Safety Precautions

Page 2 BB6100 Operating Manual

1.4 Machine Specific Safety Practices

P/N: 57017, Rev. 4 Page 3

Page 4 BB6100 Operating Manual

P/N: 57017, Rev. 4 Page 5

TABLE 1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

TABLE 2. RISK ASSESSMENT CHECKLIST AFTER SET-UP

Page 6 BB6100 Operating Manual

FIGURE 2-1. BB6100 COMPONENTS

P/N: 57017, Rev. 4 Page 7

2.1.1 Recommended tools

2.2 Receipt and inspection

Page 8 BB6100 Operating Manual

P/N: 57017, Rev. 4 Page 9

Page 14 BB6100 Operating Manual

• Magnetic base dial indicator

3.1 Clamp collars

3.2 About Boring Machine Support

P/N: 57017, Rev. 4 Page 15

3.3 Installing End-mount Bearing Support

3.3.1 To install the end-mount bearing support

Page 16 BB6100 Operating Manual

4. Slide the bearing supports onto the ends of the bar.

FIGURE 1. LEAD SCREW (TOP) AND BEARING RING (RIGHT)

16. Do the following to precisely align the boring bar:

Page 18 BB6100 Operating Manual

3.4 ID-mount bearing support

P/N: 57017, Rev. 4 Page 19

TABLE 3. ID-MOUNT BEARING COMPONENT FIGURE IDENTIFICATION

Page 20 BB6100 Operating Manual

FIGURE 3. SMALL PLATE CHUCK (LEFT) AND JACKING SCREW (RIGHT)

P/N: 57017, Rev. 4 Page 21

FIGURE 4. SLIDE JAWS IN AGAINST THE STOP BLOCK

d. Tighten the jaw clamping screws.

5. Slide one bearing support assembly onto the boring bar.

Page 22 BB6100 Operating Manual

3.4.1 If mounting an end-mount bearing

3.4.2 Clamping the bearing assembly to the bar

3.5 Preload bearing kit

P/N: 57017, Rev. 4 Page 23

3.6 RDU Setup

Page 24 BB6100 Operating Manual

P/N: 57017, Rev. 4 Page 25

3.7 Mounting the Mechanical Axial Feed Unit

Page 26 BB6100 Operating Manual

3.7.1 Setting feed direction and rate

3.7.2 Neutral (no feed)

3.7.3 Feed away from the axial feed unit

P/N: 57017, Rev. 4 Page 27