Climax BB8100 User manual

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

P/N 57064, Rev. 5 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted,
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of CLIMAX. CLIMAX hereby grants permission to download a single copy of this manual and of any
revision hereto onto an electronic storage medium to be viewed and to print one copy of this manual or
any revision hereto, pro- vided that such electronic or printed copy of this manual or revision must
contain the complete text of this copyright notice and provided further that any unauthorized
commercial distribution of this manual or any revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[email protected].
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]. For quick and accurate service, please provide your representative with the following:
•Your name
•Shipping address
•Telephone number
•Machine model
•Serial number (if applicable)
•Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street Newberg, Oregon 97132
USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate Bredbury
Industrial Park Horsfield Way
Stockport SK6 2SU, UK Telephone: +44 (0) 161-
406-1720
CLIMAX | H&S Tool (European Headquarters)
Am Langen
Graben 8 52353
Düren, Germany
Telephone: [phone]
E-mail: [email protected]
CLIMAX | H&S Tool (Asia Pacific Head-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East
Headquarters)
Warehouse #5, Plot:
369 272 Um Sequim
Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B BB8100 Operating Manual
CLIMAX WORLDWIDE LOCATIONS

P/N 57064, Rev. 5 Page C
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 pre- paid, to the factory. CLIMAX will, at its
option, either repair or replace the defective part and/ or correct any defect in the labor performed,
both at no charge, and return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
•Damage after the date of shipment not caused by defects in 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.

Page D BB8100 Operating Manual
CE INFORMATION

P/N 57064, Rev. 5 Page i
TABLE OF CONTENTS
INTRODUCTION .......................................................................................................... 1
ABOUT THIS MANUAL...................................................................................................................1
SAFETY WARNING SYMBOLS.......................................................................................................1
GENERAL SAFETY.......................................................................................................................2
MACHINE SPECIFIC SAFETY PRACTICES ......................................................................................3
RISK ASSESSMENT AND HAZARD MITIGATION ..............................................................................4
RISK ASSESSMENT CHECKLIST ...................................................................................................5
INSPECTING THE MACHINE..........................................................................................................6
BASIC COMPONENTS ..................................................................................................................7
OVERVIEW................................................................................................................... 9
ROTATIONAL DRIVE ASSEMBLY ....................................................................................................9
MECHANICAL AXIAL FEED ASSEMBLY............................................................................................9
HYDRAULIC POWER ..................................................................................................................10
General description.............................................................................................................10
Power unit pendant.............................................................................................................10
Hydraulic motor...................................................................................................................10
BEARING SUPPORT ASSEMBLIES................................................................................................11
End-mount self-aligning bearing support assembly (with spider) .......................................11
End-mount self-aligning bearing assembly (without spider) ...............................................11
ID-mount non self-aligning bearing support assembly (with spider) ...................................12
Non self-aligning bearing assembly (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 SETUP..............................................................15
END-MOUNT BEARING SUPPORT ASSEMBLY SETUP.....................................................................16
ID-mount bearing support assembly setup .........................................................................18
ROTATIONAL DRIVE ASSEMBLY SETUP .......................................................................................21
MOUNTING THE AXIAL FEED ASSEMBLY TO THE BAR....................................................................22
ATTACHING THE MECHANICAL RAPID FEED (OPTIONAL EQUIPMENT) ...........................................23
MOUNTING AN OPTIONAL ELECTRIC AXIAL FEED ASSEMBLY.........................................................25
Setting the Axial Feed Rate ................................................................................................26
SETTING THE FEED DIRECTION ..................................................................................................26
Setting feed direction while the bar is rotating ....................................................................26
Setting feed direction when the bar is stopped...................................................................26
Disengaging the feed..........................................................................................................26
SETTING THE FEED RATE...........................................................................................................27
TOOLING SETUP........................................................................................................................27
Tool carrier setup................................................................................................................27
To lock the tool carrier on the bar for other operations.......................................................28
To remove the brass nut.....................................................................................................29
BORING29
Manual boring head assembly setup ..................................................................................29

Page ii BB8100 Operating Manual
Micro Adjustment Boring Head............................................................................................30
BORING HEAD SETUP.................................................................................................................33
FACING HEAD............................................................................................................................34
Manual facing head assembly setup...................................................................................34
Facing head radial feed.......................................................................................................35
INSTALLING THE FACING SLIDE ARM ONTO THE TOOL CARRIER.....................................................42
Install the slide arm onto the tool carrier .............................................................................42
Adjusting the tool carrier for perpendicularity......................................................................43
Feedbox assembly ..............................................................................................................43
INSTALL THE COUNTERWEIGHT ARM ONTO THE TOOL CARRIER....................................................43
HYDRAULIC POWER PREPARATION AND CONNECTION .................................................................44
OPERATION................................................................................................................. 45
PRE-START CHECKS..................................................................................................................45
Before operating the portable boring bar.............................................................................45
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
DISASSEMBLY...........................................................................................................................49
Standard disassembly.........................................................................................................49
Alternative disassembly.......................................................................................................50
MAINTENANCE............................................................................................................ 51
RECOMMENDED LUBRICANTS.....................................................................................................51
BORING BAR/LEADSCREW..........................................................................................................51
AXIAL FEED ASSEMBLY ..............................................................................................................51
ROTATIONAL DRIVE ASSEMBLY...................................................................................................51
BEARING SUPPORT ASSEMBLY...................................................................................................52
TOOL HEAD ASSEMBLY ..............................................................................................................52
Manual boring head assembly ............................................................................................52
Manual facing head assembly.............................................................................................52
Tool carrier52
HYDRAULIC POWER UNIT AND MOTOR ........................................................................................52
General hydraulic system....................................................................................................52
Hydraulic motor ...................................................................................................................52
Hydraulic filter and fluid.......................................................................................................52
TROUBLESHOOTING ..................................................................................................................54
STORAGE .................................................................................................................... 55
SPECIFICATIONS........................................................................................................ 56
TOOL KIT AND SPARE PARTS................................................................................... 66
EXPLODED VIEWS AND PARTS ................................................................................ 69

P/N 57064, Rev. 5 Page iii
SCHEMATICS .............................................................................................................. 95
SDS .............................................................................................................................. 99

Page iv BB8100 Operating Manual
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P/N 57064, Rev. 5 Page 1
INTRODUCTION
This manual describes how to use the Model BB8100 Portable Boring Bar. This precision
machine tool is designed for on-site boring without costly disassembly of equipment. All
parts and components meet CLIMAX’s strict quality standards. For maximum safety and
performance, read and understand the entire manual before operating the boring bar.
About this manual
Information in this manual is up-to-date at time of going to print. Because CLIMAX is
committed to continued product improvement, the machine you receive may differ slightly
from the one described here.
Safety Warning Symbols
The purpose 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 symbols or pictographs. Failure to obey safety warnings can
result in serious injury. Always follow safety precautions to reduce the risk of hazards and
serious injury.
DANGER
Indicates a hazardous situation that could be fatal or cause serious injury.
WARNING
Indicates a potentially hazardous situation that could be fatal or cause
serious injury.
CAUTION
Indicates a potentially hazardous situation that could result in minor to
moderate injury, damage to the machine or interruption of an important
process.
!
NOTICE
Provides critical information for the completion of a task. There is no
associated hazard to people or the machine.

Page 2 BB8100 Operating Manual
General Safety
The primary challenge for most on-site maintenance is that repairs are often done under
difficult conditions.
CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a
joint effort. As the operator of this machine, you are expected to do your part by closely
examining the job site and following the operating procedures outlined in this manual, your
own company rules, and local regulations.
WARNING
For maximum safety and performance, read and understand this entire
manual and all other related safety instructions before using this
equipment. Failure to follow the instructions and guidelines in this manual
could cause personal injury, fatalities and property damage.
QUALIFIED PERSONNEL
Before operating this machine, you must receive
training specific to this machine from a qualified
trainer. Do not operate the machine If you are
not familiar with the proper and safe operation.
OBEY WARNING LABELS
Obey all warning labels. Failure to follow
instructions or heed warnings could result in
injury, or even be fatal. Proper care is your
responsibility. Contact CLIMAX immediately for
replacement manuals or safety decals.
INTENDED USE
Use this machine according to the instructions in
this operating manual. Do not use this machine
for any purpose other than its intended use as
described in this manual.
STAY CLEAR OF MOVING PARTS
Keep clear of the machine during operation.
Never lean toward or reach into the machine to
remove chips or to adjust the machine while it is
running.
ROTATING MACHINERY
Rotating machinery can seriously injure an
operator. Lock out all power sources before you
interact with the machine.
KEEP YOUR WORK AREA CLEAN AND
TIDY
Keep all cords and hoses away from moving
parts during operation. Do not clutter the area
around the machine.
SECURE LOOSE CLOTHING AND LONG
HAIR
Rotating machinery can cause serious injuries.
Do not wear loose fitting clothing or jewelry. Tie
back long hair or wear a hat.
HAZARDOUS ENVIRONMENTS
Do not use the machine near explosive
chemicals, toxic fumes, inappropriate radiation
hazards or other hazardous environments.
FLYING CHIPS
Flying metal chips can cut or burn. Do not
remove chips until after the machine has been
locked out, all power sources are off and the
machine has stopped.

P/N 57064, Rev. 5 Page 3
Machine Specific Safety Practices
All aspects of the machine have been designed with safety in mind. Following are
safety practices that you should keep in mind when using the CLIMAX BB8100
Boring Bar Machine.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
Eye and hearing protection must be worn while using
the machine. These safety items do not impose
constraints to the safe operation of the machine.
OPERATING CONDITIONS
Do not operate the machine if it is not mounted to the
workpiece as described in this manual.
TOOLING
The machine is provided with all the tools for the setup
and operation of the machine.
LIFTING
Avoid lifting heavy objects by yourself as serious injury
can result. Always follow your plant’s procedures for
lifting heavy objects.
CUTTING FLUIDS
There are no cutting or cooling fluids used with this
machine.
DANGER ZONE
The operator and other persons can be anywhere in
the vicinity of the machine. The operator must make
sure there are no other persons in danger from the
machine.
METAL FRAGMENT HAZARD
The machine dispenses metallic fragments during
normal operation. You should wear eye protection and
gloves at all times when working with the machine.
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 this machine
that are capable of producing hazardous EMC, UV or
other radiation hazards. The machine does not use
lasers nor does it create hazardous materials such as
gasses or dust.
ADJUSTMENTS AND MAINTENANCE
All adjustments, lubrication and maintenance should
be done with the machine stopped, and disconnected
from power. The shut-off valve should be locked and
tagged out before any maintenance occurs.
WARNING LABELS
Warning labels are attached to your machine upon
delivery. If any labels are defaced or missing, be sure
to contact CLIMAX immediately for replacements.
MAINTENANCE
Check that the machine components are free of debris
and properly lubricated prior to use.
CLAMP COLLARS
To prevent the bar from sliding through the support
bearings, or falling, use P/N 40708 –The collars are
made in matching sets and must be used to secure
the bar when the machine is in the vertical orientation.
Torque these collars to 100 ft-lbs (136 Nm), using the
clamp collars to prevent over tightening of the
bearings. Clamp collars should be positioned ABOVE
at least 2 support bearings when installed in a vertical
orientation. Clamp collars should be shouldered
against the bearing when in use.

Page 4 BB8100 Operating Manual
Risk Assessment and Hazard Mitigation
Machine Tools are specifically designed to perform precise material-removal operations.
Stationary Machine Tools include lathes and milling machines and are typically found in a
machine shop. They are mounted in a fixed location during operation and are considered to be a
complete, self-contained machine. Stationary Machine Tools achieve the rigidity needed to
accomplish material-removal operations from the structure that is an integral part of the machine
tool.
In contrast, Portable Machine Tools are designed for on-site machining applications. They
typically attach directly to the workpiece itself, or to an adjacent structure, and achieve their
rigidity from the structure to which it is attached. The design intent is that the Portable Machine
Tool and the structure to which it is attached become one complete machine during the material-
removal process.
To achieve the intended results and to promote safety, the operator must under- stand and follow
the design intent, set-up, and operation practices that are unique to Portable Machine Tools.
The operator must perform an overall review and on-site risk assessment of the intended
application. Due to the unique nature of portable machining applications, identifying one or more
hazards that must be addressed is typical.
When performing the on-site risk assessment, it is important to consider the Portable Machine
Tool and the workpiece as a whole.

P/N 57064, Rev. 5 Page 5
Risk Assessment Checklist
The following checklist is not intended to be an all-inclusive list of things to watch out for
when setting up and operating this Portable Machine Tool. However, these checklists are
typical of the types of risks the assembler and operator should consider. Use these
checklists as part of your risk assessment:
TABLE 1-1. 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 machine assembly instructions.

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 pre- cautions to
keep workers away from the identified fall path.

I considered how this machine operates and identified the best placement for the controls,
cabling, and the operator.

I evaluated and mitigated any other potential risks specific to my work area.
TABLE 1-2. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After set-up

I checked that the machine is safely installed and the potential fall path is clear. If the machine is
installed at an elevated position, 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 required maintenance with the recommended lubricants.

I checked that all affected personnel have the recommended personal protective equipment, as
well as any site-required or regulatory equipment.

I checked that all affected personnel understand and are clear of the danger zone.

I evaluated and mitigated any other potential risks specific to my work area.

Page 6 BB8100 Operating Manual
Inspecting the Machine
Your CLIMAX product was inspected and tested prior to shipment, and 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. 1. Inspect the shipping container(s) for damage.
2. Check the contents of the shipping container(s) 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 is a highly configurable machine with many options and accessories. This manual
covers the use and operation of all of those possible options. The machine configuration
purchased by a customer may not contain all of the options and accessories detailed
herein. If a specific machine application requires additional options or accessories, contact
CLIMAX for assistance in obtaining the needed components.

P/N 57064, Rev. 5 Page 7
Basic Components
Figure 1. Components

Page 8 BB8100 Operating Manual
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P/N 57064, Rev. 5 Page 9
OVERVIEW
Model BB8100 Portable Boring Bar is a moving-head style line-boring machine. The 8"
(203 mm) diameter machine will bore 14.5–85.6" (368.3–2,174.2 mm) diameters and face
23.1–97.7" (586.7–2,481.6 mm) diameters.
Rotational drive assembly
The rotational drive assembly can be positioned anywhere along the bar.
Locking rings hold the assembly securely in place. Two torque arms
provide stability.
Mechanical axial feed assembly
The tool head feeds axially along the bar using the mechanical axial 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.
The 8" mechanical axial feed assembly can be mounted
to either end of the boring bar. Feed rate is reversible
and variable up to 0.040" (1.016 mm) per revolution.
Feed direction can be reversed or set to Neutral by
pulling or pushing the shifter knob.
Because the hand wheel component of the axial feed
assembly does not turn while the bar is rotating the feed
rate can be adjusted during operation.
The assembly includes a 15" (381 mm) trip rod.
Figure 3. Mechanical axial feed
assembly
Figure 2. Rotational
drive assembly

Page 10 BB8100 Operating Manual
Hydraulic power
General description
The hydraulic power unit is an electrically driven piston pump with a horizontally mounted
motor. The unit has a 20-gpm pump and a 5-gallon (19 liter) reservoir.
Features include:
•Relief valve for system over pressure protection
•System pressure gage and shut-off valve
•Spin-on oil filter
•Combination fluid level and temperature gage
•Electric motor starter and motor overload heaters.
The hydraulic power unit connects to the rotational drive hydraulic motor with a pair of 25-
foot (7.6-meter) long hoses and quick disconnect 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 unit pump, connect the
hydraulic motor to the power unit before plugging in and
turning on the power unit.
Power unit pendant
The hydraulic power unit comes with a standard control pendant. The pendant, with
25-foot (7.6 m) cord, has the following controls:
•High/low volume control
•Jog/run
•Pressure start
•Pressure stop
•Power unit on
•Power unit off
Hydraulic motor
The high-torque low-speed hydraulic motor mounts directly to the rotational drive
assembly. Motor ports are 7/8-14 SAE O-ring type. Motor fittings are included with the
hydraulic power unit. A fitting kit may be purchased separately.