Climax AUTOBOREWELDER BW3000 User manual

BW3000
BW3000 AUTOBOREWELDER
OPERATING MANUAL
P/N 52815
February 2019
Revision 7

P/N 52815, Rev. 7 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, dissem-
inated, downloaded, or stored in any storage medium, without the express prior written consent 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
[e-mail].
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: [phone]
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 BW3000 Operating Manual
CLIMAX GLOBAL LOCATIONS

P/N 52815, Rev. 7 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 BW3000 Operating Manual
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P/N 52815, Rev. 7 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 GLOSSARY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
2.1.1 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
2.1.2 Stock components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
2.1.3 Torches and torch accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
2.1.4 Consumables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
2.1.5 Cables and conduits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
2.2 ACCESSORIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22
2.2.1 Wirefeeder accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
2.2.2 Mounting accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
2.2.3 BoreWelder accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24
2.2.4 Plate, offset head protector (inverted operation) - - - - - - - - - - - - - - - - - - - - - - 25
2.3 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
2.4 DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
2.5 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
2.6 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31
3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 RECEIPT AND INSPECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33
3.2 LIFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
3.3 MACHINE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34
3.3.1 Mounting system (when not using the boring bar interface)- - - - - - - - - - - - - - - - - 34
3.3.2 Attaching the BW3000 using the adjustable base - - - - - - - - - - - - - - - - - - - - - 35
3.3.3 Attaching the control box - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37
3.3.4 Adjusting parallelism using the torch extension as a guide - - - - - - - - - - - - - - - - - 37
3.3.5 Centering the BoreWelder with the torch extension (coarse center)- - - - - - - - - - - - - 39
3.3.6 Installing a welding torch and setting the clearance - - - - - - - - - - - - - - - - - - - - 40
3.3.7 Fine centering with the adjustable base - - - - - - - - - - - - - - - - - - - - - - - - - - 42
3.3.8 Understanding the boring bar interface - - - - - - - - - - - - - - - - - - - - - - - - - - 43

Page ii BW3000 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
3.3.9 Adjusting the reach - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43
3.3.10 Attaching the wirefeed conduit and loading wire - - - - - - - - - - - - - - - - - - - - - - 43
3.3.11 Attaching the weld cables and gas hose- - - - - - - - - - - - - - - - - - - - - - - - - - 44
3.3.12 Setting the axial and rotational start positions - - - - - - - - - - - - - - - - - - - - - - - 45
4 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.1 PRE-OPERATION CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
4.2 CHOOSING THE CONTROL SETTINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
4.2.1 Setting the wire speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49
4.2.2 Setting the step- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
4.2.3 Setting the arc voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50
4.2.4 Choosing shielding gas and setting the gas flow rate - - - - - - - - - - - - - - - - - - - 51
4.3 PRE-WELD CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.4 STARTING, STOPPING, AND INTERRUPTING THE WELD PROCESS - - - - - - - - - - - - - - - - - - - 52
4.4.1 Starting to weld- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.4.2 Stopping the weld - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.5 USING ARC INTERRUPT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.6 USING AUTO SKIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.7 USING PIE MODE AND CARRIAGE RETURN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.7.1 Pie mode- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.7.2 Carriage return - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
4.8 WELDING TIPS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.8.1 Achieving the smoothest and least violent arc action - - - - - - - - - - - - - - - - - - - 56
4.8.2 Avoiding wire flip by using a wire with a large cast - - - - - - - - - - - - - - - - - - - - - 56
4.8.3 Cleaning glass inclusions from the bore - - - - - - - - - - - - - - - - - - - - - - - - - - 57
4.8.4 Providing appropriate axial movement each revolution- - - - - - - - - - - - - - - - - - - 57
4.9 WELDING IN THE HORIZONTAL AXIS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.9.1 Procedure for horizontal axis welding - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.9.2 Offset head settings when using extensions in the horizontal axis - - - - - - - - - - - - - 60
5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
5.1 MAINTENANCE CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2 MAINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2.1 BoreWelder maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62
5.2.2 BoreWelder adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.2.3 Wirefeeder maintenance and adjustments- - - - - - - - - - - - - - - - - - - - - - - - - 65
5.2.4 Torches, conduits, and cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
5.2.5 Control box maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68

P/N 52815, Rev. 7 Page iii
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
5.3 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
5.3.1 Common welding problems and their cures - - - - - - - - - - - - - - - - - - - - - - - - 71
5.3.2 Mechanical/electrical troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - 74
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
6.1.1 Short-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 77
6.1.2 Long-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
6.2 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
6.3 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78
APPENDIX A ASSEMBLY DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Page iv BW3000 Operating Manual
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P/N 52815, Rev. 7 Page v
LIST OF FIGURES
FIGURE PAGE
2-1 BW3000 AutoBoreWelder and external components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-2 BW3000 components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-3 Control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-4 Enclosed wirefeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-5 Shop-style wirefeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-6 Radial mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-7 Torch extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-8 Zero offset alignment mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2-9 Push-pull wirefeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2-10 Control box panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2-11 BoreWelder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2-12 BW3000 dimensions (P/N 85576) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2-13 Shop-style wirefeeder dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-1 Adjustable base and mounting hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-2 Spring washer alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-3 Radial mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-4 Zero offset alignment mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3-5 Alignment at 9 o’clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-6 Alignment at 6 o’clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-7 Torch positioned in orientation nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3-8 Adjustment knob technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3-9 X and Y axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3-10 Swivel connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3-11 Toggle switch in normal position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4-1 Function cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4-2 Conduit shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4-3 Components for locking the head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5-1 Components for daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-2 Components for offset head adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5-3 Knob rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5-4 Inserting the liner into the torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5-5 Illustration of graping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6-1 Packaging arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
A-1 BW3000 assembly 1 (P/N 85576). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
A-2 BW3000 assembly 2 (P/N 85576). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
A-3 BW3000 assembly parts list 1 (P/N 85576) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
A-4 BW3000 assembly parts list 2 (P/N 85576) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
A-5 Offset head spindle assembly (P/N 83085). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
A-6 Shroud with metal connector assembly (P/N 68374) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
A-7 Shroud with plastic connector assembly (P/N 68379). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
A-8 Radial mount assembly (P/N 83081) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
A-9 Adjustable base assembly (P/N 29037) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
A-10 Shop-style wirefeeder assembly (P/N 82207). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
A-11 Shop-style wirefeeder assembly parts list (P/N 82207) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Page vi BW3000 Operating Manual
LIST OF FIGURES (CONTINUED)
FIGURE PAGE
A-12 Wire straightener (for shop-style wirefeeder only) assembly (P/N 35357) . . . . . . . . . . . . . . . . . . . . . 92
A-13 Enclosed wirefeeder assembly (P/N 69018) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
A-14 Enclosed wire feeder push/pull ready 24 VDC assembly (P/N 82174). . . . . . . . . . . . . . . . . . . . . . . . 94
A-15 Enclosed wire feeder push/pull ready 24 VDC assembly parts list (P/N 82174). . . . . . . . . . . . . . . . . 95
A-16 Feed system assembly (P/N 82097). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A-17 Feed system assembly parts list (P/N 82097). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
A-18 Compact 6" (152 mm) face torch assembly (P/N 48013) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
A-19 Compact 6" (152 mm) face torch assembly parts list (P/N 48013) . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
A-20 8" (203 mm) face torch assembly (P/N 28186) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A-21 8" (203 mm) face torch assembly parts list (P/N 28186). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
A-22 Conical seat torch assembly (P/N 28020). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
A-23 Conical seat torch assembly parts list 1 (P/N 28020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
A-24 Conical seat torch assembly parts list 2 (P/N 28020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A-25 OD trammel torch assembly (P/N 81384) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A-26 Standard torches #2–12 assembly (P/N 82215) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
A-27 Torch #1A assembly (P/N 39723). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
A-28 Torch #13/24 assembly (P/N 34473) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
A-29 Torch bearing mount assembly (P/N 70132) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
A-30 Extension torch 3" (76 mm) and 6" (152 mm) assembly (P/N 82155) . . . . . . . . . . . . . . . . . . . . . . . 110
A-31 Extension torch 12" (305 mm) and 18" (457 mm) assembly (P/N 85213) . . . . . . . . . . . . . . . . . . . . 111
A-32 Conduit wire feed assembly (P/N 78533) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
A-33 Shielding gas hose assembly (P/N 30774) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
A-34 Electrode stick holder assembly (P/N 36169) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
A-35 Power supply cable 14 pin plastic connectors assembly (P/N 72101) . . . . . . . . . . . . . . . . . . . . . . . 115
A-36 Power supply cable 6 pin plastic connectors assembly (P/N 72138) . . . . . . . . . . . . . . . . . . . . . . . . 116
A-37 Feederless miller cable for P/N 69007 (P/N 69021) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A-38 BW3000 controller plastic/metal connectors assembly (P/N 87304) . . . . . . . . . . . . . . . . . . . . . . . . 118
A-39 BW3000 controller metal connectors assembly (P/N 87304) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
A-40 BW3000 controller plastic/metal connectors assembly parts list 1 (P/N 87304) . . . . . . . . . . . . . . . . 120
A-41 BW3000 controller plastic/metal connectors assembly parts list 2 (P/N 87304) . . . . . . . . . . . . . . . . 121
B-1 BoreWelder with metal or plastic connectors schematic (P/N 87413) . . . . . . . . . . . . . . . . . . . . . . . . 124
B-2 Wire feeder with metal connectors schematic (P/N 87414) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
B-3 Wire feeder with plastic connectors schematic (P/N 87415). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
B-4 Power supply interface cable with plastic connector schematic (P/N 87419) . . . . . . . . . . . . . . . . . . . 127
B-5 Power supply interface cable schematic with plastic connector (P/N 87421) . . . . . . . . . . . . . . . . . . . 128
B-6 Metal connectors system layout (P/N 70186 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
B-7 Metal connectors ladder schematic (P/N 70186 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
B-8 Chart controller with metal connectors (P/N 70186 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

P/N 52815, Rev. 7 Page vii
LIST OF TABLES
TABLE PAGE
1-1 Sound levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-2 Risk assessment checklist before set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Risk assessment checklist after set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-4 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1 BW3000 external component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-2 BW3000 component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2-3 Consumable kit (P/N 66947) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2-4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2-5 Push-pull wirefeeder component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2-6 Control panel component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2-7 Control panel definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2-8 Sub-component mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3-1 Adjustable base and mounting hardware component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3-2 Spring washer alignment component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3-3 9 o’clock alignment component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3-4 6 o’clock alignment component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3-5 Available torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3-6 X and Y axes identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4-1 Rotation speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-2 Wire speed settings and amperage (0.035 diameter wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4-3 Wire speed at startup (with 0.035 diameter wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-4 Estimated step settings at a travel speed of 20 IPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4-5 Shielding gas guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4-6 Pre-weld checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4-7 Function cycle identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4-8 Locking the head component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5-1 Maintenance intervals and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5-2 Daily maintenance component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-3 Offset head adjustment component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5-4 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
A-1 Tool kit P/N 69971. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Page viii BW3000 Operating Manual
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P/N 52815, Rev. 7 Page 1
1 INTRODUCTION
IN THIS CHAPTER:
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 GLOSSARY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
1.1 HOW TO USE THIS MANUAL
This manual describes information necessary for the setup, operation, mainte-
nance, storage, shipping, and decommissioning of the BW3000.
The first page of each chapter includes a summary of the chapter contents to help
you locate specific information. The appendices contain supplemental product
information to aid in setup, operation, and maintenance tasks.
Read this entire manual to familiarize yourself with the BW3000 before attempt-
ing to set it up or operate it.
1.2 SAFETY ALERTS
Pay careful attention to the safety alerts printed throughout this manual. Safety
alerts will call your attention to specific hazardous situations that may be encoun-
tered when operating this machine.
Examples of safety alerts used in this manual are defined here1:
DANGER
indicates a hazardous situation which, if not avoided, WILL result in
death or severe injury.
WARNING
indicates a hazardous situation which, if not avoided, COULD result in
death or severe injury.
1. For more information on safety alerts, refer to ANSI/NEMA Z535.6-2011, Product
safety Information in Product Manuals, Instructions, and Other Collateral Materials.

Page 2 BW3000 Operating Manual
CAUTION
indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
indicates a hazardous situation which, if not avoided, could result in
property damage, equipment failure, or undesired work results.
1.3 GENERAL SAFETY PRECAUTIONS
CLIMAX leads the way in promoting the safe use of portable machine tools.
Safety is a joint effort. You must do your part by:
• Being aware of your work environment
• Closely following the operating procedures and safety precautions con-
tained in this manual
• Closely following your employer’s safety guidelines
When operating or working around the machine, observe the safety precautions
below.
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. Conduct a risk assessment (Section 1.5 and Section 1.5 on
page 4) of each job site before setting up and operating this machine.
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 – This machine produces radiation in the
visible and ultraviolet spectrum range called arc rays. Always wear appro-
priate personal protective gear when operating this or any other machine
tool.
• Always wear welding PPE for eyes and exposed skin when observing
or working around the machine during operation.
• Wear flame-resistant clothing with long sleeves and legs (such as heavy
shirts and cuffless pants made of a durable flame-resistant material for
protection from sparks and flame) when operating the machine, as hot
flying spatter from the workpiece may burn bare skin. Other personnel
in the area must be protected from the arc rays by a screen or a warning
not to watch or otherwise expose themselves to the rays or to any hot
spatter.

P/N 52815, Rev. 7 Page 3
• The operator and any personnel observing the machine when in use
must use a protective shield with a filter and cover plates that conform
to ANSI Z87.1 standards.
• Operators should use weld curtains and Shade 9 handheld shields,
Shade 3 sunglasses with side shields for operators, and a hand-held
weld helmet for operators.
The hand-held helmet is held between the process and the operator,
allowing the operator to view the control box without raising a conven-
tional helmet. It’s also easier to inspect the process with a hand-held
helmet, as you can hold the helmet near the process without bumping
into the BW3000 or the part being welded.
Work area – Keep the work area around the machine clear of clutter. Restrain
cords and hoses connected to the machine. Keep other cords and hoses
away from the work area.
Danger zone – The danger zone of this machine is inside the bore during
welding operations. The main danger of this machine is from the arc flash,
and is mainly visual in nature. All persons in the area of the machine need
to have proper shielding from the radiation produced while welding. Keep
combustibles or any other fire hazards well away from the work area. For
in-shop use, have a fire extinguisher readily available.
Moving parts – Many CLIMAX machines have numerous exposed moving
parts and interfaces that can cause severe impact, pinching, cutting, and
other injuries.
During machine operation:
• Keep hands and tools away from moving parts.
• Wear proper PPE for welding and always maintain a clear working area
to prevent tripping hazards.
Hot surfaces – During operation, torches and extensions will get hot enough
to cause severe burns. Pay attention to hot-surface warning labels and wear
gloves, avoiding contact with bare skin until the machine has cooled.
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS
Hazardous environments – Do not operate the machine in environments
where explosive materials, toxic chemicals, or radiation may be present.
Do not expose the machine to rain or wet conditions.
Welding hazards – This machine produces radiation in the visible and ultra-
violet spectrum range. Always wear welding PPE for eyes and exposed
skin when observing or working around the machine during operation. For
more information on welding hazards and safety precautions, refer to ANSI
749.1, Safety in Welding and Cutting.
Sound level – This machine produces potentially harmful sound levels.

Page 4 BW3000 Operating Manual
Always wear hearing protection when operating the machine or working
around it.
During testing, the machine produced the following sound levels.1
Hoses, pendants, and electrical cables – Follow these rules:
• Do not abuse the pendant cable as this can damage the cable and pen-
dant.
• Never use the cord for carrying, pulling, or unplugging.
• Remove any and all kinks before straightening the cable.
• Keep cords and hoses away from heat, oil, sharp edges, and moving
parts.
• Plugs must match the outlet. Never modify the plugs in any way. Do
not use an adapter plug with grounded power tools.
• Always examine hoses and cables for damage before use.
Adjustments and maintenance – Stop the machine and lock out all power
sources before performing any adjustment, lubrication, or maintenance.
Controls – The machine controls are designed to withstand the rigors of nor-
mal use.
The on/off switches are clearly visible and identifiable. When you leave the
machine, disconnect all power sources to the machine.
1.5 RISK ASSESSMENT AND HAZARD MITIGATION
Welding tools are specifically designed to perform precise metal-joining and over-
lay operations. Some welding tools are used in controlled environments such as
factories and repair shops; however, portable welding tools are used in a wide vari-
ety of conditions. A portable welding tool typically attaches directly to the work-
piece itself, or to an adjacent structure. The design intent is that the portable
welding tool and the structure to which it is attached become one complete
machine during the welding processes.
To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, setup, and operation practices that are unique to
portable welding tools. Hazards include the potential for operator injury, as well as
the potential for damage to the workpiece and to the welding equipment itself.
TABLE 1-1. SOUND LEVELS
The declared sound power level is: 59.7 dBA
The declared operator sound pressure level is: 58.0 dBA
The declared bystander sound pressure level is: 56.4 dBA
1. Machine sound testing was conducted in accordance with European Harmonized
Standards EN ISO 3744:2010 and EN 11201:2010.

P/N 52815, Rev. 7 Page 5
Precautions are required to avoid injury from burns, electric shock, vision damage,
inhalation of poisonous gases and fumes, and exposure to intense ultraviolet radia-
tion. When welding is performed on motorized equipment, precaution is required
to minimize the risk of fuel ignition or electrical damage to vehicle instrumenta-
tion. Power sources must be evaluated for proper voltage and current rating. To
avoid damaging generators, weld power supplies, and welding equipment, power
cabling must be maintained and replaced as required.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of welding tool applications, identi-
fying one or more hazards that must be addressed is typical. When performing the
on-site risk assessment, it is important to consider the portable welding tool and
the workpiece as a whole.
1.6 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 con-
sider. Use these checklists as part of your risk assessment:
TABLE 1-2. 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 including shielding from arc rays.
I read the machine assembly instructions (Section 3) and took inventory of all the items required but not sup-
plied (Section 2.6).
I took inventory of all the items required but not supplied (Section 2.4).
I considered how this machine operates and identified the best placement for the controls, cabling, and the
operator.
I have assessed for additional risks unique to this application of the Portable Welding tool.
TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After Set-up
I checked that the machine is safely installed (according to Section 3) 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 planned for containment of any weld spatter produced by the machine.
I followed the required Maintenance Intervals (Section 5.2).
I checked that all affected personnel have the recommended personal protective equipment, as well as any
equipment required by the site or other regulations.

Page 6 BW3000 Operating Manual
I checked that all affected personnel understand the danger zone and are clear of it or UV guarding is present.
I examined the area surrounding the workpiece for flammable materials and removed them if possible. I have
an appropriate fire extinguisher nearby.
I have a fire extinguisher nearby.
I have assessed for additional risks unique to this application of the Portable Machine tool.
TABLE 1-3. RISK ASSESSMENT CHECKLIST AFTER SET-UP
After Set-up