Climax Bw2600 User manual

BW2600

AUTOBOREWELDER

BW2600 OPERATING MANUAL

ORIGINAL INSTRUCTIONS

P/N 85555

January 2019

Revision 6

P/N 85555, Rev. 6 Page A

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

revision hereto is prohibited.

At CLIMAX, we value your opinion.

For comments or questions about this manual or other CLIMAX documentation, please e-mail

documentation@cpmt.com.

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): +1-503-538-2815

Toll-free (North America): 1-800-333-8311

Fax: 503-538-7600

H&S Tool World Headquarters

715 Weber Dr.

Wadsworth, OH 44281 USA

Telephone: +1-330-336-4550

Fax: 1-330-336-9159

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: +49 (0) 24-219-1770

E-mail: ClimaxEurope@cpmt.com

CLIMAX | H&S Tool (Asia Pacific

Headquarters)

316 Tanglin Road #02-01

Singapore 247978

Telephone: +65-9647-2289

Fax: +65-6801-0699

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: +971-04-321-0328

Page B BW2600 Operating Manual

CLIMAX GLOBAL LOCATIONS

P/N 85555, Rev. 6 Page C

CE DOCUMENTATION

Page D BW2600 Operating Manual

LIMITED WARRANTY

CLIMAX Portable Machining & Welding Systems, 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 orig-

inal 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 85555, Rev. 6 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 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6

1.8 LABEL LOCATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8

2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

2.1.1 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

2.1.2 Stock components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

2.1.3 Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

2.2 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

2.3 MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25

2.4 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 PREPARING THE MACHINE FOR USE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.1.1 Inspecting the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27

3.1.2 Assessing the work area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.2 LIFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.3 INSTALLING THE BORE WELDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28

3.3.1 Mounting to a boring bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29

3.3.2 Installing the bore welder with an adjustable base - - - - - - - - - - - - - - - - - - - - - 38

3.3.3 Finishing the installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42

3.4 INSTALLING ACCESSORIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

3.4.1 Standard torch adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

3.4.2 Torch #00 and #0 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

3.4.3 Torch extension support kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48

4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1 OPERATION MODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

4.2 PRINCIPLES OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

4.3 PRE-OPERATION CHECKS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

4.4 PREPARING THE BORE WELDER FOR WELDING - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

4.4.1 Setting the rotation speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

Page ii BW2600 Operating Manual

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

4.4.2 Setting the gas flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

4.4.3 Setting the wire speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

4.4.4 Checking the step setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54

4.4.5 Attaching the weld ground clamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

4.5 WELDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56

4.5.1 Welding safety during adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56

4.5.2 Weld interrupt options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

4.6 WELDING POINTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

4.6.1 Arc voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

4.6.2 Using 0.035" wire- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

4.6.3 Shielding gas- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

4.6.4 Wire and gas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59

4.6.5 Spindle feed and wire location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

4.6.6 Welding in the horizontal axis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60

5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

5.1 OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

5.2 MAINTENANCE INTERVALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

5.3 MAINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

5.4 REPLACING LINERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

5.5 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

5.5.1 If the feed will not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

5.5.2 If there is a lack of fusion to the bore surface - - - - - - - - - - - - - - - - - - - - - - - 65

5.5.3 If the wire feeding stops and wire burns back to tip - - - - - - - - - - - - - - - - - - - - 65

5.5.4 If weld beads are “ropey” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66

5.5.5 If there is too much spatter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66

5.5.6 If the weld is porous - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

5.5.7 If experiencing wire flip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67

5.5.8 If steel weld deposits are too hard to machine - - - - - - - - - - - - - - - - - - - - - - - 68

5.5.9 If the weld is “graping” in the horizontal axis - - - - - - - - - - - - - - - - - - - - - - - - 68

5.5.10 If the weld voltage is hard to control - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

5.6 TRAINING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

5.7 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70

5.8 TOOL KIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71

6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

6.1 STORAGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

6.1.1 Short-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

P/N 85555, Rev. 6 Page iii

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION PAGE

6.1.2 Long-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

6.2 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

APPENDIX A EXPLODED VIEWS AND PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Page iv BW2600 Operating Manual

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