BB4500-BB5000 BORING MACHINE. OPERATING MANUAL

• Your name

• Shipping address

• Telephone number

• Machine model

• Serial number (if applicable)

• Date of purchase

CLIMAX World Headquarters

H&S Tool World Headquarters

2712 East 2nd Street

715 Weber Dr.

Newberg, Oregon 97132 USA

Wadsworth, OH 44281 USA

Telephone (worldwide): +1-503-538-2815

Telephone: +1-330-336-4550

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

Fax: 1-330-336-9159

Fax: 503-538-7600

hstool.com

CLIMAX | H&S Tool (UK Headquarters)

CLIMAX | H&S Tool (European Headquarters)

Unit 7 Castlehill Industrial Estate

Am Langen Graben 8

Bredbury Industrial Park

52353 Düren, Germany

Horsfield Way

Telephone: +49 24-219-1770

Stockport SK6 2SU, UK

E-mail: ClimaxEurope@cpmt.com

Telephone: +44 (0) 161-406-1720

CLIMAX | H&S Tool (Asia Pacific Head-

CLIMAX | H&S Tool (Middle East Headquarters)

quarters)

Warehouse #5, Plot: 369 272

316 Tanglin Road #02-01

Um Sequim Road

Singapore 247978

Al Quoz 4

PO Box 414 084

Telephone: +65 9647-2289

Dubai, UAE

Fax: +65 6801-0699

Telephone: +971 04-321-0328

P/N 92974, Rev. 3

Page A

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

BB4500-BB5000 Operating Manual

TABLE OF CONTENTS

CHAPTER/SECTION

PAGE

INTRODUCTION

1.1

HOW TO USE THIS MANUAL

1.2

SAFETY ALERTS

1.3

GENERAL SAFETY PRECAUTIONS

1.4

MACHINE-SPECIFIC SAFETY PRECAUTIONS

1.5

RISK ASSESSMENT AND HAZARD MITIGATION

1.6

RISK ASSESSMENT CHECKLIST

1.7

LABELS

1.7.1

Label identification

1.7.2

BB4500-BB5000 label locations

OVERVIEW

2.1

BB4500 FEATURES

2.2

BB5000 FEATURES

2.3

COMPONENTS

2.3.1

Rotational drive unit

2.3.2

Axial feed unit

2.3.3

Leadscrew

2.3.4

BB4500 tool heads

2.3.5

BB5000 tool heads

2.3.6

BB4500 boring bar

2.3.7

BB5000 boring bar

2.3.8

Spherical bearing mounts

2.4

CONTROLS

2.4.1

Hydraulic power unit and hydraulic motors

2.4.2

BB5000 servo motors

2.4.3

Electric motor

2.4.4

Air motor

2.4.5

Pneumatic conditioning unit

2.5

DIMENSIONS

2.6

SPECIFICATIONS

2.6.1

Electrical specifications

2.7

ITEMS REQUIRED BUT NOT SUPPLIED

SETUP

3.1

RECEIPT AND INSPECTION

3.2

LIFTING AND RIGGING

3.3

MACHINE ASSEMBLY

P/N 92974, Rev. 3

Page i

TABLE OF CONTENTS (CONTINUED)

CHAPTER/SECTION

PAGE

3.3.1

Bar and mounting bracket assembly

3.3.2

Tooling and tool head assembly

3.3.3

RDU and AFU assembly

3.4

AXIAL FEED

3.4.1

Selecting the feed direction

3.4.2

Setting the feed rate

3.4.3

Automatic feed stop

3.5

POWER CONNECTION

3.5.1

Hydraulic machines

3.5.2

BB5000 servo drive machine

3.5.3

Electrical machines

3.5.4

Pneumatic machines

3.6

BB4500-BB5000 WITH SMALL DIAMETER BARS

OPERATION

4.1

PRE-OPERATION CHECKS

4.2

TOOL BIT SELECTION

4.3

OPERATION

4.3.1

Starting the machine

4.4

SHUTDOWN

4.5

DISASSEMBLY

MAINTENANCE

5.1

MAINTENANCE CHECKLIST

5.2

APPROVED LUBRICANTS

5.3

MAINTENANCE TASKS

5.3.1

AFU

5.3.2

Boring bar

5.3.3

Hydraulic power system

5.3.4

Electric motor assembly

5.3.5

Air motor assembly

5.3.6

BB5000 servo motor

5.3.7

4:1 RDU gearbox

5.3.8

Cutting fluid

5.4

QUALITY CHECKS

5.5

TROUBLESHOOTING

STORAGE AND SHIPPING

6.1

STORAGE

Page ii

BB4500-BB5000 Operating Manual

LIST OF FIGURES

FIGURE

PAGE

1-1 AFU label locations

1-2 RDU label locations

2-1 BB4500-BB5000 components with Eibenstock motor (BB5000 shown)

2-2 RDU

2-3 AFU

2-4 BB4500 tool heads

2-5 BB5000 tool heads

2-6 Single-arm spherical bearing mount

2-7 Double-arm spherical bearing mount

2-8 Universal spherical bearing mount

2-9 BB5000 servo drive dimensions

2-10 RDU and Eibenstock motor dimensions

2-11 Air motor

2-12 Pneumatic conditioning unit

2-13 BB4500 dimensions

2-14 BB5000 dimensions

3-1 Setup cones

3-2 Boring bar insertion

3-3 Setup cone installation

3-4 Centering the spherical bearings

3-5 Positioning the spherical bearings

3-6 Aligning the bar

3-7 Inserting the tool bit

3-8 Tool head setup

3-9 Positioning the RDU

3-10 Positioning the AFU

3-11 Clamp collars on the AFU

3-12 AFU components

3-13 Feed box arrows

3-14 Automatic feed stop

3-15 Servo motor main control panel

3-16 Servo motor pendant controls

3-17 Air control valve handle

3-18 Collets (BB5000 version shown)

3-19 BB5000 RDU collet keyway

3-20 Snap ring removal

3-21 Small bore kit adapter insertion

3-22 Snap ring replacement

4-1 Disengaging the axial feed

4-2 AFU disassembly components

5-1 Electric motor with handle

A-1 Axial feed unit assembly (P/N 43378)

A-2 Axial feed unit assembly parts list (P/N 43378)

A-3 Boring heads set assembly (P/N 43576)

P/N 92974, Rev. 3

Page v

LIST OF FIGURES (CONTINUED)

FIGURE

PAGE

A-4 Boring heads set 4-10 metric diameter assembly (P/N 43576)

A-5 Boring heads set 4-10" diameter assembly (P/N 43575)

A-6 RDU 2nd gen assembly (P/N 53912)

A-7 RDU 2nd gen assembly (P/N 53912)

A-8 Hydraulic motor assembly (P/N 39848)

A-9 Single-arm mount assembly (P/N 43262)

A-10 Universal mount assembly (P/N 43267)

A-11 Double-arm bearing mount assembly (P/N 43279)

A-12 Large and small set cones assembly (P/N 49060)

A-13 Eibenstock motor assembly (P/N 88012)

A-14 Eibenstock motor assembly -- gen. 2 only

A-15 Eibenstock motor assembly parts list -- gen. 2 only

B-1 Axial feed unit assembly (P/N 28636)

B-2 Axial feed unit assembly parts list (P/N 28636)

B-3 HD axial feed unit assembly (P/N 91518)

B-4 HD axial feed unit assembly parts list (P/N 91518)

B-5 Air motor CE assembly (P/N 28697)

B-6 Air motor CE assembly (P/N 28614)

B-7 Pneumatic connection assembly (P/N 15088)

B-8 Hydraulic motor assembly (P/N 39848)

B-9 Single-arm mount assembly (P/N 37472)

B-10 Double-arm mount assembly (P/N 37473)

B-11 Universal bearing mount assembly (P/N 36959)

B-12 ID bearing mount assembly (P/N 46293)

B-13 Setup cones 2.75-8.37" (70-213 mm) diameter assembly (P/N 26507)

B-14 Setup cones 8.37-12" (213-305 mm) diameter assembly (P/N 26508)

B-15 Servo drive 460 CE assembly (P/N 52876)

100

B-16 Servo drive 460 CE assembly parts list (P/N 52876)

101

B-17 RDU 12:1 assembly (P/N 53165)

102

B-18 RDU 12:1 assembly parts list (P/N 53165)

103

B-19 RDU 4th generation assembly (P/N 49684)

104

B-20 RDU 4th generation assembly parts list (P/N 49684)

105

B-21 Servo drive 230V CE assembly (P/N 54321)

106

B-22 Servo drive 230V CE assembly (P/N 54321)

107

B-23 Servo motor RDU adapter assembly (P/N 51536)

108

B-24 Servo motor guard assembly (P/N 52937)

109

B-25 Servo shroud fan assembly (P/N 56773)

110

B-26 Servo drive motor 230V non-CE assembly (P/N 71071)

111

B-27 Servo drive motor 460V non-CE assembly (P/N 71072)

112

B-28 Eibenstock motor assembly -- gen. 2 only

113

B-29 Eibenstock motor assembly parts list -- gen. 2 only

114

B-30 Leadscrew assembly (P/N 28654)

115

C-1 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz CE schematic (P/N 88035 C00467) 122

C-2 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz domestic assembly (P/N 88036 C00468)

123

Page vi

BB4500-BB5000 Operating Manual

LIST OF FIGURES (CONTINUED)

FIGURE

PAGE

C-3 BB4500-BB5000 Eibenstock controller 2nd gen 120V domestic assembly (P/N 88037 C00465) . . . 124

C-4 BB4500-BB5000 Eibenstock controller 2nd gen 120V CE assembly (P/N 88038 C00466)

125

C-5 BB5000 motor 230V and 460V fan assembly (P/N 91811 E00034)

126

C-6 BB5000 servo motor 230VAC and 460VAC power cable assembly (P/N 91811 E00048)

127

C-7 BB5000 Eibenstock motor cable assembly 2nd gen 120V 12AWG schematic (P/N 88649 E00170). 128

C-8 BB5000 Eibenstock motor cable assembly 2nd gen 230V 14AWG schematic (P/N 88650 E00171). 129

C-9 BB5000 Eibenstock power cable assembly 2nd gen 120V domestic L5-30P plug (P/N 88652 E00172).

130

C-10 BB5000 Eibenstock power cable assembly 2nd gen 120V CE 332P4W pin/sleeve plug (P/N 88653

E00173)

131

C-11 BB5000 Eibenstock power cable assembly 2nd gen 230V CE CEE7/7 Schuko plug (P/N 88654 E00174)

132

C-12 BB5000 Eibenstock power cable assembly 2nd gen 230V domestic L6-15P plug (P/N 88655 E00175)

133

C-13 Pneumatic conditioning unit schematic (P/N 59248)

134

C-14 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz CE assembly (P/N 88035 B00367) 135

C-15 BB4500-BB5000 Eibenstock controller 2nd gen 230V 50-60 hz domestic assembly (P/N 88036 B00368)

136

C-16 BB4500-BB5000 Eibenstock controller 2nd gen 120V domestic assembly (P/N 88037 B00365) . . 137

C-17 BB4500-BB5000 Eibenstock controller 2nd gen 120V CE assembly (P/N 88038 B00366)

138

C-18 BB5000 servo controller 3rd gen 460VAC CE assembly (P/N A00099)

139

C-19 BB5000 Eibenstock controller 2nd gen 120V domestic assembly (P/N A00100)

140

C-20 BB5000 servo pendant assembly (P/N B00024)

141

D-1 Servo amp function keys

143

P/N 92974, Rev. 3

Page vii

LIST OF TABLES

TABLE

PAGE

1-1 Sound levels

1-2 Risk assessment checklist before set-up

1-3 Risk assessment checklist after set-up

1-4 BB4500-BB5000 labels

2-1 BB5000 component identification

2-2 Power options

2-3 Test data

2-4 Setup cones

2-5 Available HPU specifications

2-6 Hydraulic motor specifications

2-7 BB5000 servo motor specification

2-8 Control box

2-10 Speed range and torque per gear

2-11 Recommended wire gauge for extension cords

2-9 Power rating

2-12 120V service parts

2-13 230V service parts

2-14 Control box

2-15 Bar RPM and torque at maximum hp

2-16 Dimensions

2-17 BB4500-BB5000 boring bar dimension identification

2-18 Sub-component mass

2-19 Boring specifications

2-20 Electrical specifications

3-1 Setup cone identification

3-2 Setup cone installation identification

3-3 Spherical bearing identification

3-4 Tool head setup identification

3-5 Clamp collars installation identification

3-6 AFU component identification

3-7 Feed box arrow identification

3-8 Automatic feed stop identification

3-9 Servo motor control functions

3-10 Collet identification

3-11 RDU collet keyway identification

3-12 Snap ring removal identification

3-13 Small bore kit adapter identification

3-14 Snap ring replacement identification

4-1 Axial feed disengagement identification

4-2 AFU disassembly identification

5-1 Maintenance intervals and tasks

5-2 Approved lubricants

5-3 Quality checks

5-4 Troubleshooting

P/N 92974, Rev. 3

Page ix

INTRODUCTION

IN THIS CHAPTER:

1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.3 GENERAL SAFETY PRECAUTIONS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.6 RISK ASSESSMENT CHECKLIST

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.7.1 LABEL IDENTIFICATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.7.2 BB4500-BB5000 LABEL LOCATIONS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

1.1

HOW TO USE THIS MANUAL

This manual describes information necessary for the setup, operation, mainte-

nance, storage, shipping, and decommissioning of the BB4500-BB5000.

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 BB4500-BB5000 before

attempting 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.

P/N 92974, Rev. 3

Page 1

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 and

valve testers. Safety is a joint effort. You, the end user, 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 assess-

ment 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 - Always wear appropriate personal pro-

tective gear when operating this or any other machine tool. Flame-resistant

clothing with long sleeves and legs is recommended when operating the

machine. Hot chips from the workpiece may burn or cut bare skin.

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.

Lifting - Many CLIMAX machine components are very heavy. Whenever

possible, lift the machine or its components using proper hoisting equip-

ment and rigging. Always use designated lifting points on the machine.

Follow lifting instructions in the setup procedures of this manual.

Lock-out/tag-out - Lock-out and tag-out the machine before performing

maintenance.

Moving parts - CLIMAX machines have numerous exposed moving parts

Page 2

BB4500-BB5000 Operating Manual

and interfaces that can cause severe impact, pinching, cutting, and other

injuries. Except for stationary operating controls, avoid contact with mov-

ing parts by hands or tools during machine operation. Remove gloves and

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 eas-

ily cut skin. Wear protective gloves and exercise caution when handling a

cutting tool or workpiece.

Hot surfaces - During operation, motors, pumps, HPUs, and cutting tools

can generate enough heat to cause severe burns. Pay attention to hot sur-

face labels, and avoid contact with bare skin until the machine has cooled.

1.4

MACHINE-SPECIFIC SAFETY PRECAUTIONS

Eye hazard - This machine produces metal chips during operation. Always

wear eye protection when operating the machine.

Sound level - This machine produces potentially harmful sound levels.

Hearing protection is required when operating this machine or working

around it. During testing, the machine produced the sound levels¹ listed in

Table 1-1.

TABLE 1-1. SOUND LEVELS

BB4500 motor

BB5000 motor

Sound power

90.0 dBA

94.0 dBA

Operator sound pressure

91.4 dBA

Bystander sound pressure

89.6 dBA

Hazardous environments - Do not operate the machine in environments

where potentially explosive materials, toxic chemicals, or radiation may be

present.

Machine mounting - Do not operate the machine unless mounted to a

workpiece in accordance with this manual. If mounting the machine in an

overhead or vertical position, do not remove hoist rigging until the machine

is mounted to the workpiece in accordance with this manual.

1. Machine sound testing was conducted in accordance with European Harmonized

Standards EN ISO 3744:2010 and EN 11201:2010.

P/N 92974, Rev. 3

Page 3

1.5

RISK ASSESSMENT AND HAZARD MITIGATION

Machine Tools are specifically designed to perform precise material-removal oper-

ations.

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 applica-

tions. They typically attach directly to the workpiece itself, or to an adjacent struc-

ture, 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 Porta-

ble Machine Tool and the workpiece as a whole.

Page 4

BB4500-BB5000 Operating Manual

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, entan-

glement, shearing, or falling objects).

 I considered the need for personnel safety guarding and installed any necessary

guards.

 I read the machine assembly instructions (Section 3.3) and took inventory of all the

items required but not supplied (Section 2.7).

 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 1-3. 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 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 checklist (Section 5.1) with the recommended

lubricants (Section 5.2).

 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.

P/N 92974, Rev. 3

Page 5

OVERVIEW

IN THIS CHAPTER:

2.1 BB4500 FEATURES

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-12

2.2 BB5000 FEATURES

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-13

2.3 COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-13

2.3.1 ROTATIONAL DRIVE UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-13

2.3.2 AXIAL FEED UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-14

2.3.3 LEADSCREW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-14

2.3.4 BB4500 TOOL HEADS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-14

2.3.5 BB5000 TOOL HEADS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-14

2.3.6 BB4500 BORING BAR

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-15

2.3.7 BB5000 BORING BAR

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-15

2.3.8 SPHERICAL BEARING MOUNTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-16

2.4 CONTROLS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-17

2.4.1 HYDRAULIC POWER UNIT AND HYDRAULIC MOTORS - - - - - - - - - - - - - - - - - - - - - - - -18

2.4.2 BB5000 SERVO MOTORS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -19

2.4.3 ELECTRIC MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-21

2.4.4 AIR MOTOR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-24

2.4.5 PNEUMATIC CONDITIONING UNIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-24

2.5 DIMENSIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-25

2.6 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-27

2.6.1 ELECTRICAL SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-28

2.7 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-29

The BB4500 and BB5000 are similar machines. The BB4500 has a smaller range

but the same major components.

The following sections describe the differences between the two machines, as well

as the components they have in common.

P/N 92974, Rev. 3

Page 11

Figure 2-1 shows the BB4500-BB5000 major components, defined in Table 2-1.

Leadscrew

FIGURE 2-1. BB4500-BB5000 COMPONENTS WITH EIBENSTOCK MOTOR (BB5000 SHOWN)

TABLE 2-1. BB5000 COMPONENT IDENTIFICATION

Number

Component

Rotational drive unit (RDU)

Spherical bearing mount (single arm shown)

Tool head assembly

Boring bar

Universal bearing mount assembly

Drive motor (electric Eibenstock motor shown)

Leadscrew

Axial feed unit (AFU)

2.1

BB4500 FEATURES

The BB4500’s modular design and diverse setup options offer innovative solutions

to difficult on-site maintenance problems. The BB4500 is designed for on-site

repair and servicing of heavy equipment at chemical plants, public utilities, mills,

mines, power stations, fluid transmission, and distribution systems.

Page 12

BB4500-BB5000 Operating Manual

2.2

BB5000 FEATURES

The BB5000 can be used easily in small workspaces. CLIMAX’s mounting com-

ponents provide the flexibility to handle tough boring jobs. The BB5000's through-

bar design allows you to mount the rotational drive and feed unit anywhere along

the bar. This flexibility means the BB5000 will complete your job where others

would not even fit.

This portable boring machine is a versatile tool. Its broad array of accessories

enables the BB5000 for use in blind boring, line boring, drilling, facing, threading,

valve repair, and trepanning. A special interface kit allows quick attachment and

precise alignment of a welder to the BB5000’s mounting fixtures. CLIMAX also

offers the industry’s broadest range of electric, hydraulic, and pneumatic power

options for added flexibility.

The BB5000 is a highly configurable machine with many options and accessories,

though this manual only covers the basic assembly components. If a specific

machine application requires accessories, contact CLIMAX for more information.

This manual also describes the operation (Section 4 on page 51) and maintenance

(Section 5 on page 57) of your BB5000. The machine is designed for on-site main-

tenance of heavy-duty industrial equipment. All parts meet CLIMAX’s strict qual-

ity standards. For maximum safety and performance, read the entire manual before

operating the machine.

2.3

COMPONENTS

The BB4500 and BB5000 have the following components.

2.3.1

Rotational drive unit

The RDU with sealed lubrication has worm gear reduction

and may be mounted anywhere along the bar. A key within

the collet drives the boring bar. The clamp ring holds the

RDU to the spherical bearing mounting bracket. A clamp col-

lar provides a snug, sliding fit between the RDU and the bar,

or it may be clamped tight for facing operations.

FIGURE 2-2. RDU

P/N 92974, Rev. 3

Page 13

2.3.2

Axial feed unit

The AFU is held in place by two clamp collars and may

be secured in any position along the bar. It travels with

the bar and tool head axially along a fixed leadscrew.

Select the feed direction by shifting the feed shaft posi-

tion (see Section 3.4.1 on page 40 for more information).

FIGURE 2-3. AFU

2.3.3

Leadscrew

The fixed leadscrew may be mounted either to the RDU or to the axial leadscrew-

mounting block.

For the BB4500, standard leadscrews have 12" (305 mm) or 24" (610 mm) of

travel.

For the BB5000, standard leadscrews have 12" (305 mm), 24" (610 mm), or 36"

(914 mm) of travel.

Other lengths are available to suit your requirements. Contact CLIMAX for more

information.

2.3.4

BB4500 tool heads

For the BB4500, the split-body tool heads may be

clamped anywhere along the bar. The set of three tool

heads bore 4-10" (102-254 mm) diameter. The tool

heads hold tool bits that are 0.5" (12 mm) square.

Boring heads accept 0.5" (12 mm) square tool bits and

machine sizes that are 4-10" (102-152 mm), 6-8"

FIGURE 2-4. BB4500 TOOL HEADS

(152-203 mm), and 8-10" (203-254 mm) in diameter.

They are compatible with either high-speed steel

(HSS) or carbide-tipped tool bits.

For boring diameters less than 4" (102 mm), use the broached tooling holes in the

bar. For boring diameters less than 2" (51 mm), use the small boring option.

Blank and pre-ground 0.5" (12 mm) tool bits are available for the slotted boring

heads.

2.3.5

BB5000 tool heads

For the BB5000, the split-body tool heads may be clamped anywhere along the

bar.

Page 14

BB4500-BB5000 Operating Manual

Two sets of tool heads are available:

• One set of five tool heads bore 4.5-12"

(114-305 mm) diameter.

• The optional large boring head features a

split-body mounting hub and two sets of tool

arms that bore 12-24" (305-610 mm) diam-

eter.

FIGURE 2-5. BB5000 TOOL

HEADS

Tool bits are 1/2" (12 mm) square. Other tool head

options are discussed in Section 3.3.2 on page 35.

2.3.6

BB4500 boring bar

Standard BB4500 bars are 1.75" (44 mm) in diameter and are available in lengths

from 4-12 ft (1.2-3.66 m) in 24" (610 mm) increments. Contact CLIMAX for bars

of other lengths and diameters.

All bars have 0.5" (12 mm) square tool bit mounting holes spaced at 10" or 6" (254

or 152 mm) intervals. Contact CLIMAX for custom hole spacing patterns.

Do the following to determine the bar length required (see Figure 2-14 on page

26):

1. Determine the workpiece overall dimension + stroke + 27" (686 mm).

2. Round up to the next 24" (610 mm) increment.

2.3.7

BB5000 boring bar

Standard BB5000 bars are 2.25" (57 mm) in diameter and are available in lengths

from 4-12 ft (1.2-3.66 m) in 24" (610 mm) increments. Contact CLIMAX for bars

of other lengths and diameters.

All bars have 0.5" (12 mm) square tool bit mounting holes spaced at 10" or 6" (254

or 152 mm) intervals. CLIMAX offers a drill jig with a tool sleeve kit for cutting

intermediate tool bit holes for special applications. Contact CLIMAX for custom

hole spacing patterns.

Do the following to determine the bar length required (see Figure 2-14 on page

26):

1. Determine the workpiece overall dimension + stroke + 27" (686 mm).

2. Round up to the next 24" (610 mm) increment.

P/N 92974, Rev. 3

Page 15

2.3.8

Spherical bearing mounts

The spherical bearing mount support brackets hold

the bar and machine in place during operation.

Each bracket includes a spherical self-aligning

bearing for quick, accurate setup. Spacer plates

may be tack welded or clamped to the workpiece to

secure the brackets in place.

FIGURE 2-6. SINGLE-ARM SPHERICAL

BEARING MOUNT

These brackets are available in single-arm, double-

arm, and universal styles. The universal mount

may also be turned into an inside diameter (ID)

mount with the purchase of an optional set of jack-

ing bolts.

FIGURE 2-7. DOUBLE-ARM SPHERICAL

BEARING MOUNT

Double-arm spherical bearing mounting brackets

are better for those applications requiring extra sup-

port, such as when boring holes exceed 8" (203 mm)

in diameter.

FIGURE 2-8. UNIVERSAL SPHERICAL

BEARING MOUNT

Page 16

BB4500-BB5000 Operating Manual

2.4

CONTROLS

Table 2-2 shows the power options available for the BB4500-BB5000. Please note

that only the BB5000 has the servo drive option.

TABLE 2-2. POWER OPTIONS

Power type

RPM¹ range

Power

Reference

10 hp HPU²: 0 - 246 RPM at

60 Hz mains power

Section 2.4.1 on

Hydraulic

10 hp (7.4 kW)

page 18

10 hp HPU: 0 - 200 RPM at

50 Hz mains power

Section 2.4.3 on

Electric

8 - 160 RPM

3.35 hp (2.5 kW)

page 21

Section 2.4.4 on

Pneumatic

0 - 120 RPM

3.0 hp (2.2 kW)

page 24

Servo

Section 2.4.2 on

3 - 230 RPM

4.7 hp (3.5 kW)

(BB5000 only)

page 19

1. Revolutions per minute (RPM)

2. Hydraulic power unit (HPU)

For more information about using the BB4500-BB5000 controls, see Section 3.5

on page 43.

The RDU used with hydraulic, pneumatic, and electric drives has a 4:1 gear reduc-

tion. The servo drive uses 12:1 gear reduction.

TABLE 2-3. TEST DATA

Material:

A-36 (mild steel)

Bore diameter:

23" (584.2 mm)

Tool bit:

High speed steel (HSS)

Bearing spacing:

22" (558.8 mm)

Bar speed:

30 - 40 RPM

Depth of cut:

100” (2,540 mm)

Feed rate:

0.003" (0.076 mm) per revolution

Length of cut:

2” (50.8 mm)

TABLE 2-4. SETUP CONES

Range

Standard

2.75-12” (70-305 mm)

Optional

1.375-5” (34.9-127 mm)

P/N 92974, Rev. 3

Page 17

2.4.1

Hydraulic power unit and hydraulic motors

CAUTION

Operating the hydraulic power unit (HPU) for extended periods of time

without connecting the hydraulic motor will overheat the system and

may damage the pump.

The high-torque, low-speed hydraulic motor mounts directly to the RDU. To

reverse the bar rotation direction, switch the hydraulic hoses at the motor or at the

HPU.

Table 2-5 on page 18 shows the available HPUs and their specifications.

TABLE 2-5. AVAILABLE HPU SPECIFICATIONS

If using an HPU not supplied by CLIMAX, the hydraulic requirement is 10 gpm at

2,000 psi (37.85 lpm at 138 bar).

Hydraulic motors with different displacement ratings are available. Please note the

following:

• If the HPU runs on 50 Hz, it produces a maximum rate of 8.3 gpm.

• If the HPU runs on 60 Hz, it produces a maximum rate of 10 gpm.

Page 18

BB4500-BB5000 Operating Manual

Refer to the correct “Maximum bar RPM” column in Table 2-6 for hydraulic motor

performance.

TABLE 2-6. HYDRAULIC MOTOR SPECIFICATIONS

Maximum bar RPM

Part number

Torque at

for motors with

Motor capacity

8.36 gpm

10 gpm (37.9

bar

60 series QD

ISO 16028 QD

(31.5 L/min)¹

L/min)²

fittings

92 ft-lbs

2.2 inch³ (36 cm³)

204

246

39837

65384

(124.7 Nm)

159 ft-lbs

3.6 inch³(59 cm³)

124

150

39843

63425

(215.6 Nm)

270 ft-lbs

5.7 inch³(93.4 cm³)

39844

63429

(367 Nm)

342 ft-lbs

7.3 inch³(119.6 cm³)

39845

69434

(463.7 Nm)

417 ft-lbs

8.9 inch³(145.8 cm³)

39846

69435

(565.4 Nm)

478 ft-lbs

11.3 inch³(185.2 cm³)

43451

69436

(648.1 Nm)

652 ft-lbs

14.1 inch³(231.1 cm³)

39847

(884.0 Nm)

764 ft-lbs

17.9 inch³(293.3 cm³)

43452

69439

(1,035.8 Nm)

1. With 50 Hz mains power.

2. With 60 Hz mains power.

2.4.2

BB5000 servo motors

NOTICE

Never disconnect any cable from this machine without first turning off

the mains disconnect switch. Interrupting the connection between the

servo amplifier and the servo motor while they are energized may

damage the servo amplifier, even if the motor is stopped. Failure to

comply with this warning will void the warranty on the control system.

P/N 92974, Rev. 3

Page 19

The 4.7 hp servo motor with a 12:1 worm gear reduction RDU provides quiet,

reversible and extreme torque for operating the BB5000.

FIGURE 2-9. BB5000 SERVO DRIVE DIMENSIONS

WARNING

Handle cables carefully. Do not pull on them, step on them, or allow

them to be kinked. Pelikan cases are water resistant, not water-proof.

Do not turn on the power unless all cables are plugged in. Do not

unplug cables unless disconnected from mains power.

Servo drives for the BB5000 are available in 230V (16 amps) or 460V (8.5 amps).

TABLE 2-7. BB5000 SERVO MOTOR SPECIFICATION

200V-240V, 50/60 Hz dual-rated, 16 amp,

Input power for the 230V system:

3-phase

380V-480V, 50/60 Hz dual-rated, 8.5 amp,

Input power for the 460V system:

3-phase

Bar

Bar speed:

3-230 RPM

Bar rated torque (continuously

3-167 RPM: 147.9 ft-lbs (200.4 Nm)

running):

Bar maximum torque:

3-230 RPM: 443.7 ft-lbs (601.6 Nm)

Rotation:

Variable speed and reversible

Motor

Manufacturer:

Mitsubishi

Speed rated continuous:

2,000 RPM

Page 20

BB4500-BB5000 Operating Manual

TABLE 2-7. BB5000 SERVO MOTOR SPECIFICATION (CONTINUED)

Speed maximum:

3,000 RPM

Speed permissible instantaneous:

3,450 RPM

Nominal rated full load hp:

4.7 hp (3.5 kW)

Motor torque rated:

12.3 ft-lbs (16.7 Nm)

Motor torque maximum:

37.0 ft-lbs (50.1 Nm)

2.4.3

Electric motor

Two electric versions of the BB5000 are available, as described in Table 2-9 on

page 22. The motor has an integrated rotation reverse switch, while the pendant

controller has an off/off switch, emergency stop, and a speed control knob.

FIGURE 2-10. RDU AND EIBENSTOCK MOTOR DIMENSIONS

NOTICE

The second-generation Eibenstock motor is incompatible with the third-

generation RDU. The second-generation Eibenstock motor requires the

fourth-generation RDU.

NOTICE

Table 2-8 shows the four mains power plugs for the control box that

CLIMAX offers. If the plug needed is not included in Table 2-8, the end

user must cut off the factory-installed plug and install their own.

TABLE 2-8. CONTROL BOX

120V Controller:

L5-30P twist-lock

120V Controller:

ISO 309/CEE17

230V Controller:

CEE 7/7 Schuko

230V Controller:

6L-15P twist-lock

P/N 92974, Rev. 3

Page 21

TABLE 2-9. POWER RATING

3.35 hp (2.5 kW)

120V motor:

20 Amps 60 Hz

3.35 hp (2.5 kW)

230V motor:

10.5 Amps 60 Hz

Both motors have a four-speed gearbox for maximum versatility. Table 2-10 speci-

fies the operating range for each gear.

TABLE 2-10. SPEED RANGE AND TORQUE PER GEAR

Rated bar

Gear

Knobs

RPM range

Bar torque

speed

● ●

8.0-23.0 RPM

20 RPM

470 ft-lb (637 Nm)

● ●●

12.5-35.5 RPM

30 RPM

300 ft-lb (407 Nm)

●● ●

35.5-101.0 RPM

90 RPM

105 ft-lb (142 Nm)

●● ●●

56.5-160.0 RPM

142.5 RPM

65 ft-lb (88 Nm)

CAUTION

Before shifting gears, remove the cutting load from the motor and stop

the motor rotation. Shifting gears while the machine is under load could

damage the motor and gearbox components.

CLIMAX’s portable machine tools require a three-wire extension cord. Extension

cords of inadequate wire size may cause a significant drop in mains voltage with a

consequent loss of power.

As the distance from the supply outlet increases, heavier gauge extension cords are

required (see Table 2-11).

TABLE 2-11. RECOMMENDED WIRE GAUGE FOR EXTENSION CORDS

Cord length

25 feet

50 feet

75 feet

100 feet

150 feet

200 feet

(7.6 m)

(15.2 m)

(22.9 m)

(30.5 m)

(45.7 m)

(61 m)

Nameplate amps

Minimum wire gauge

0-5.0

5.1-8.0

8.1-12.0

12.1-15.0

15.1-20.0

Page 22

BB4500-BB5000 Operating Manual

Table 2-12 and Table 2-13 list the service parts for both motors.

TABLE 2-12. 120V SERVICE PARTS

Part number

Description

Quantity

83595

Rotor complete

82698

Carbon brush

83593

PCB / circuit board

83594

Stator complete

TABLE 2-13. 230V SERVICE PARTS

Part number

Description

Quantity

90776

Rotor Complete

90778

Brush Holder

85088

Carbon Brush

83591

Anti Parasite Condenser

85089

PCB / Circuit Board

82699

Cap

90779

Stator Complete

83601

Grooved Ball Bearing 6201 LUZ

90780

Locking Ring 32x1,2

83602

Shaft Seal Ring 15x21x3 KEIV

90238

Work Spindle

90781

Shaft Seal Ring 30x42x7

90782

Grooved Ball Bearing 6005 2RS

90783

O-ring 106x2

85494

Switch Button Long

85493

Switch Button Short

90784

Connector Socket

90785

Insert

90786

Screw 3x10

87279

Reversing switch

90787

Connector Pin 2,5 mm2

90788

Connector Pin 0.75 mm2

P/N 92974, Rev. 3

Page 23

2.4.4

Air motor

The 3 hp (2.24 kW) air motor is reversible and operates

under the specifications listed in Table 2-14.

TABLE 2-14. CONTROL BOX

Air pressure required:

90 psi (6.2 bar)

Air flow required:

95 ft3/min (2.7 m³/min)

FIGURE 2-11. AIR MOTOR

The available air motor assemblies produce boring bar

speeds and torques listed in Table 2-15.

TABLE 2-15. BAR RPM AND TORQUE AT MAXIMUM HP

Air motor part number

Bar RPM

Torque

28614

120 RPM

115 ft-lb (156 Nm)

28697

57 RPM

234 ft-lb (318 Nm)

The assembly includes the RDU mounting flange and associated hardware. For a

complete air-powered system, order an air motor assembly and connection pack-

age. The air connection package contains an air filter and lubricator, and hoses

with quick disconnect fittings.

CAUTION

To maintain the air motor and avoid invalidating your warranty, always

route incoming air through the pneumatic conditioning unit (PCU).

2.4.5

Pneumatic conditioning unit

The PCU (shown in Figure 2-12 on page 25) provides clean dry air and lubrication

to the air motor. Install the PCU in the air supply circuit immediately before the

BB4500 or BB5000.

WARNING

Always stop the machine and lock out/tag out the PCU before making

adjustments to controls or machine components. Failure to follow this

safety precaution may result in severe injury.

Page 24

BB4500-BB5000 Operating Manual

TABLE 2-17. BB4500-BB5000 BORING BAR DIMENSION IDENTIFICATION

Number

Component

Stroke

Workpiece: distance between outer edges of the workpiece = X

2.6

SPECIFICATIONS

TABLE 2-18. SUB-COMPONENT MASS

Component

Mass in lbs (kg)

Motor:

43 lbs (20 kg)

Adapter assembly (P/N 51536):

10 lbs (5 kg)

Rotational drive unit (P/N 53165):

31 lbs (14 kg)

Total for motor, adapter assembly and RDU:

85 lbs (39 kg)

Pendant:

4 lbs (2 kg)

HPU - 10 HP:

695 lbs (315.2 kg)

Machine total weight (including single arm

444 lbs (201 kg)

mounts, setup cones, and hydraulic motor):

Approximate boring bar ship weight (including

1.48 lbs/inch

the metal shipping container):

(0.264 kg/cm)

TABLE 2-19. BORING SPECIFICATIONS

Component

BB4500 range

BB5000 range

Boring bar diameter (standard):

1.75" (45 mm)

2.25" (57 mm)

1.75" (45 mm)

Boring bar diameter (optional):

1.25" (32 mm)

Boring diameter (standard):

2-10" (51-254 mm)

2.5-12" (64-305 mm)

Boring diameter (optional):

1.5-5" (38-127 mm)

1.375-24" (35 - 610 mm)

Boring stroke (standard):

12" (305 mm)

24 (610 mm)

Boring stroke (optional):

36" (914 mm)

P/N 92974, Rev. 3

Page 27

2.6.1

Electrical specifications

CLIMAX electrical equipment is suitable for use in the physical environment and

operating conditions specified below. When the physical environment or the oper-

ating conditions are outside those specified, consult CLIMAX before putting the

electrical equipment into service.

TABLE 2-20. ELECTRICAL SPECIFICATIONS

Mains voltage (AC):

±10% of nominal

Mains frequency (AC):

±1% of nominal

10% of RMS volts

Mains harmonics:

2nd through 30th harmonic

Voltage imbalance (3-phase supplies):

2% maximum

200% of nominal

Voltage impulses:

1.5 milliseconds (ms) maximum duration

Voltage interruption:

3 ms maximum with 1 second between

Voltage dip (brownout):

20% of peak volts for 1 second maximum

Voltage supplied from batteries:

±10% of nominal

Voltage interruption (DC):

5 ms maximum

Ambient temperature (operating):

41-104°F (5-40°C)

Ambient temperature (transport and

-13-131°F (-25-55°C)

storage):

Relative humidity:

20-95% non-condensing

Altitude:

6,600 ft (2,000 m)

IP54 environment except for some motors

Contaminants:

and slip ring assemblies that are IP 20

Not greater than that listed on the controls

Available fault current:

nameplate

Vibration

Pushbuttons:

5g at 5-300 Hz

Relays, contactors, and breakers:

2g at 5-300 Hz

Touchscreen HMI:

1g at 9-150 Hz

Servo amplifiers and PLC:

1g at 9-150 Hz

Physical shock (impact)

Pushbuttons:

30g for 18ms

Relays, contactors, and breakers:

6g for 11ms

Touchscreen HMI:

15g three times in X, Y, and Z

Servo amplifiers and PLC:

1g three times in X, Y, and Z

Page 28

BB4500-BB5000 Operating Manual

SETUP

IN THIS CHAPTER:

3.1 RECEIPT AND INSPECTION

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-31

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

-32

3.3 MACHINE ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-32

3.3.1 BAR AND MOUNTING BRACKET ASSEMBLY

- - - - - - - - - - - - - - - - - - - - - - - - - - -

-33

3.3.2 TOOLING AND TOOL HEAD ASSEMBLY

- - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-35

3.3.2.1 PLACING THE TOOL BIT INTO THE BAR - - - - - - - - - - - - - - - - - - - - - - - - - -

-36

3.3.2.2 PLACING THE TOOL HEAD ONTO THE BORING HEAD - - - - - - - - - - - - - - - - - - - - -36

3.3.3 RDU AND AFU ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-37

3.4 AXIAL FEED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-40

3.4.1 SELECTING THE FEED DIRECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-40

3.4.2 SETTING THE FEED RATE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-41

3.4.3 AUTOMATIC FEED STOP

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-42

3.5 POWER CONNECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-43

3.5.1 HYDRAULIC MACHINES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-43

3.5.2 BB5000 SERVO DRIVE MACHINE

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-44

3.5.3 ELECTRICAL MACHINES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-46

3.5.4 PNEUMATIC MACHINES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-46

3.6 BB4500-BB5000 WITH SMALL DIAMETER BARS - - - - - - - - - - - - - - - - - - - - - - - - - - - - -47

This section describes the setup and assembly procedures for the BB4500-BB5000

boring machine.

3.1

RECEIPT AND INSPECTION

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 containers for damage.

2. Check the contents of the shipping containers against the included invoice

to make sure that all components have been shipped.

3. Inspect all components for damage.

5Contact CLIMAX immediately to report damaged or missing components.

NOTICE

Keep the shipping container and all packing materials for future storage

and shipping of the machine.

P/N 92974, Rev. 3

Page 31

The machine ships from CLIMAX with a heavy coating of LPS 3. The recom-

mended cleaner is LPS PreSolve Orange Degreaser. All parts must be cleaned

before use.

3.2

LIFTING AND RIGGING

WARNING

Do not lift the BB4500-BB5000 boring machine when fully assembled,

as it can weigh up to 444 lbs (201 kg). To prevent serious injury to

yourself and others, always follow the operating procedures outlined in

this manual, your own company rules, and local regulations for heavy

lifting. Serious injury or fatalities can result from improper lifting

methods.

Falling or uncontrolled swinging of machinery can cause serious injury

or be fatal to the operator and bystanders.

3.3

MACHINE ASSEMBLY

A basic setup is described in the following sections, but individual applications

may require different setups based on, but not limited to, the following factors:

• The size of the bore

• The number of bores and bearings

• Distance between the bores

• Distance between the bearings

• Style of bearings (single arm, double arm, universal)

Contact CLIMAX for assistance with a custom application.

The BB4500-BB5000’s through-bar design allows for mounting the rotational

drive unit (RDU) and feed box anywhere along the bar. They do not need to be

mounted next to each other. This allows assembly of the BB4500-BB5000 in very

restricted spaces. Special setup cones are also available to make it easier to center

and stabilize the bar in the workpiece bore.

Exactly attaching and aligning the tack mounting plates is designed to be straight-

forward. The initial fixture mounting may be 5° or more out of alignment. CLI-

MAX’s spherical mounting system enables the BB4500-BB5000 to align perfectly

with the bore.

The BB4500-BB5000 also features four precision alignment screws for precisely

dialing into the center of an existing bore or into a bore that is not exactly true.

The BB4500-BB5000 modular design eliminates the problem of lifting heavy,

bulky, one-piece machines on the job site. The BB4500-BB5000 quickly assem-

bles and disassembles, one component at a time.

Page 32

BB4500-BB5000 Operating Manual

3.3.1

Bar and mounting bracket assembly

To roughly align a CLIMAX boring

bar in a workpiece, use centering

cones. These cones approximately

center the bar until bearing supports

and brackets are secured with clamps

or welds, as appropriate. Cone sets are

in two sizes, cover a wide range, and

are offered as optional equipment

with the BB4500-BB5000.

TABLE 3-1. SETUP CONE IDENTIFICATION

FIGURE 3-1. SETUP CONES

Number

Component

Cone

Workpiece

The goal is to support the boring bar in place until clamping or welds on tack

plates are completed. Then remove the cones and make precise adjustments to cen-

ter the bar.

Setup cones (optional equipment)

Do the following to install the setup cones:

1. Clean the bore and the boring bar to remove grease, oil, and dirt.

2. Carefully slide the boring

bar through the holes to be

bored (see Figure 3-2).

CAUTION

To avoid bodily injury or bar

damage and to ease setup,

lift heavy loads (bars over

72” [1,829 mm]) using a

sling.

FIGURE 3-2. BORING BAR INSERTION

P/N 92974, Rev. 3

Page 33

3. Slide a setup cone (or a sub-

stitute device) onto each

end of the bar to center the

bar in the bore.

TABLE 3-2. SETUP CONE INSTALLATION IDENTIFICATION

Number

Component

Setup cone

Spherical bearing mounting bracket

Standoffs (add as needed for clearance

to remove the setup cones)

4. Tighten the set screw to

secure one of the cones.

FIGURE 3-3. SETUP CONE INSTALLATION

5. While pulling on the bar

from the opposing end to seat the first cone, slide the second cone snug into

place. Tighten the set screw.

6. Mount the clamp collar next to one setup cone. Loosen the set screw in the

cone and drive it into the bore using the socket-head jacking screw. Tighten

the set screw in the setup cone to hold it securely in place.

7. Repeat step 3 through step 6 until the cones are seated in the bores and

there is no bar movement.

8. Center the spherical bearings in the mount-

ing brackets by doing the following:

a) Loosen the hex bolts.

b) Adjust the four set screws until the

bearing is centered.

c) Tighten the hex bolts.

FIGURE 3-4. CENTERING THE SPHERI-

CAL BEARINGS

Page 34

BB4500-BB5000 Operating Manual

TABLE 3-3. SPHERICAL BEARING IDENTIFICATION

Number

Component

Loosen bolts to adjust bearing

Adjust screws to center bearings in brackets

9. Mount the tack weld plates

to the spherical bearing

mounting brackets. If more

FIGURE 3-5. POSITIONING THE SPHERICAL BEARINGS

clearance is required, weld

1" x 1" x 6" (12 mm x 12

mm x 72 mm) the tack weld

blocks to the tack weld mounting spacer plates.

10. Temporarily clamp the bracket assemblies to the workpiece. Leave enough

room to remove the cones after the brackets are welded in place.

11. Check that the setup cones are still securely in position.

12. Securely weld all standoffs and brackets in place.

13. Remove the temporary clamps.

14. Loosen the set screws in the setup cones.

15. Remove the bar from the brackets and remove the setup cones.

16. Carefully reinstall the bar through the mounting brackets.

If necessary, precisely align the bar

by doing the following:

1. Loosen the hex bolts hold-

ing the bearing to the

bracket.

2. Attach a dial indicator to

the bar and touch the stylus

to the workpiece ID.

3. Rotating the bar, adjust the

set screws to center the bar.

4. Tighten the hex bolts to

keep the bearing and the bar

in place.

FIGURE 3-6. ALIGNING THE BAR

3.3.2

Tooling and tool head assembly

These machines are designed to cover a wide range of boring applications. The bar

design allows for inserting a tool bit into the bar or clamping a tool head assembly

P/N 92974, Rev. 3

Page 35

onto the bar. This gives you multiple positions of the tool bit. CLIMAX has

designed these so that you can use a variety of tool bit types.

The cutting speed is primarily determined by the hardness of the metal being

machined and the type of tool bit used. Other factors include the power source,

feed and depth of cut, and cooling medium being used.

Generally, carbide cutting tools operate at higher RPM than high-speed steel

(HSS) tools. For more information, see Section 4.2 on page 52.

3.3.2.1

Placing the tool bit into the bar

Do the following to insert the tool

bit into the bar:

1. Retract the set screw that is

located 90° from the tool

slot.

2. Insert the tool bit into the

tool slot so that it slides

freely into the broached

hole (see Figure 3-7).

3. Clamp the tool bit into

place by re-tightening the

set screw.

4. Set the tool bit to the cor-

rect radius for cutting the

required diameter. There

FIGURE 3-7. INSERTING THE TOOL BIT

are multiple ways to set the

desired radius (for instance,

using a bore measuring tool).

3.3.2.2

Placing the tool head onto the boring head

TABLE 3-4. TOOL HEAD SETUP IDENTIFICATION

Number

Component

Set screws

Tool head mounting screw

Tool head

Boring bar

Tool bit

Cutting direction

FIGURE 3-8. TOOL HEAD SETUP

Page 36

BB4500-BB5000 Operating Manual

Do the following for standard setup, referring to Figure 3-8 on page 36:

1. Using the clamping screw, secure the tool head tightly to the boring bar.

2. Select either a HSS or a brazed carbide tool bit.

3. Position the tool head on the bar with the open side of the tool slot toward

the workpiece in the feed direction.

4. Slide the tool bit into the tool head with the cutting face toward the tighten-

ing screws. This will position the cutting face at or slightly below the cen-

terline.

TIP:

Tool bits are either right-handed or left-handed. This allows for feeding

both directions with the same rotation direction.

5. Use a dial indicator to set the tool bit to achieve the desired depth of cut.

The maximum recommended cutting depth is 0.125" (3 mm). Tighten the

tool bit mounting screws.

TIP:

CLIMAX offers a bore measuring tool specially built for setting the tool

bit height and checking the actual bore diameter. Contact CLIMAX for

more information on this tool.

3.3.3

RDU and AFU assembly

The compact RDU may be placed

anywhere along the bar.

Before beginning set-up, plan the

relationship between the RDU,

motor, and axial feed unit (AFU) to

allow for enough space.

FIGURE 3-9. POSITIONING THE RDU

P/N 92974, Rev. 3

Page 37

The AFU may be set anywhere

along the bar. It is not necessary to

insert the leadscrew directly into

the RDU. The leadscrew may be

screwed into the tack weld block

that may then be welded or

clamped directly to the workpiece.

CAUTION

Take care not to bend or

unduly stress the leadscrew

FIGURE 3-10. POSITIONING THE AFU

during installation.

Do the following:

1. Carefully slide the bar through the spherical mounting bearings.

TIP:

If positioning the AFU between the mounting support brackets, slide it

onto the bar at this point rather than in step 10.

2. Insert the bar into the opposing bearing bracket.

3. Install the RDU onto the bar, positioning it against the spherical bearing

bracket so that one of the spring pins engages one of the slots in the bearing

mount.

4. Tighten the clamp ring to 30 ft-lbs (41 Nm). Slide the bar to see if it is free

to move. If it does not move, the clamp ring is too tight. Loosen the clamp

ring bolt until the bar has some resistance but moves freely.

CAUTION

The clamp ring must be tightened before the machine is turned on. Do

not rely on the spring pins to hold the rotational torque of the machine.

5. Tighten the clamp collar over the collet, as shown in Figure 3-11 on page

39. Turn the collar screw until the collar is snug, but the bar slides easily

through the unit. In most boring applications, this collar can remain loose.

Page 38

BB4500-BB5000 Operating Manual

FIGURE 3-11. CLAMP COLLARS ON THE AFU

TABLE 3-5. CLAMP COLLARS INSTALLATION IDENTIFICATION

Number

Component

Tighten the clamp collars

Jam nut

Leadscrew (Screw one end into the AFU, the other end into the RDU.

Tighten the jam nut.)

6. Hold the motor assembly so that the motor shaft is able to slide into the

RDU housing. The key in the motor shaft must align with the keyway in

the main drive worm.

7. Push the motor into the housing until the flange is snug against the drive

housing face.

8. Tighten the mounting screws.

9. Install the leadscrew into the AFU. Check that the jam nut is on the other

end of the leadscrew.

10. Slide the AFU onto the bar, if not already done so to position it between the

mounting support brackets.

11. Thread the leadscrew into the RDU housing. Secure the leadscrew by tight-

ening the jam nut snug against the face of the drive housing.

P/N 92974, Rev. 3

Page 39

12. If mounting the leadscrew away from the RDU, weld the tack weld block

to a fixed object and screw the leadscrew into it. Secure the leadscrew by

tightening the jam nut snug against the face of the tack weld block.

13. Position the AFU and bar to achieve the required feed distance and to place

a tooling hole in the correct position for machining.

14. Tighten the axial feed clamp collar screws to fasten the collar to the bar.

3.4

AXIAL FEED

3.4.1

Selecting the feed direction

The feed direction has three positions:

• Forward

• Neutral

• Reverse

Pushing the three-position feed shaft in on one side or the other will feed in the

direction indicated by the arrow on that side of the body. Check that the engage-

ment pins are fully engaged. The neutral (middle) position is for no feed.

A shaft under load may require a firm bump to disengage.

If the axial feed box fails to feed the tool head, check the shear pins. Replacement

pins are included with the AFU. To replace a pin, see Section 5.3.1 on page 59.

CAUTION

Feeding the bar into a fixed object could damage the internal feed

clutches.

FIGURE 3-12. AFU COMPONENTS

Page 40

BB4500-BB5000 Operating Manual

TABLE 3-6. AFU COMPONENT IDENTIFICATION

Number

Component

Arrow #1

Push to feed in direction of arrow #1

Feed shaft

Feed stop pin

Feed adjusting knob for direction #1

Auto-stop arm assembly

Push to feed in direction of arrow #2

Drive bushing

Arrow #2

3.4.2

Setting the feed rate

The feed rate is adjusted by an

adjusting screw. Each feed rate is

independent of the other; FORWARD

and REVERSE have separate feed

adjusting knobs.

TABLE 3-7. FEED BOX ARROW IDENTIFICATION

Number

Component

Maximum (feeds in the direction shown on

the feed box)

Minimum (feeds in the direction shown on

the feed box)

FIGURE 3-13. FEED BOX ARROWS

The feed rate operates by the fol-

lowing rules:

• Turning the knob counter-clockwise (out) increases the feed rate.

• Turning the knob clockwise (in) decreases the feed rate.

• The feed range is up to 0.018" (0.45 mm) per revolution of the bar.

• Maximum feed is reached when the knob is approximately 0.625" (16

mm) away from the feed box.

• Minimum feed is reached when the knob completely collapses the

compression spring approximately 0.25" (6 mm).

P/N 92974, Rev. 3

Page 41

CAUTION

The AFU will not stop until the pin is pushed in completely. To prevent

overfeeding, check that the stop arm is positioned correctly.

3.4.3

Automatic feed stop

The automatic feed stop feature (see Figure 3-14) stops the AFU at any point along

the leadscrew.

Do the following to use the automatic feed stop:

1. Clamp a stop arm onto the leadscrew at the position intended for the axial

feed to stop. (Assemblies are included for stopping in either direction.)

2. Check that the stop arm is positioned to press against the feed stop screw

assembly.

FIGURE 3-14. AUTOMATIC FEED STOP

TABLE 3-8. AUTOMATIC FEED STOP IDENTIFICATION

Number

Component

Stop arm assembly

Feeding stops when the pin is pushed all the way in by the stop arm

Stop arm assembly

When the axial feed box nears the stop arm, the stop arm will depress the feed stop

screw assembly to stop the axial feed.

Do the following to retract the tool head:

1. Place the feed box in NEUTRAL.

2. Hand crank the tool bit away from the workpiece.

Page 42

BB4500-BB5000 Operating Manual

NOTICE

To protect tool bits from chipping, place the feed box in NEUTRAL before

stopping bar rotation.

3.5

POWER CONNECTION

3.5.1

Hydraulic machines

For the BB4500-BB5000, do the following to connect the hydraulic power:

1. Disconnect the mains power to the HPU.

2. Inspect all electrical cables and check the oil level in the hydraulic reser-

voir.

3. Inside the electrical enclosure, check that all three phases of mains power

(L1, L2, L3), and the safety ground wire are properly connected.

DANGER

High voltage in the electrical enclosure can cause serious or fatal injury.

Unplug the power unit before servicing the pump motor.

4. Close the electrical enclosure. Connect the power unit to mains power.

5. After checking that all hydraulic hose quick coupler fittings are clean, con-

nect the hydraulic hoses between the HPU and the hydraulic motor on the

boring bar. The hose connection may be switched to reverse the bar rota-

tion direction.

Checking the hydraulic pump rotation direction

NOTICE

Rotating the hydraulic pump in the wrong direction may damage the

pump and result in poor performance.

To check the hydraulic pump rotation direction, jog the power unit momentarily.

Check that the hydraulic pump is rotating in the direction indicated by the arrow

on the pump housing.

If it is not rotating in the direction of the arrow, do the following:

1. Turn off and lock out the electric power to the HPU.

2. Call a qualified person to open the electrical enclosure and identify wires

L1, L2, and L3 on the magnetic contactor. Switch any two of these wires.

Close the electrical enclosure.

P/N 92974, Rev. 3

Page 43

CAUTION

Do not reset the pressure relief valve on the HPU pump. It is factory set

to the correct pressure to avoid system damage.

3.5.2

BB5000 servo drive machine

CAUTION

Never disconnect any cable from this machine without first turning the

main disconnect off. Interrupting the connection between the servo

amplifier and the servo motor while energized will damage the servo

amplifier, even if the motor is stopped. Failure to comply with this

warning will void the warranty on the control system.

For the BB5000 servo drive

machines, do the following to con-

nect the servo drive power:

1. Before connecting the servo

drive system to mains

power, examine all cables

for damage. Repair or

replace the cable if neces-

FIGURE 3-15. SERVO MOTOR MAIN CONTROL PANEL

sary.

2. Connect the servo motor

encoder cable, power cable, and cooling fan power cable.

3. Connect the encoder and operator pendant cable to the main control panel

(see Figure 3-15 and Figure C-19 on page 140).

4. Plug the mains power cable into the mains power source.

The MAINS POWER DISCONNECT switch on the control panel is an external emer-

gency stop circuit that ensures operation can be stopped and power switched off

immediately.

WARNING

Electrical equipment can shock or cause an explosion if used near wet

or flammable materials. Do not operate the motor if it is wet or in a

hazardous environment.

Servo motor pendant

Table 3-9 on page 45 shows the functions of the pendant controls (seen in Figure

3-16 on page 45) used to operate a servo-motor powered machine.

Page 44

BB4500-BB5000 Operating Manual

FIGURE 3-16. SERVO MOTOR PENDANT CONTROLS

TABLE 3-9. SERVO MOTOR CONTROL FUNCTIONS

Function

Action

Press and hold for three seconds to start the control system

Reset

on power up, or to reset after an E-Stop.

Start

Hold for three seconds to start the spindle rotation.

RPM

Controls the rotational bar speed from 3-230 RPM.

Indicates that the servo drive has stopped due to a fault con-

dition, such as the following:

Fault light

•

Motor overload

•

Loss of feedback

•

Motor is disconnected

Press to immediately stop all machine functions and discon-

E-stop

nect the motor from power.

Stop

Press to stop the spindle rotation.

Direction

Turn to change the direction of bar rotation.

Warns that a fault condition is imminent unless the load is

Overload indicator

reduced.

NOTICE

The 230V and 460V units cannot be converted between voltages.

There is no servo drive for the BB4500.

P/N 92974, Rev. 3

Page 45

3.5.3

Electrical machines

WARNING

Electrical equipment can shock or cause an explosion if used near wet

or flammable materials. Do not operate the motor if it is wet or exposed

to combustible materials.

CAUTION

The motor rotation reverse switch must be operated only when the

motor is completely stopped. Failure to do so can damage the

equipment.

Do the following to connect the electrical power:

1. Check the power cords and plugs for damage. Repair or replace any if nec-

essary.

2. Plug the motor into the control box.

3. Connect the control box mains power cord to a grounded outlet of the cor-

rect voltage. 120V motors are rated at 20 amps full load; 230V motors are

rated at 11.5 amps full load.

3.5.4

Pneumatic machines

For your safety and protection, the

BB4500-BB5000 pneumatic sys-

tem has an air control valve with a

brightly colored oval handle (seen

in Figure 3-17) clearly indicating

the airflow direction.

Quick-disconnects between the

incoming air supply and the

machine enable the operator to

FIGURE 3-17. AIR CONTROL VALVE HANDLE

quickly disconnect the machine if

necessary.

The pneumatic conditioning unit (PCU) air filter and lubricator must be used to

protect the pneumatic system and maintain the machine warranty. The lubricator is

set to deliver oil at a rate of 20-30 drops per minute at full throttle.

CAUTION

If the machine stops moving unexpectedly, lock out the pneumatic

safety valve located at the filter lubricator assembly before performing

any troubleshooting.

Page 46

BB4500-BB5000 Operating Manual

3.6

BB4500-BB5000 WITH SMALL DIAMETER BARS

For the BB4500, boring bars with a diameter of less than 1.75" (44 mm) are easily

adapted to accept the standard RDU, AFU, and the spherical bearing mounting

brackets (see Figure 3-18).

For the BB5000, boring bars with a

SPHERICAL

diameter of less than 2.25" (57.15

BEARING

COLLETS

mm) are easily adapted to accept

the standard RDU, AFU, and the

spherical bearing mounting brack-

ets (see Figure 3-18). This adapta-

tion for the 1.25" (32 mm) boring

bar is offered as a CLIMAX small

bore kit (P/N 28698).

TABLE 3-10. COLLET IDENTIFICATION

AFU COLLET

RDU COLLET

Number

Component

FIGURE 3-18. COLLETS (BB5000 VERSION SHOWN)

Spherical bearing collets

RDU collet

AFU collet

NOTICE

The small bore kit adapter collets fit into the existing collets. Do not

remove existing collets from the RDU and AFU.

The AFU collet is serrated on both ends and has no keyway. The RDU collet is ser-

rated on one end only.

The RDU collet has a keyway milled into the outside diameter with two bolt heads

visible (see Figure 3-19 on page 48). Those bolts are for retaining the key in the

inner diameter of the collet, which will accept the keyway of the 1.25" boring bar.

P/N 92974, Rev. 3

Page 47

OPERATION

IN THIS CHAPTER:

4.1 PRE-OPERATION CHECKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-51

4.2 TOOL BIT SELECTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-52

4.3 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-52

4.3.1 STARTING THE MACHINE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-52

4.3.1.1 HYDRAULIC DRIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-52

4.3.1.2 ELECTRICAL DRIVE

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-52

4.3.1.3 PNEUMATIC DRIVE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-53

4.3.1.4 SERVO DRIVE (BB5000 ONLY) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-54

4.4 SHUTDOWN - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-54

4.5 DISASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-55

Do not operate this machine without adequate training to fully understand the safe

setup, operation, and maintenance procedures.

CAUTION

To avoid serious injury, keep clear of moving machinery during

operation. Apply cutting oil with a squirt can.

For machines with air motors, if the machine stops moving

unexpectedly, lock out the pneumatic safety valve located at the filter

lubricator assembly before performing any troubleshooting.

4.1

PRE-OPERATION CHECKS

Do the following checks before operating the machine:

1. Complete the risk assessment checklist in Table 1-3 on page 5.

2. Check that the work area is clear of non-essential personnel and equipment.

3. Check that all hand tools are removed from inside the machine and the

work area.

4. Check that the machine control/observation area will not be in the path of

hot flying chips during machine operation.

5. Check the machine is securely mounted to the workpiece.

6. Check that air hoses are routed and secured to avoid tripping, entangle-

ment, damage from hot chips, or other damage should an air hose or con-

nection fail.

7. Check the tool condition and sharpness.

8. Check that power lines and cables are properly connected.

9. Check that all machine parts, including the tool head, tool bit, and collar

clamps are secure.

P/N 92974, Rev. 3

Page 51

10. Check that the feed direction and rate are correctly set.

11. Check that all preventive maintenance has been completed.

4.2

TOOL BIT SELECTION

Bar rotation speed is adjustable depending on the power option chosen (electric,

hydraulic, pneumatic). The cutting speed is primarily determined by the hardness

of the metal being machined and the type of tool bit used. Other factors include the

power source, feed and depth of cut, and cooling medium being used.

Generally, carbide cutting tools operate at a higher RPM than high-speed steel

(HSS) tools.

If using a HSS tool bit, set the speed shift lever to LOW. Chips should be the color

of the base material or no darker than a light straw in color.

When using carbide tool bits, set the speed shift lever to HIGH. These chips should

be dark brown to blue.

4.3

OPERATION

4.3.1

Starting the machine

Check that the tool bit is installed so that, as the boring bar rotates, it presents its

cutting edge to the workpiece. Before machining, lubricate the bore and tool bit

with cutting oil.

4.3.1.1

Hydraulic drive

Do the following to start the hydraulic drive:

1. Turn the HPU to its minimum flow rate (lowest speed).

2. Jog the HPU to verify direction of bar rotation. Do the following to reverse

bar rotation:

a) Turn off the HPU.

b) Reverse the hydraulic hoses.

3. With power switched on, adjust the bar speed by turning the hydraulic

speed control knob (located on the control pendant) for one of the follow-

ing results:

• Counter-clockwise to decrease RPM.

• Clockwise to increase RPM.

4.3.1.2

Electrical drive

Do the following to start the electrical drive:

1. Set the rotation speed on the speed control to minimum.

Page 52

BB4500-BB5000 Operating Manual

2. Turn on power at the motor controller.

3. Adjust the bar rotation speed as required by the bore size, tooling, and

material requirements.

4. Adjust the feed rate.

The motor has thermal and current overload protections built in. If the motor is

pushed beyond its protected range, it will stop. To prevent this, monitor the amp

meter on the controller and do not let the reading exceed its rated maximum

amperage (10.5 amps for the 230V and 20 amps for the 120V).

This motor is also reversible, allowing it to change the bar rotation direction.

CAUTION

Always stop the motor completely before switching the rotation

direction. Failure to do so may damage both the motor and the

controller.

CAUTION

Brush wear depends on the load and RPM. Regularly check both

brushes for excessive wear and replace if necessary.

4.3.1.3

Pneumatic drive

Do the following to start the pneumatic drive:

1. Using the quick disconnect fittings, connect the pneumatic motor to the

pneumatic conditioning unit (PCU).

2. Check that the incoming air pressure is 90-psi (6.2-bar) minimum.

3. Control the boring bar speed by slowly adjusting the air control valve.

NOTICE

The 3 hp (2.24 KW) air motor is reversible. Connect the airline so that,

as the boring bar rotates, the tool bit presents its cutting edge to the

workpiece. If the tool bit is backward, reverse the quick disconnects at

the motor to change the bar rotation direction.

CAUTION

If the machine stops moving unexpectedly, lock out the pneumatic

safety valve located at the filter lubricator assembly before performing

any troubleshooting.

P/N 92974, Rev. 3

Page 53

4.3.1.4

Servo drive (BB5000 only)

If using the servo drive with the BB5000, do the following to start the servo drive

(see Figure 3-16 on page 45):

1. Pull the E-stop up.

2. Press and hold the RESET button for three seconds, or until the fault light

turns off.

3. Select the rotation direction.

4. Press START.

To stop, press the STOP button.

4.4

SHUTDOWN

To protect tool bits from chipping, always place the feed box in neutral before

stopping the bar rotation.

Do the following to shut down the machine:

1. Disengage the axial feed by pushing the feed shaft until the pins on both

sides of the feed box are free of the drive bushings.

FIGURE 4-1. DISENGAGING THE AXIAL FEED

TABLE 4-1. AXIAL FEED DISENGAGEMENT IDENTIFICATION

Number

Component

Push to feed in direction of arrow #1

Page 54

BB4500-BB5000 Operating Manual

MAINTENANCE

IN THIS CHAPTER:

5.1 MAINTENANCE CHECKLIST

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-57

5.2 APPROVED LUBRICANTS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-58

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

-59

5.3.1 AFU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-59

5.3.2 BORING BAR - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-59

5.3.3 HYDRAULIC POWER SYSTEM

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-59

5.3.4 ELECTRIC MOTOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-60

5.3.5 AIR MOTOR ASSEMBLY - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-60

5.3.6 BB5000 SERVO MOTOR

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-61

5.3.7 4:1 RDU GEARBOX

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-61

5.3.8 CUTTING FLUID

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-61

5.4 QUALITY CHECKS

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-61

5.5 TROUBLESHOOTING

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-62

5.1

MAINTENANCE CHECKLIST

Table 5-1 lists maintenance intervals and tasks.

TABLE 5-1. MAINTENANCE INTERVALS AND TASKS

Interval

Task

Reference

Inspect the power cord for damage and replace as necessary.

Fill the lubricator oil cup in the air motor assembly with 6 oz (177.4

Section 5.3.5 on

mL) of AW 32.

page 60

Spray the ACME screw and tool heads with WD-40.

Before each use

Section 5.3.2 on

Clean and lightly oil the bar.

page 59

Spray the spherical bearing mounting bracket bearing mounts with

WD-40.

Before and after

Remove debris, oil, and moisture from machine surfaces.

each use

P/N 92974, Rev. 3

Page 57

TABLE 5-1. MAINTENANCE INTERVALS AND TASKS (CONTINUED)

Interval

Task

Reference

Clean and lightly oil (do not grease) the leadscrew in the axial feed

Section 5.3.1 on

unit (AFU).

page 59

Every six months, fill the 4:1 servo rotational drive unit (RDU) gear-

Section 5.3.7 on

box with 1 oz (29.5 mL) of Mobil SHC 634 synthetic oil.

page 61

Every six months, repack the spherical bearings in the spherical

bearing mounting bracket with 2 cc’s (2 mL) of Jetlube 550.

Every six months or 500 hours, repack the gearbox with one

Periodically

ounce of Mobilith SHC 460 Synthetic gear grease.

Every two years, replace the hydraulic oil with AW 32. Fill to the

Section 5.3.3 on

sight glass.

page 59

Section 5.3.4 on

Check both brushes for excessive wear and replace if necessary.

page 60

Check the air system periodically to verify that the air pressure is

Section 5.3.5 on

90 psi (6.2 bar).

page 60

Section 5.3.1 on

Disassemble the AFU to clean, lubricate, and replace the seals.

page 59

Annually

Repack the AFU gearbox with 1 oz (29.6 mL) of Mobilith SHC 460

Section 5.3.1 on

grease.

page 59

As needed

Sharpen or replace the tool bits.

5.2

APPROVED LUBRICANTS

CLIMAX recommends using the following lubricants at the locations indicated.

CAUTION

Avoid damage, premature machine wear, and protect your warranty by

using only approved lubricants.

TABLE 5-2. APPROVED LUBRICANTS

Application Area

Lubricant

Quantity

Frequency

4:1 RDU

Mobilith SHC 460 Synthetic

1 oz

Every 6 months

12:1 RDU (BB5000

Mobil SHC 634 Synthetic

5 oz

Every 6 months

only)

AFU

Mobilith SHC 460

1 oz

Yearly

Spherical bearings

JetLube 550

2 cc

Every 6 months

To sight

Hydraulic oil

AW 32

Every 2 years

glass

Page 58

BB4500-BB5000 Operating Manual

TABLE 5-2. APPROVED LUBRICANTS (CONTINUED)

Application Area

Lubricant

Quantity

Frequency

Per use through

Air motor

AW 32

6 oz

the lubricator

ACME screw

Boring bar

WD 40

Per use by hand

required

Tool heads

Unpainted surfaces

Cutting fluid

DoAll AL2000

As required

required

Long-term rust pre-

For storage more

LPS-3

ventative

required

than 3 months

Tool bits, work piece

Koolkut

Per use by hand

required

5.3

MAINTENANCE TASKS

Maintenance tasks are described in the following sections.

5.3.1

AFU

Clutch performance may be compromised if the machine has been “crashed,” has

seen over a thousand hours of operation, or is operated in a dirty environment.

If the axial feed fails, check that the shear pins are intact. Extra pins are included

with the assembly. The pins must be in place (notched end out) to engage the feed.

NOTICE

Freezing temperatures may cause the axial feed box to run sluggishly.

5.3.2

Boring bar

Check the bar regularly for nicks, cuts, or abrasions. Dress the bar smooth if neces-

sary. A bar with nicks or gouges can damage the bearing supports and RDU

beyond repair. Wipe the bar clean with solvent to remove dirt and chips.

5.3.3

Hydraulic power system

For information on maintaining the hydraulic power system, see the manufac-

turer’s documentation for your hydraulic system.

P/N 92974, Rev. 3

Page 59

5.3.4

Electric motor assembly

WARNING

The handle (PN 75648)

clamped onto the motor acts

as a torque restraint and only

an authorized CLIMAX

representative should remove

and reinstall it. If the handle

needs to be removed, contact

CLIMAX. Failure to do this

could cause severe damage

to the machine or bodily injury.

FIGURE 5-1. ELECTRIC MOTOR WITH HANDLE

Replace or repair any damaged or

abraded parts, including brushes.

Use only grounded, properly rated electrical outlets.

CAUTION

Brush wear mostly depends on the load and RPM. Depending on

operating conditions, periodically check both brush for excessive wear

and replace if necessary.

WARNING

Electrical equipment can shock or cause an explosion if used near wet

or flammable materials. Do not operate the motor if it is wet or exposed

to combustible materials.

5.3.5

Air motor assembly

Do the following to increase the life of the air motor:

• Route the air supply through a lubricator and filter.

• Use nonrestrictive air lines and fittings.

• Set the air motor speed only by adjusting the air control valve.

CAUTION

Do not attempt to adjust air motor speed by changing the in-line air

pressure from 90 psi (6.2 bar).

• Use air oil that has antioxidants and rust inhibitors. The lubricator

should deliver oil at a rate of 20-30 drops per minute at full throttle.

• Drain water from the air filter.

Page 60

BB4500-BB5000 Operating Manual

5.3.6

BB5000 servo motor

CAUTION

Let the surface of the servo cool before handling.

Servo temperatures of less than 140° F (60° C) are expected, as well as the forma-

tion of an oil droplet over an eight-hour use period. Replace oil with 5 ounces of

Mobil SHC 634 Oil after the first 40 hours and then additionally every 80 hours.

Running at a high RDU temperature of more than 220° F (104° C) for over 30 min-

utes at a time or reaching an RDU temperature of 260° F (127° C) will limit the life

of the RDU and can create oil leakage.

Replace oil with 5 ounces of Mobil SHC 634 Oil every 40 hours.

If the motor does not stop when the speed control knob is turned to zero, see

Appendix D on page 143.

5.3.7

4:1 RDU gearbox

Improperly packed bearings or improperly torqued bearing nuts will significantly

damage the gearbox. Have the gearbox serviced at CLIMAX every six months in

order to maintain the warranty.

5.3.8

Cutting fluid

Only use water-based cutting fluids with the CLIMAX air mist system. Refill the

reservoir with DoAll AL2000 as required.

5.4

QUALITY CHECKS

TABLE 5-3. QUALITY CHECKS

Area

Check

Rotate the collet by hand, checking for free movement.

AFU

Check the feed engagement pins, feed operation, feed stop pins, and that feed

screws are not bent.

RDU

Manually retract the spring plungers and drive key, checking for free movement.

Tool heads

All hardware is present and in good condition for each tool head.

Bearing mounts

All single-arm mount screws and washers are in good condition.

Tack weld plates (P/N 19869)

Welds are ground off and a flat surface is present for welding.

Safety devices and labels

Present and in good condition (see Section 1.7 on page 6).

Steel container (P/N 37732)

In good condition and all packaging materials are new.

P/N 92974, Rev. 3

Page 61

5.5

TROUBLESHOOTING

This section is intended to help you solve basic machine performance problems.

For serious maintenance or if you have questions on the following procedures,

contact CLIMAX.

TABLE 5-4. TROUBLESHOOTING

Problem

Remedy

•

Fully engage the feed shaft pin in the bushing slot.

•

Check that the pin has not sheared.

•

Clean the leadscrew.

AFU does not

•

Check that the feed rate is not too low.

advance the bar

•

Check that the AFU is clamped tightly to the bar.

•

Check that none of the clamp collars, except those on the AFU, are over tightened.

•

Check that the stop arm has not depressed one of the stop feed screw assemblies.

•

Sharpen the tool bit.

•

Decrease the nose radius on the tool bit.

•

Increase the feed rate.

Tool chatter

•

Increase or decrease the drive motor speed.

•

Change the depth of cut.

•

Add additional support arms or place the existing support arms closer to the workpiece.

Machine is

Tighten all clamps and hardware. Provide additional support.

unstable

•

Check that the HPU is turned on.

•

Check that the HPU pump motor is rotating as indicated by the arrow on the pump body

(see Section 3.5.1 on page 43).

•

Check the oil level in the HPU.

RDU will not

•

Check that the speed control is at maximum flow.

rotate

•

Check the hydraulic hose connections.

•

On electric powered units, check electrical connections and circuit breakers (see Section

3.5.3 on page 46).

•

Check that the control box on electric motors is plugged into the motor and turned on.

Feed is in

Check the feed shaft position on the AFU (see Section 3.4 on page 40).

wrong direction

•

Check the fluid level and add more if necessary.

HPU fails to

•

Check that the pump motor is turning in the correct direction (see Section 3.5.1 on

deliver fluid

page 43).

•

Check hydraulic connections for obstructions or leaks.

•

Check that the power unit and electrical supply are compatible.

•

Check that the unit is plugged in.

HPU motor does

•

Check for faulty wiring.

not run

•

Check the reset switch in the electrical box.

•

Check the fuses in the electrical box.

Servo motor

does not stop

See Appendix D on page 143.

when turned to

zero

Page 62

BB4500-BB5000 Operating Manual

STORAGE AND SHIPPING

IN THIS CHAPTER:

6.1 STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-63

6.1.1 SHORT-TERM STORAGE

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-63

6.1.2 LONG-TERM STORAGE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-63

6.2 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-63

6.3 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

-64

6.1

STORAGE

Proper storage of the boring machine will extend its usefulness and prevent undue

damage.

Before storing, do the following:

1. Clean the machine with solvent to remove grease, metal chips, and mois-

ture.

2. Remove hoses to the HPU. Do not remove the ramp feature hoses.

Store the boring machine in its original shipping container. Keep all packing mate-

rials for repackaging the machine.

6.1.1

Short-term storage

Do the following for short-term storage (three months or less):

1. Remove the tooling.

2. Lower and support the spindle.

3. Remove the hoses to the HPU. Do not remove the ramp feature hoses.

4. Clean the machine to remove dirt, grease, metal chips, and moisture.

5. Spray all black and bare metal surfaces with LPS-3 to prevent corrosion.

6. Store in a protected area.

6.1.2

Long-term storage

For long-term storage (longer than three months), follow the short-term storage

instructions, but use LPS-3 instead of LPS-2.

6.2

SHIPPING

The boring machine can be shipped in its original shipping container.

P/N 92974, Rev. 3

Page 63

APPENDIX A BB4500 ASSEMBLY DRAWINGS

Drawing list

FIGURE A-1. AXIAL FEED UNIT ASSEMBLY (P/N 43378)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66

FIGURE A-2. AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 43378) - - - - - - - - - - - - - - - - - - - - - - - - - 67

FIGURE A-3. BORING HEADS SET ASSEMBLY (P/N 43576) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68

FIGURE A-4. BORING HEADS SET 4-10 METRIC DIAMETER ASSEMBLY (P/N 43576) - - - - - - - - - - - - - - - - - - 69

FIGURE A-5. BORING HEADS SET 4-10" DIAMETER ASSEMBLY (P/N 43575) - - - - - - - - - - - - - - - - - - - - - 70

FIGURE A-6. RDU 2ND GEN ASSEMBLY (P/N 53912)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71

FIGURE A-7. RDU 2ND GEN ASSEMBLY (P/N 53912)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72

FIGURE A-8. HYDRAULIC MOTOR ASSEMBLY (P/N 39848)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73

FIGURE A-9. SINGLE-ARM MOUNT ASSEMBLY (P/N 43262) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 74

FIGURE A-10. UNIVERSAL MOUNT ASSEMBLY (P/N 43267) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 75

FIGURE A-11. DOUBLE-ARM BEARING MOUNT ASSEMBLY (P/N 43279)

- - - - - - - - - - - - - - - - - - - - - - - 76

FIGURE A-12. LARGE AND SMALL SET CONES ASSEMBLY (P/N 49060)

- - - - - - - - - - - - - - - - - - - - - - - 77

FIGURE A-13. EIBENSTOCK MOTOR ASSEMBLY (P/N 88012) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78

FIGURE A-14. EIBENSTOCK MOTOR ASSEMBLY -- GEN. 2 ONLY - - - - - - - - - - - - - - - - - - - - - - - - - - - 79

FIGURE A-15. EIBENSTOCK MOTOR ASSEMBLY PARTS LIST -- GEN. 2 ONLY - - - - - - - - - - - - - - - - - - - - - - 80

TABLE A-1. BB4500 RECOMMENDED SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

TABLE A-2. BB4500-BB5000 SPARE PARTS KIT (P/N 97276)

- - - - - - - - - - - - - - - - - - - - - - - - - - - 81

TABLE A-3. BB4500 TOOL KIT IN INCHES (P/N 43580) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82

TABLE A-4. BB4500 TOOL KIT IN METRIC (P/N 43582) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83

P/N 92974, Rev. 3

Page 65

3$576 /,67

,7(0

47<

'(6&5,37,21

:$6+(5 7+5867

,' ;

2' ;

5,1* 61$3

%5* 7+5867

,' ;

2' ;

%5* &$0 )2//2:

;

3,1 '2:(/

[

:$6+(5 7+5867

,' ;

2' ;

%5* %$//

;

6($/

,' ;

2' ;

635,1* &203

2' ;

:,5( ;

/21* 67$,1/(66

%$// 67((/

',$

$50 5$7&+(7

6+$)7 )(('

%86+,1* '5,9(

635,1* 3/81*(5

/,*+7 )25&(

%5* 52//(5 &/87&+

;

6($/

,' ;

2' ;

/,3

5,1* 61$3

%(9(/('

3/81*(5 %$// 386+),7

+$1'/( &5$1. 02',),('

/($' 187 %%

$;,$/ )((' 90,

*($5 +(/,&$/ $;,$/ )((' %%

$66(0%/(' $;,$/ )((' 81,7 +286,1*

%5* &83

2' [

:,'(

%5* &21(

,' ;

:,'(

6723

$50

$66<

187

81) .(36

635,1* &203

2' ;

:,5( ;

%/2&. 7$&.:(/' %%

&/$03 &2//$5 02',),('

5' *(1 $)8

&2//(7 %%

/$%(/ :$51,1* +$1' &586+ )25&(

/$%(/ :$51,1* (17$1*/(0(17 2) +$1' 527$7,1* 6+$)7

/$%(/ :$51,1* &877,1* 2) ),1*(56 527$7,1* %/$'( *5$3+,&

7$// 75,$1*/( <(//2:

6&5(: $66< )((' 6723 *(1

FIGURE A-2. AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 43378)

P/N 92974, Rev. 3

Page 67

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

10160

SCREW 1/4-20 X 3/4 SHCS

10588

SCREW DRIVE #2 x 1/4 HOLE SIZE .089

11684

SCREW 5/16-18 X 3/4 SSSCP

11821

BRG CUP 4.4375 OD X .750 WIDE

11822

BRG CONE 2.75 ID X 1.00 WIDE

12387

BRG THRUST 1.259 ID X 1.937 OD X .0781

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID

12592

SCREW 1/4-20 X 2-3/4 SHCS

15212

SCREW 1/2-20 X 2-1/4 SHCS

16594

BALL NYLON 3/16 DIA

16666

WASHER THRUST 1.250 ID X 1.937 OD X .060

19232

SCREW 10-24 X 3/8 SHCS

21956

FTG PLUG 3/8 NPTM SOCKET

27348

SEAL 2.750 ID X 4.000 OD X .375

27353

BRG NEEDLE 1 ID X 1-1/4 OD X 1 CLOSED

28219

NUT MAIN BRG PRELOAD

28220

BUSHING LEADSCREW FLANGED

28589

BUSHING FLANGED 1 5P ACME THREADED

29154

PLATE SERIAL YEAR MODEL CE 2.0 X 3.0

29207

SPRING PLUNGER HAND RETRACT 1/2 X 13

45900

SCREW 1/4-28 X 1/2 SHCS

46902

LABEL WARNING HOT SURFACE

49665

HOUSING RDU BB5000 4TH

49667

CAP WORM HOUSING BB5000 4TH GEN

52307

BRG BALL THRUST 40 MM ID X 60 MM OD X 13 MM

53610

HANDLE PULL 1/4 CBORE MTG 2.17 X 5.75 X 1.02W COATED

53613

SPACER .67 OD X .266 ID X 1.875 LG

53910

CLAMP RING RDU MOUNT BB4500 HD

53911

COLLET MAIN DRIVE BB4500 4TH GEN

53913

KEY MAIN DRIVE BB4500 HD

54920

RING O 1/16 X 2-1/4 ID X 2-3/8 OD

54921

RING O 4-3/8 ID X 4-5/8 OD X 1/8

54922

RING O 1/16 X 1-3/8 ID X 1-1/2 OD VITON 75 DUROMETER

55708

SEAL 1.500 ID X 2.000 OD X .375 HIGH TEMP

A/R

55784

SHIM 1.7 ID X 2.3 OD .001 THICK

A/R

55790

SHIM 1.7 ID X 2.3 OD .002 THICK

A/R

55791

SHIM 1.7 ID X 2.3 OD .005 THICK

59044

LABEL WARNING CONSULT OPERATOR'S MANUAL

73954

SET WORM GEAR 4:1 BB5000 4TH GEN 1PC WORM

78741

LABEL WARNING CRUSH FOOT

78748

LABEL WARNING FLYING DEBRIS/LOUD NOISE

80207

LABEL WARNING - ENTANGLEMENT/ROTATING SHAFT GRAPHIC 1.95 TALL TRIANGLE YELLOW

FIGURE A-7. RDU 2ND GEN ASSEMBLY (P/N 53912)

Page 72

BB4500-BB5000 Operating Manual

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

11238

WASHER LOCK 1/2

11826

SCREW 1/2-13 X 1-1/4 HHCS

A/R

SEE CHART

39828

KIT FTG 1/2 HYD QUICK COUPLERS

78619

LABEL WARNING HOT SURFACE GRAPHIC 1.95" TALL TRIANGLE YELLOW (KB)

PART No

DESCRIPTION

MOTOR HYD P/N

39837

MOTOR ASSY HYD 2.2 CU IN KEYED 1/2 FTG

27477

39843

MOTOR ASSY HYD 3.6 CU IN KEYED 1/2 FTG

20684

39844

MOTOR ASSY HYD 5.7 CU IN KEYED 1/2 FTG S-SERIES

21530

39845

MOTOR ASSY HYD 7.3 CU IN KEYED 1/2 FTG

20231

39846

MOTOR ASSY HYD 8.9 CU IN KEYED S-SERIES 1/2 FTG

21531

39847

MOTOR ASSY HYD 14.1 CU IN KEYED 1/2 FTG

34585

43451

MOTOR ASSY HYD 11.3 CU IN KEYED 1/2 FTG

21532

43452

MOTOR ASSY HYD 17.9 CU IN KEYED 1/2 FTG

21534

43552

MOTOR ASSY HYD 22.5 CU IN KEYED SHAFT

30567

FIGURE A-8. HYDRAULIC MOTOR ASSEMBLY (P/N 39848)

P/N 92974, Rev. 3

Page 73

1.2

1.3

2.2

1.1

SET CONES SETUP 6 TO 10 DIA 1-3/4 KEYED BAR

43384

2.1

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

42228

CONE SETUP 6 TO 10 BB4500 1-3/4 BAR

1.1

29092

SCREW MOD 3/8-24 X 1-3/16 SSSFD

1.2

29091

PIN STOP

1.3

42228

CONE SETUP BB4000 6" TO 10"

42508

CLAMP COLLAR MODIFIED 1 3/4 ID

2.1

42508

CLAMP COLLAR MODIFIED

2.2

17125

SCREW 5/16-24 X 1-1/2 SHCS

1.1

1.2

2.1

1.3

SET CONES SETUP 2 TO 6 DIA 1-3/4 KEYED BAR

43383

2.2

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

41220

CONE SETUP 2 TO 6 BB4500 1-3/4 BAR

1.1

29092

SCREW MOD 3/8-24 X 1-3/16 SSSFD

1.2

29091

PIN STOP

1.3

41220

CONE SETUP 2" TO 6" BB4000

42508

CLAMP COLLAR MODIFIED 1 3/4 ID

2.1

42508

CLAMP COLLAR MODIFIED

2.2

17125

SCREW 5/16-24 X 1-1/2 SHCS

FIGURE A-12. LARGE AND SMALL SET CONES ASSEMBLY (P/N 49060)

P/N 92974, Rev. 3

Page 77

AVAILABLE CONFIGURATIONS

PART NO

DESCRIPTION

88008

MOTOR ELECTRIC ASSY EIBENSTOCK 120 V 4 SPEED REVERSIBLE GEN 2

88009

MOTOR ELECTRIC ASSY EIBENSTOCK 230 V 4 SPEED REVERSIBLE GEN 2

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

11873

SCREW 5/16-18 X 3-1/2 SHCS

12646

SCREW 1/2-13 X 1-1/4 SHCS

15724

KEY 1/4 SQ X 1.37 SQ BOTH ENDS

56300

LABEL CLIMAX LOGO .66 X 1.75

59037

LABEL WARNING - WEAR EAR PROTECTION

59044

LABEL WARNING - CONSULT OPERATOR'S MANUAL 1.5 DIA

75648

FLANGE MOTOR MTG ELEC RDU BB5000

78824

LABEL WARNING - DO NOT EXPOSE TO WATER

84393

LABEL EIBENSTOCK RPM RANGES

88004

NFIS MOTOR ELECTRIC 4 SPEED REVERSIBLE 120V CE EIBENSTOCK EAU 34/4.3 CB GEN 2

88005

NFIS MOTOR ELECTRIC 4 SPEED REVERSIBLE 230V CE EIBENSTOCK EAU 34/4.3 CB GEN 2

FIGURE A-13. EIBENSTOCK MOTOR ASSEMBLY (P/N 88012)

Page 78

BB4500-BB5000 Operating Manual

TABLE A-1. BB4500 RECOMMENDED SPARE PARTS

Part

Component

Description

Quantity

number

Rotational

12395

Clamp collar

drive unit

12436

Leadscrew

assembly

27356

1-5 Acme Nut

29552

Clamp collar

27015

Shear pin

25957

Clutch

Axial feed box

assembly

27197

Lead nut

92494

Screw assembly, feed stop

26850

Crank

11734

Screw 3/8-16 X 3/4 SSSCP

13356

Screw 5/8-11 X 2-1/2 SHCS

Boring head/

bar

11691

Screw 1/2-13 X 1.5 SHCS

10191

Screw 3/8-16 X 1 SHCS

14036

Screw 1/2-13 x 2 SHCS

Spherical

22662

Washer ½

bearing

26250

Screw 5/16-24 x 2 HHCS

mounting

brackets

21798

Washer 5/16

26252

Screw 1/2-20 x 2 SSSFP

29840

Hydraulic oil - 76 Unax AW 32 anti-wear fluid

HPU

20273

Key

82698

SP brush carbon pair for Eibenstock EAU 34/4.1

Electric motor

assembly

26845

3/8 short arm ball driver hex wrench

TABLE A-2. BB4500-BB5000 SPARE PARTS KIT (P/N 97276)

Part

Description

Quantity

number

10191

SCREW 3/8-16 X 1 SHCS

11691

SCREW 1/2-13 X 1-1/2 SHCS

11734

SCREW 3/8-16 X 3/4 SSSCP

P/N 92974, Rev. 3

Page 81

TABLE A-2. BB4500-BB5000 SPARE PARTS (CONTINUED)KIT (P/N 97276)

Part

Description

Quantity

number

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID (VMI)

13356

SCREW 5/8-11 X 2-1/2 SHCS

14036

SCREW 1/2-13 X 2 SHCS

20273

KEY 1/4 SQ X 1.00 SQ BOTH ENDS (KB)

21798

WASHER 5/16 FLTW HARDENED 1/8 THK BLK OX

WASHER 1/2 FLTW HARDENED 1-1/8 OD X 1/8 THICK

22662

BLACK OXIDE

26250

SCREW 5/16-24 X 2 HHCS

26252

SCREW 1/2-20 X 2 SSSFP

WRENCH HEX 3/8 SHORT ARM BONDHUS BONDHUS

26845

10914 BALLDRIVER

26850

HANDLE CRANK MODIFIED

27356

NUT 1-5 ACME 7/8 TALL 1-1/2 HEX FINISHED

KIT SERVICE BB5000 BB4500 AFU 3RD GEN COM-

38545

PREHENSIVE

SP BRUSH CARBON SINGLE (NOT A PAIR) FOR

82698

EIBENSTOCK EAU 34/4.1 BB4500 BB5000 120V (2

WIRES)

82949

BAG TOOL 14 X 5.5 X 6 POLYESTER

TABLE A-3. BB4500 TOOL KIT IN INCHES (P/N 43580)

Part

Description

Quantity

number

14251

WRENCH TEE 3/16 HEX (KB)

14650

WRENCH END 1/2 COMBINATION LONG

25550

WRENCH HEX 5/16 X 11.4 BALLDRIVER T-HANDLE

29041

WRENCH END 1-1/2 THIN (SINGLE OPEN END)

31858

BIT TOOL HSS 1/2 X 1.8 LH FINISHING SINGLE TC

31859

BIT TOOL HSS 1/2 X 4.0 LH FINISHING SINGLE TC

31867

BIT TOOL HSS 1/2 X 1.8 LH ROUGHING SINGLE

31868

BIT TOOL HSS 1/2 X 4.0 LH ROUGHING SINGLE

32342

BIT TOOL HSS 1/2 X 2.5 LH FINISHING SINGLE TC

Page 82

BB4500-BB5000 Operating Manual

TABLE A-3. BB4500 TOOL KIT IN INCHES (CONTINUED)(P/N 43580)

Part

Description

Quantity

number

32344

BIT TOOL HSS 1/2 X 2.5 LH ROUGHING SINGLE

33784

WRENCH TORX T-27V

33999

WRENCH HEX SET .050 - 3/8 BONDHUS BALL END

34895

CASE COMPARTMENT 8 X 4-1/8 X 1-3/16

44026

PRINT LAYOUT BB4500 PACKAGING

55923

WRENCH TEE 1/4 HEX

55924

WRENCH 3/8 HEX T-HANDLE

60880

HAMMER DEAD BLOW 42OZ

82949

BAG TOOL 14 X 5.5 X 6 POLYESTER

92974

MANUAL INSTRUCTION BB4500 BB5000 BORING BAR

TABLE A-4. BB4500 TOOL KIT IN METRIC (P/N 43582)

Part

Description

Quantity

number

14251

WRENCH TEE 3/16 HEX (KB)

14650

WRENCH END 1/2 COMBINATION LONG

25550

WRENCH HEX 5/16 X 11.4 BALLDRIVER T-HANDLE

29041

WRENCH END 1-1/2 THIN (SINGLE OPEN END)

33784

WRENCH TORX T-27V

33999

WRENCH HEX SET .050 - 3/8 BONDHUS BALL END

34571

BIT TOOL HSS 12MM X 4.0 LH FINISH SINGLE TC

34572

BIT TOOL HSS 12MM X 2.5 LH FINISH SINGLE TC

34573

BIT TOOL HSS 12MM X 1.8 LH FINISH SINGLE TC

34576

BIT TOOL HSS 12MM X 4.0 LH ROUGHING SINGLE

34577

BIT TOOL HSS 12MM X 2.5 LH ROUGHING SINGLE

34578

BIT TOOL HSS 12MM X 1.8 LH ROUGHING SINGLE

34895

CASE COMPARTMENT 8 X 4-1/8 X 1-3/16

35516

HAMMER DEAD BLOW 1-3/4 DIA HEAD

38678

WRENCH HEX SET 1.5 - 10MM BONDHUS BALL END

44026

PRINT LAYOUT BB4500 PACKAGING

55923

WRENCH TEE 1/4 HEX

P/N 92974, Rev. 3

Page 83

APPENDIX B BB5000 ASSEMBLY DRAWINGS

Drawing list

FIGURE B-1. AXIAL FEED UNIT ASSEMBLY (P/N 28636)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86

FIGURE B-2. AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 28636) - - - - - - - - - - - - - - - - - - - - - - - - - 87

FIGURE B-3. HD AXIAL FEED UNIT ASSEMBLY (P/N 91518) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88

FIGURE B-4. HD AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 91518) - - - - - - - - - - - - - - - - - - - - - - - 89

FIGURE B-5. AIR MOTOR CE ASSEMBLY (P/N 28697) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90

FIGURE B-6. AIR MOTOR CE ASSEMBLY (P/N 28614) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 91

FIGURE B-7. PNEUMATIC CONNECTION ASSEMBLY (P/N 15088)

- - - - - - - - - - - - - - - - - - - - - - - - - - 92

FIGURE B-8. HYDRAULIC MOTOR ASSEMBLY (P/N 39848)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

FIGURE B-9. SINGLE-ARM MOUNT ASSEMBLY (P/N 37472) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 94

FIGURE B-10. DOUBLE-ARM MOUNT ASSEMBLY (P/N 37473) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

FIGURE B-11. UNIVERSAL BEARING MOUNT ASSEMBLY (P/N 36959)

- - - - - - - - - - - - - - - - - - - - - - - - 96

FIGURE B-12. ID BEARING MOUNT ASSEMBLY (P/N 46293) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 97

FIGURE B-13. SETUP CONES 2.75-8.37" (70-213 MM) DIAMETER ASSEMBLY (P/N 26507) - - - - - - - - - - - - - - 98

FIGURE B-14. SETUP CONES 8.37-12" (213-305 MM) DIAMETER ASSEMBLY (P/N 26508) - - - - - - - - - - - - - - 99

FIGURE B-15. SERVO DRIVE 460 CE ASSEMBLY (P/N 52876)

- - - - - - - - - - - - - - - - - - - - - - - - - - 100

FIGURE B-16. SERVO DRIVE 460 CE ASSEMBLY PARTS LIST (P/N 52876) - - - - - - - - - - - - - - - - - - - - - 101

FIGURE B-17. RDU 12:1 ASSEMBLY (P/N 53165) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102

FIGURE B-18. RDU 12:1 ASSEMBLY PARTS LIST (P/N 53165) - - - - - - - - - - - - - - - - - - - - - - - - - - 103

FIGURE B-19. RDU 4TH GENERATION ASSEMBLY (P/N 49684) - - - - - - - - - - - - - - - - - - - - - - - - - - 104

FIGURE B-20. RDU 4TH GENERATION ASSEMBLY PARTS LIST (P/N 49684)

- - - - - - - - - - - - - - - - - - - - 105

FIGURE B-21. SERVO DRIVE 230V CE ASSEMBLY (P/N 54321)

- - - - - - - - - - - - - - - - - - - - - - - - - 106

FIGURE B-22. SERVO DRIVE 230V CE ASSEMBLY (P/N 54321)

- - - - - - - - - - - - - - - - - - - - - - - - - 107

FIGURE B-23. SERVO MOTOR RDU ADAPTER ASSEMBLY (P/N 51536)

- - - - - - - - - - - - - - - - - - - - - - 108

FIGURE B-24. SERVO MOTOR GUARD ASSEMBLY (P/N 52937) - - - - - - - - - - - - - - - - - - - - - - - - - - 109

FIGURE B-25. SERVO SHROUD FAN ASSEMBLY (P/N 56773) - - - - - - - - - - - - - - - - - - - - - - - - - - - 110

FIGURE B-26. SERVO DRIVE MOTOR 230V NON-CE ASSEMBLY (P/N 71071)

- - - - - - - - - - - - - - - - - - - 111

FIGURE B-27. SERVO DRIVE MOTOR 460V NON-CE ASSEMBLY (P/N 71072)

- - - - - - - - - - - - - - - - - - - 112

FIGURE B-28. EIBENSTOCK MOTOR ASSEMBLY -- GEN. 2 ONLY - - - - - - - - - - - - - - - - - - - - - - - - - - 113

FIGURE B-29. EIBENSTOCK MOTOR ASSEMBLY PARTS LIST -- GEN. 2 ONLY - - - - - - - - - - - - - - - - - - - - - 114

FIGURE B-30. LEADSCREW ASSEMBLY (P/N 28654) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115

TABLE B-1. BB5000 RECOMMENDED SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116

TABLE B-2. BB4500-BB5000 SPARE PARTS KIT (P/N 97276)

- - - - - - - - - - - - - - - - - - - - - - - - - - 117

TABLE B-3. LEADSCREW SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117

TABLE B-4. HYDRAULIC METRIC SPARE PARTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118

TABLE B-5. BB5000 TOOL KIT IN INCHES (P/N 28784) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119

TABLE B-6. BB5000 TOOL KIT IN METRIC (P/N 34580) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119

P/N 92974, Rev. 3

Page 85

3$576 /,67

,7(0

47<

'(6&5,37,21

:$6+(5 7+5867

,' ;

2' ;

5,1* 61$3

%5* 7+5867

,' ;

2' ;

%5* &$0 )2//2:

;

3,1 '2:(/

[

:$6+(5 7+5867

,' ;

2' ;

%5* %$//

;

6($/

,' ;

2' ;

635,1* &203

2' ;

:,5( ;

/21* 67$,1/(66

%$// 67((/

',$

&2//(7 $)8 %%

%$5

$50 5$7&+(7

6+$)7 )(('

%86+,1* '5,9(

635,1* 3/81*(5

/,*+7 )25&(

%5* 52//(5 &/87&+

;

6($/

,' ;

2' ;

/,3

5,1* 61$3

%(9(/('

3/81*(5 %$// 386+),7

+$1'/( &5$1. 02',),('

/($' 187 %%

$;,$/ )((' 90,

*($5 +(/,&$/ $;,$/ )((' %%

$66(0%/(' $;,$/ )((' 81,7 +286,1*

%5* &83

2' [

:,'(

%5* &21(

,' ;

:,'(

6723

$50

$66<

187

81) .(36

635,1* &203

2' ;

:,5( ;

%/2&. 7$&.:(/' %%

&/$03 &2//$5 02',),('

5' *(1 $)8

/$%(/ :$51,1* +$1' &586+ )25&(

/$%(/ :$51,1* (17$1*/(0(17 2) +$1' 527$7,1* 6+$)7

/$%(/ :$51,1* &877,1* 2) ),1*(56 527$7,1* %/$'( *5$3+,&

7$// 75,$1*/( <(//2:

6&5(: $66< )((' 6723 *(1

FIGURE B-2. AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 28636)

P/N 92974, Rev. 3

Page 87

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

10538

BRG THRUST .625 ID X 1.125 OD X .0781

11823

WASHER THRUST .625 ID X 1.125 OD X .030

12388

BRG BALL 2.7559 X 4.3307 X .7874

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID

16505

SEAL 1.375 ID X 1.750 OD X .197 (KB)

19561

SPRING COMP .148 OD X .023 WIRE X .50 LONG STAINLESS

19562

BALL STEEL 5/32 DIA

20890

BRG BALL .8750 ID X 1.3125 OD X .281

25957

BRG ROLLER CLUTCH 1 X 1.312 X .625

26828

PLUNGER BALL PUSHFIT

26850

(NOT SHOWN) HANDLE CRANK MODIFIED

27015

PIN MODIFIED 3/16 x 3/4 GROOVED

27198

GEAR HELICAL AXIAL FEED BB5000

27203

BRG CUP 2.328 OD x .470 WIDE

27204

BRG CONE 1.3775 ID X .66 WIDE

27222

(NOT SHOWN )STOP ARM ASSY

28756

(NOT SHOWN) BLOCK TACKWELD BB5000

43982

RING SNAP 4.331 ID METRIC 110

49696

CLEVIS STOP PIN

49697

SCREW 1/2-13 X 3 KHS MOD BB5000 4TH GEN FEED STOP

49699

SPRING COMP .72 OD X .063 WIRE X .88 LONG

52347

BRG CAM FOLLOWER .500 OD X .375 WIDE W/ 1/4-28 STUD

54712

BRG ROLLER CLUTCH 1 ID X 1-5/16 OD X 1.063 SS SPRINGS

56301

NUT 1/4-28 LOCKING STAR WASHER

56307

HOUSING AXIAL FEED BB5000 4TH GEN

56308

BUSHING DRIVE BB5000 4TH GEN

56309

COLLET AFU BB5000 2-1/4 BAR 4TH GEN

56310

ARM RATCHET BB5000 4TH GEN

56314

SPRING PLUNGER 5/8-11 X 1.5 FORCE 3.5 TO 10.5 LBS

56349

NUT LEAD BB5000 AXIAL FEED

56380

SHAFT FEED BB5000 4TH GEN PROTOTYPE

FIGURE B-4. HD AXIAL FEED UNIT ASSEMBLY PARTS LIST (P/N 91518)

P/N 92974, Rev. 3

Page 89

AIR MOTOR

(REFERENCE ONLY)

ASSEMBLED

SCALE 1 : 15

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

70IN

10310

HOSE 801 SERIES PUSHLOK 1/2

16IN

10310

HOSE 801 SERIES PUSHLOK 1/2

10311

FTG BARB 1/2 NPTM X 1/2 HOSE

10321

FTG REDUCER BUSHING 1 NPTM X 1/2NPTF

13208

FTG QUICK COUPLER 1/2B 1/2NPTF FEMALE AIR

13209

FTG QD NIPPLE 1/2B 1/2 NPTM PNEUMATIC

15243

MUFFLER AIR MOTOR

19730

EXHAUST DEFLECTOR

35667

VALVE BALL 1/2 NPTM X 1/2 NPTF OVAL HANDLE

35692

FTG ELBOW 1/2 NPTM X 1/2 NPTF ST 90 DEG BRASS

55800

FTG QUICK COUPLER 1B 1 NPTF FEMALE AIR BRASS

55801

FTG QUICK COUPLER 1B 1 NPTM MALE AIR NON-VALVED BRASS

55802

FTG TEE 1 NPTF (3) BRASS

55803

FTG BARB 1 NPTM X 1 HOSE BRASS

55804

FTG CONNECTOR 1 NPTF X 1NPTF BRASS

60IN

55805

HOSE PUSH LOK 801 X 1 GREY

55832

FTG ELBOW 1 NPTM X 1 NPTM 90 DEG

58380

FTG QUICK COUPLER UNIVERSAL 1 NPTM

59248

PNEUMATIC CONDITIONING UNIT 1 IN W/ L.P. DROP OUT AND E-STOP CE

62564

FTG QUICK COUPLER UNIVERSAL 1/2 NPTF

FIGURE B-7. PNEUMATIC CONNECTION ASSEMBLY (P/N 15088)

Page 92

BB4500-BB5000 Operating Manual

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

11238

WASHER LOCK 1/2

11826

SCREW 1/2-13 X 1-1/4 HHCS

A/R

SEE CHART

39828

KIT FTG 1/2 HYD QUICK COUPLERS

78619

LABEL WARNING HOT SURFACE GRAPHIC 1.95" TALL TRIANGLE YELLOW (KB)

PART No

DESCRIPTION

MOTOR HYD P/N

39837

MOTOR ASSY HYD 2.2 CU IN KEYED 1/2 FTG

27477

39843

MOTOR ASSY HYD 3.6 CU IN KEYED 1/2 FTG

20684

39844

MOTOR ASSY HYD 5.7 CU IN KEYED 1/2 FTG S-SERIES

21530

39845

MOTOR ASSY HYD 7.3 CU IN KEYED 1/2 FTG

20231

39846

MOTOR ASSY HYD 8.9 CU IN KEYED S-SERIES 1/2 FTG

21531

39847

MOTOR ASSY HYD 14.1 CU IN KEYED 1/2 FTG

34585

43451

MOTOR ASSY HYD 11.3 CU IN KEYED 1/2 FTG

21532

43452

MOTOR ASSY HYD 17.9 CU IN KEYED 1/2 FTG

21534

43552

MOTOR ASSY HYD 22.5 CU IN KEYED SHAFT

30567

FIGURE B-8. HYDRAULIC MOTOR ASSEMBLY (P/N 39848)

P/N 92974, Rev. 3

Page 93

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

26845

(NOT SHOWN) WRENCH HEX 3/8 SHORT ARM BONDHUS BONDHUS 10914 BALLDRIVER

52188

ASSY SHIPPING CASE WITH CUT FOAM FOR BB5000 SERVO PACKAGE

53165

RDU 12:1 BB5000 4TH GEN

55583

LAMINATED PENDANT INSTRUCTION (NOT SHOWN)

56027

SERVO DRIVE MOTOR ASSEMBLY 460V 4TH GEN

5.1

51536

ADAPTER BB5000 RDU TO SERVO MOTOR

5.2

52937

GUARD ASSY BB5000 SERVO MOTOR

5.3

53464

LABEL WARNING HOT HAND

5.4

53482

LABEL WARNING VOLTAGE

5.5

53483

LABEL WARNING VOLTAGE CABLE

5.6

56773

ASSY FAN & SHROUD BB5000 SERVO ASSY

5.7

96888

ASSY BB5000 SERVO DRIVE 460VAC CONTROLS MOTOR AND CABLES CE 4TH GEN

5.7.1

53263

PENDANT BB5000 SERVO DRIVE

5.7.2

120

56269

SLEEVE WELD COVER 1" DIA STRAIGHTLINE W/VELCRO CLOSURE (10 FT)

5.7.3

57016

ASSY CABLE FAN BB5000 SERVO DRIVE 242 IN LONG

5.7.4

66908

ASSY CORDSET BB5000 SERVO INCOMING POWER CABLE 90 DEG CONN LONG 2ND GEN

5.7.5

91716

SERVO MOTOR MODEL HG-SR 3.5 kW 2000 RPM 400V KEYED SHAFT

5.7.6

96884

CORDSET OPERATOR PENDANT BB5000 SERVO DRIVE 5M LONG 4TH GEN

5.7.7

96885

ASSY ENCODER CABLE BB5000 SERVO DRIVE 6 M LONG 4TH GEN

5.7.8

96886

ASSY CABLE BB5000 SERVO POWER CABLE 90 DEG CONN 6M LONG 4TH GEN

5.7.9

96887

ASSY CONTROLLER SERVO DRIVE BB5000 460/3/50-60 CE 4TH GEN

92974

MANUAL INSTRUCTION BB45000 BB5000 BORING BAR

FIGURE B-16. SERVO DRIVE 460 CE ASSEMBLY PARTS LIST (P/N 52876)

P/N 92974, Rev. 3

Page 101

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

10160

SCREW 1/4-20 X 3/4 SHCS

10588

SCREW DRIVE #2 x 1/4 HOLE SIZE .089

11684

SCREW 5/16-18 X 3/4 SSSCP

11821

BRG CUP 4.4375 OD X .750 WIDE

11822

BRG CONE 2.75 ID X 1.00 WIDE

12387

BRG THRUST 1.259 ID X 1.937 OD X .0781

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID

12592

SCREW 1/4-20 X 2-3/4 SHCS

16594

BALL NYLON 3/16 DIA

16666

WASHER THRUST 1.250 ID X 1.937 OD X .060

19232

SCREW 10-24 X 3/8 SHCS

19610

SCREW 5/8-18 X 2-1/4 SHCS

21956

FTG PLUG 3/8 NPTM SOCKET

27348

SEAL 2.75 X 4.00 X .375

27353

BRG NEEDLE 1 ID X 1-1/4 OD X 1 CLOSED

28219

NUT MAIN BRG PRELOAD

28220

BUSHING LEADSCREW FLANGED

28589

BUSHING FLANGED 1 5P ACME THREADED

29154

PLATE SERIAL YEAR MODEL CE 2.0 X 3.0 (KB)

29207

SPRING PLUNGER HAND RETRACT 1/2 X 13

45900

SCREW 1/4-28 X 1/2 SHCS

46902

LABEL WARNING HOT SURFACE GRAPHIC 1.13" TALL

49665

HOUSING RDU BB5000 4TH GEN

49666

KEY MAIN DRIVE BB5000 4TH GEN

52303

CLAMP RING RDU MOUNT BB5000 4TH

52307

BRG BALL THRUST 40 MM ID X 60 MM OD X 13 MM

53168

COLLET MAIN DRIVE BB5000 4TH GEN

53610

HANDLE PULL 1/4 CBORE MTG 2.17 X 5.75 X 1.02W COATED

53613

SPACER .67 OD X .266 ID X 1.875 LG

54131

LABEL "12:1"

54133

LABEL OIL RDU

54916

RING O 3/16 X 1 ID X 1-3/8 OD VITON 75 DUROMETER

54920

RING O 1/16 X 2-1/4 ID X 2-3/8 OD

54921

RING O 4-3/8 ID X 4-5/8 OD X 1/8

54922

RING O 1/16 X 1-3/8 ID X 1-1/2 OD VITON 75 DUROMETER

55090

CAP WORM HOUSING 12:1 RDU BB5000

55708

SEAL 1.500 ID X 2.000 OD X .375 HIGH TEMP

A/R

55784

SHIM 1.7 ID X 2.3 OD .001 THICK

A/R

55790

SHIM 1.7 ID X 2.3 OD .002 THICK

A/R

55791

SHIM 1.7 ID X 2.3 OD .005 THICK

59044

LABEL WARNING - CONSULT OPERATOR'S MANUAL

78688

SET WORM GEAR 12:1 BB5000 4TH GEN 1PC WORM

78741

LABEL WARNING CRUSH FOOT

78748

LABEL WARNING FLYING DEBRIS/LOUD NOISE

80207

LABEL WARNING - ENTANGLEMENT/ROTATING SHAFT GRAPHIC 1.95 TALL TRIANGLE YELLOW

FIGURE B-18. RDU 12:1 ASSEMBLY PARTS LIST (P/N 53165)

P/N 92974, Rev. 3

Page 103

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

10160

SCREW 1/4-20 X 3/4 SHCS

10588

SCREW DRIVE #2 x 1/4 HOLE SIZE .089

11684

SCREW 5/16-18 X 3/4 SSSCP

11821

BRG CUP 4.4375 OD X .750 WIDE

11822

BRG CONE 2.75 ID X 1.00 WIDE

12387

BRG THRUST 1.259 ID X 1.937 OD X .0781

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID

12592

SCREW 1/4-20 X 2-3/4 SHCS

16594

BALL NYLON 3/16 DIA

16666

WASHER THRUST 1.250 ID X 1.937 OD X .060

19232

SCREW 10-24 X 3/8 SHCS

19610

SCREW 5/8-18 X 2-1/4 SHCS

21956

FTG PLUG 3/8 NPTM SOCKET

27348

SEAL 2.750 ID X 4.000 OD X .375

27353

BRG NEEDLE 1 ID X 1-1/4 OD X 1 CLOSED

28219

NUT MAIN BRG PRELOAD

28220

BUSHING LEADSCREW FLANGED

28589

BUSHING FLANGED 1 5P ACME THREADED

29154

PLATE SERIAL YEAR MODEL CE 2.0 X 3.0 (KB)

29207

SPRING PLUNGER HAND RETRACT 1/2 X 13

45900

SCREW 1/4-28 X 1/2 SHCS

46902

LABEL WARNING HOT SURFACE GRAPHIC 1.13" TALL

49665

HOUSING RDU BB5000 4TH

49666

KEY MAIN DRIVE BB5000 4TH GEN

49667

CAP WORM HOUSING BB5000 4TH GEN

52303

CLAMP RING RDU MOUNT BB5000 4TH

52307

BRG BALL THRUST 40 MM ID X 60 MM OD X 13 MM

53168

COLLET MAIN DRIVE BB5000 4TH GEN

53610

HANDLE PULL 1/4 CBORE MTG 2.17 X 5.75 X 1.02W COATED

53613

SPACER .67 OD X .266 ID X 1.875 LG

54920

RING O 1/16 X 2-1/4 ID X 2-3/8 OD

54921

RING O 4-3/8 ID X 4-5/8 OD X 1/8

54922

RING O 1/16 X 1-3/8 ID X 1-1/2 OD VITON 75 DUROMETER

55708

SEAL 1.500 ID X 2.000 OD X .375 HIGH TEMP

A/R

55784

SHIM 1.7 ID X 2.3 OD .001 THICK

A/R

55790

SHIM 1.7 ID X 2.3 OD .002 THICK

A/R

55791

SHIM 1.7 ID X 2.3 OD .005 THICK

59044

LABEL WARNING - CONSULT OPERATOR'S MANUAL

73954

SET WORM GEAR 4:1 BB5000 4TH GEN 1PC WORM

78741

LABEL WARNING CRUSH FOOT

78748

LABEL WARNING FLYING DEBRIS/LOUD NOISE

80207

LABEL WARNING - ENTANGLEMENT/ROTATING SHAFT GRAPHIC 1.95

TALL TRIANGLE YELLOW

FIGURE B-20. RDU 4TH GENERATION ASSEMBLY PARTS LIST (P/N 49684)

P/N 92974, Rev. 3

Page 105

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

26845

(NOT SHOWN) WRENCH HEX 3/8 SHORT ARM BONDHUS BONDHUS 10914 BALLDRIVER

52188

ASSY SHIPPING CASE WITH CUT FOAM FOR BB5000 SERVO PACKAGE

53165

RDU 12:1 BB5000 4TH GEN

55583

LAMINATED PENDANT INSTRUCTION (NOT SHOWN)

56026

SERVO DRIVE MOTOR ASSEMBLY 230V 4TH GEN

5.1

51536

ADAPTER BB5000 RDU TO SERVO MOTOR

5.2

52937

GUARD ASSY BB5000 SERVO MOTOR

5.3

53464

LABEL WARNING HOT HAND

5.4

53482

LABEL WARNING VOLTAGE

5.5

53483

LABEL WARNING VOLTAGE CABLE

5.6

56773

ASSY FAN & SHROUD BB5000 SERVO ASSY

5.7

96891

ASSY BB5000 SERVO DRIVE 230VAC CONTROLS MOTOR AND CABLES CE 4TH GEN

5.7.1

53263

PENDANT BB5000 SERVO DRIVE

5.7.2

120

56269

SLEEVE WELD COVER 1" DIA STRAIGHTLINE W/VELCRO CLOSURE (10 FT)

5.7.3

57016

ASSY CABLE FAN BB5000 SERVO DRIVE 242 IN LONG

5.7.4

66908

ASSY CORDSET BB5000 SERVO INCOMING POWER CABLE 90 DEG CONN LONG 2ND GEN

5.7.5

91716

SERVO MOTOR MODEL HG-SR 3.5 kW 2000 RPM 400V KEYED SHAFT

5.7.6

96884

CORDSET OPERATOR PENDANT BB5000 SERVO DRIVE 5M LONG 4TH GEN

5.7.7

96885

ASSY ENCODER CABLE BB5000 SERVO DRIVE 6 M LONG 4TH GEN

5.7.8

96886

ASSY CABLE BB5000 SERVO POWER CABLE 90 DEG CONN 6M LONG 4TH GEN

5.7.9

96890

ASSY CONTROLLER SERVO DRIVE BB5000 230/3/50-60 CE 4TH GEN

92974

MANUAL INSTRUCTION BB45000 BB5000 BORING BAR

FIGURE B-22. SERVO DRIVE 230V CE ASSEMBLY (P/N 54321)

P/N 92974, Rev. 3

Page 107

PARTS LIST

ITEM

QTY

P/N:

DESCRIPTION

10702

WASHER 1/4 FLTW SAE

13252

SCREW 1/4-20 X 1-3/4 SHCS

13296

(NOT SHOWN) MOUNTING BASE WIRE TIE ADHESIVE BACKED LARGE

19001

SCREW 1/4-20 X 1-1/2 BHSCS

2 IN

22800

(NOT SOWN) TUBE SHRINK .125 DIA BLACK

28617

NUT 8-32 LOCKING STAR WASHER

53462

HANDLE PULL 1/4 CBORE MTG 2.0 X 5.12 X 1.02W PLASTIC COATED

56587

SHROUD FAN BB5000 RDU SERVO

56757

RECEPTACLE MICROFAST 3 POLE MALE 1/4 NPT THD 0.5M LONG CONDUCTORS

56767

SPACER ROUND .252 ID X .625 OD X .75 ALUMINUM

56771

SCREW 8-32 X 1-1/2 BHSCS

56772

WASHER #8 FLTW RUBBER .93 THICK

56774

FAN 4.69" SQUARE X 1" 24 VDC 80CFM

56775

GUARD FAN STEEL WIRE 4.13" SQUARE BOLT PATTERN

FIGURE B-25. SERVO SHROUD FAN ASSEMBLY (P/N 56773)

Page 110

BB4500-BB5000 Operating Manual

TABLE B-1. BB5000 RECOMMENDED SPARE PARTS

Part

Component

Description

Quantity

number

2 Rotational

Drive Unit & 2

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID

Axial Feed-

box Assembly

25957

BRG ROLLER CLUTCH 1 ID X 1.312 OD X .625

26850

HANDLE CRANK MODIFIED

Axial Feed-

27015

PIN DOWEL MODIFIED .187 DIA X .75 GROOVED

box Assembly

27197

LEAD NUT BB4500 BB5000 AXIAL FEED

92494

SCREW ASSY FEED STOP GEN 2

10191

SCREW 3/8-16 X 1 SHCS

11691

SCREW 1/2-13 X 1-1/2 SHCS

Boring Head /

Bar

11734

SCREW 3/8-16 X 3/4 SSSCP

13356

SCREW 5/8-11 X 2-1/2 SHCS

20273

KEY 1/4 SQ X 1.00 SQ BOTH ENDS

WRENCH HEX 3/8 SHORT ARM BONDHUS BALL-

Electric Motor

26845

DRIVER

Assembly

SP BRUSH CARBON PAIR FOR EIBENSTOCK EAU 34/

82698

4.1 BB4500 BB5000

Leadscrew

27356

NUT 1-5 ACME 7/8 TALL 1-1/2 HEX FINISHED

Assembly

48909

KEY 1/4 SQ X 1.00 RADIUS BOTH ENDS

Servo Motor

Assembly

53195

KEY 10mm X 8mm X 2.05 LONG RADIUS BOTH END

14036

SCREW 1/2-13 X 2 SHCS

Spherical

21798

WASHER 5/16 FLTW HARDENED 1/8 THK BLK OX

Bearing

22662

WASHER 1/2 FLTW HARDENED 1-1/8 OD X 1/8 THICK

Mounting

Brackets

26250

SCREW 5/16-24 X 2 HHCS

26252

SCREW 1/2-20 X 2 SSSFP

Page 116

BB4500-BB5000 Operating Manual

TABLE B-2. BB4500-BB5000 SPARE PARTS KIT (P/N 97276)

Part

Description

Quantity

number

10191

SCREW 3/8-16 X 1 SHCS

11691

SCREW 1/2-13 X 1-1/2 SHCS

11734

SCREW 3/8-16 X 3/4 SSSCP

12395

CLAMP COLLAR SPLIT HINGED 2-1/2 ID (VMI)

13356

SCREW 5/8-11 X 2-1/2 SHCS

14036

SCREW 1/2-13 X 2 SHCS

20273

KEY 1/4 SQ X 1.00 SQ BOTH ENDS (KB)

21798

WASHER 5/16 FLTW HARDENED 1/8 THK BLK OX

WASHER 1/2 FLTW HARDENED 1-1/8 OD X 1/8 THICK

22662

BLACK OXIDE

26250

SCREW 5/16-24 X 2 HHCS

26252

SCREW 1/2-20 X 2 SSSFP

WRENCH HEX 3/8 SHORT ARM BONDHUS BONDHUS

26845

10914 BALLDRIVER

26850

HANDLE CRANK MODIFIED

27356

NUT 1-5 ACME 7/8 TALL 1-1/2 HEX FINISHED

KIT SERVICE BB5000 BB4500 AFU 3RD GEN COM-

38545

PREHENSIVE

SP BRUSH CARBON SINGLE (NOT A PAIR) FOR

82698

EIBENSTOCK EAU 34/4.1 BB4500 BB5000 120V (2

WIRES)

82949

BAG TOOL 14 X 5.5 X 6 POLYESTER

TABLE B-3. LEADSCREW SPARE PARTS

Part

Description

Quantity

number

28654

ASSY LEADSCREW 12 INCH FEED

28687

ASSY LEADSCREW 24 INCH FEED

28688

ASSY LEADSCREW 36 INCH FEED

P/N 92974, Rev. 3

Page 117

TABLE B-4. HYDRAULIC METRIC SPARE PARTS

Part

Description

Quantity

number

10191

SCREW 3/8-16 X 1 SHCS

11691

SCREW 1/2-13 X 1-1/2 SHCS

11734

SCREW 3/8-16 X 3/4 SSSCP

13356

SCREW 5/8-11 X 2-1/2 SHCS

14036

SCREW 1/2-13 X 2 SHCS

21798

WASHER 5/16 FLTW HARDENED 1/8 THK BLK OX

22662

WASHER 1/2 FLTW HARDENED 1-1/8 OD X 1/8 THICK

25957

BRG ROLLER CLUTCH 1 ID X 1.312 OD X .625

26250

SCREW 5/16-24 X 2 HHCS

26252

SCREW 1/2-20 X 2 SSSFP

26850

HANDLE CRANK MODIFIED

27015

SP PIN DOWEL MODIFIED .187 DIA X .75 GROOVED

27197

LEAD NUT BB4500 BB5000 AXIAL FEED

92494

SCREW ASSY FEED STOP GEN 2

27356

NUT 1-5 ACME 7/8 TALL 1-1/2 HEX FINISHED

29207

SPRING PLUNGER HAND RETRACT 1/2 X 13

33999

WRENCH HEX SET .050 - 3/8 BONDHUS BALL END

34571

BIT TOOL HSS 12MM X 4.0 LH FINISH SINGLE TC

34572

BIT TOOL HSS 12MM X 2.5 LH FINISH SINGLE TC

34573

BIT TOOL HSS 12MM X 1.8 LH FINISH SINGLE TC

34576

BIT TOOL HSS 12MM X 4.0 LH ROUGHING SINGLE

34577

BIT TOOL HSS 12MM X 2.5 LH ROUGHING SINGLE

34578

BIT TOOL HSS 12MM X 1.8 LH ROUGHING SINGLE

34642

SCREW M16 X 1.5 X 8 SSSFP

38678

WRENCH HEX SET 1.5 - 10MM BONDHUS BALL END

53670

ELEMENT FILTER 5/10HP HPU 10 MICRON

63533

TOOL HOLDER SET 12MM

63543

INSERT 80 DEG DIAMOND 3/8 IC .015 R KC-5010

64446

OIL HYDRAULIC 5 GALLON 76 UNAX AW 32

Page 118

BB4500-BB5000 Operating Manual

TABLE B-5. BB5000 TOOL KIT IN INCHES (P/N 28784)

Part

Description

Quantity

number

14251

WRENCH TEE 3/16 HEX (KB)

14650

WRENCH END 1/2 COMBINATION LONG

16794

WRENCH HEX BIT 3/8 DRIVER X 1/2 DRIVE

25550

WRENCH HEX 5/16 X 11.4 BALLDRIVER T-HANDLE

29041

WRENCH END 1-1/2 THIN (SINGLE OPEN END)

29199

WRENCH HEX 1/2 LONG ARM

29660

WRENCH HEX BIT 5/16 DRIVER X 12 DRIVE

29661

WRENCH HINGE HANDLE 1/2 DRIVE 17 IN HANDLE

31857

BIT TOOL HSS 1/2 X 1.0 LH FINISHING SINGLE

31858

BIT TOOL HSS 1/2 X 1.8 LH FINISHING SINGLE TC

31866

BIT TOOL HSS 1/2 X 1.0 LH ROUGHING SINGLE

31867

BIT TOOL HSS 1/2 X 1.8 LH ROUGHING SINGLE

32342

BIT TOOL HSS 1/2 X 2.5 LH FINISHING SINGLE TC

32344

BIT TOOL HSS 1/2 X 2.5 LH ROUGHING SINGLE

33785

WRENCH TORX T-45 (KB)

33999

WRENCH HEX SET .050 - 3/8 BONDHUS BALL END

55923

WRENCH TEE 1/4 HEX

55924

WRENCH TEE 3/8 HEX

60880

HAMMER DEAD BLOW 42OZ

82949

BAG TOOL 14 X 5.5 X 6 POLYESTER

92974

MANUAL INSTRUCTION BB4500 BB5000 BORING BAR

TABLE B-6. BB5000 TOOL KIT IN METRIC (P/N 34580)

Part

Description

Quantity

number

13052

WRENCH HEX BIT SOCKET 1/2 X 1/2

14251

WRENCH TEE 3/16 HEX

14650

WRENCH END 1/2 COMBINATION LONG

16794

WRENCH HEX BIT 3/8 DRIVER X 1/2 DRIVE

25550

WRENCH HEX 5/16 X 11.4 BALLDRIVER T-HANDLE

P/N 92974, Rev. 3

Page 119

TABLE B-6. BB5000 TOOL KIT (CONTINUED)IN METRIC (P/N 34580)

Part

Description

Quantity

number

29041

WRENCH END 1-1/2 (SINGLE OPEN END)

29199

WRENCH HEX 1/2 LONG ARM

29652

WRENCH HEX 3MM SHORT ARM

29660

WRENCH HEX BIT 5/16 DRIVER X 12 DRIVE

29661

WRENCH HINGE HANDLE 1/2 DRIVE 17 IN HANDLE

33785

WRENCH TORX T-45

33999

WRENCH HEX SET .050 - 3/8 BONDHUS BALL END

34568

WRENCH HEX 5MM SHORT ARM

34572

BIT TOOL HSS 12MM X 2.5 LH FINISH SINGLE TC

34573

BIT TOOL HSS 12MM X 1.8 LH FINISH SINGLE TC

34574

BIT TOOL HSS 12MM X 1.0 LH FINISH SINGLE TC

34577

BIT TOOL HSS 12MM X 2.5 LH ROUGHING SINGLE

34578

BIT TOOL HSS 12MM X 1.8 LH ROUGHING SINGLE

34579

BIT TOOL HSS 12MM X 1.0 LH ROUGHING SINGLE

35340

WRENCH HEX 8MM SHORT ARM

35516

HAMMER DEAD BLOW 1-3/4 DIA HEAD

55923

WRENCH TEE 1/4 HEX

55924

WRENCH 3/8 HEX T-HANDLE

82949

BAG TOOL 14 X 5.5 X 6 POLYESTER

MANUAL INSTRUCTION BB4500 BB5000 BORING

92974

BAR

Page 120

BB4500-BB5000 Operating Manual

APPENDIX C SCHEMATICS

Schematic list

FIGURE C-1. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50-60 HZ CE SCHEMATIC (P/N 88035 C00467)

122

FIGURE C-2. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50-60 HZ DOMESTIC ASSEMBLY (P/N 88036 C00468)

123

FIGURE C-3. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY (P/N 88037 C00465) 124

FIGURE C-4. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V CE ASSEMBLY (P/N 88038 C00466) - - - 125

FIGURE C-5. BB5000 MOTOR 230V AND 460V FAN ASSEMBLY (P/N 91811 E00034) - - - - - - - - - - - - - - - 126

FIGURE C-6. BB5000 SERVO MOTOR 230VAC AND 460VAC POWER CABLE ASSEMBLY (P/N 91811 E00048) - - - - 127

FIGURE C-7. BB5000 EIBENSTOCK MOTOR CABLE ASSEMBLY 2ND GEN 120V 12AWG SCHEMATIC (P/N 88649 E00170) 128

FIGURE C-8. BB5000 EIBENSTOCK MOTOR CABLE ASSEMBLY 2ND GEN 230V 14AWG SCHEMATIC (P/N 88650 E00171) 129

FIGURE C-9. BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 120V DOMESTIC L5-30P PLUG (P/N 88652 E00172)

130

FIGURE C-10. BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 120V CE 332P4W PIN/SLEEVE PLUG (P/N 88653

E00173) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131

FIGURE C-11. BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 230V CE CEE7/7 SCHUKO PLUG (P/N 88654 E00174)

132

FIGURE C-12. BB5000 EIBENSTOCK POWER CABLE ASSEMBLY 2ND GEN 230V DOMESTIC L6-15P PLUG (P/N 88655 E00175)

133

FIGURE C-13. PNEUMATIC CONDITIONING UNIT SCHEMATIC (P/N 59248)

- - - - - - - - - - - - - - - - - - - - - 134

FIGURE C-14. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50-60 HZ CE ASSEMBLY (P/N 88035 B00367)

135

FIGURE C-15. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 230V 50-60 HZ DOMESTIC ASSEMBLY (P/N 88036

B00368) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136

FIGURE C-16. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY (P/N 88037 B00365) 137

FIGURE C-17. BB4500-BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V CE ASSEMBLY (P/N 88038 B00366) - - 138

FIGURE C-18. BB5000 SERVO CONTROLLER 3RD GEN 460VAC CE ASSEMBLY (P/N A00099) - - - - - - - - - - - 139

FIGURE C-19. BB5000 EIBENSTOCK CONTROLLER 2ND GEN 120V DOMESTIC ASSEMBLY (P/N A00100) - - - - - - - 140

FIGURE C-20. BB5000 SERVO PENDANT ASSEMBLY (P/N B00024) - - - - - - - - - - - - - - - - - - - - - - - - 141

P/N 92974, Rev. 3

Page 121