BB8100 BORING MACHINE. OPERATING MANUAL ORIGINAL INSTRUCTIONS (2023)

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.

P/N 57064, Rev. 9

Page C

TABLE OF CONTENTS

INTRODUCTION

ABOUT THIS MANUAL

SAFETY WARNING SYMBOLS

GENERAL SAFETY

MACHINE SPECIFIC SAFETY PRACTICES

RISK ASSESSMENT AND HAZARD MITIGATION

RISK ASSESSMENT CHECKLIST

INSPECTING THE MACHINE

BASIC COMPONENTS

OVERVIEW

ROTATIONAL DRIVE ASSEMBLY

MECHANICAL AXIAL FEED ASSEMBLY

HYDRAULIC POWER

General description

Power unit pendant

Hydraulic motor

BEARING SUPPORT ASSEMBLIES

End-mount self-aligning bearing support assembly (with spider)

End-mount self-aligning bearing assembly (without spider)

ID-mount non self-aligning bearing support assembly (with spider)

Non self-aligning bearing assembly (without spider)

CLAMP COLLARS

BORING BAR AND LEADSCREW ASSEMBLY

AXIAL TOOL CARRIER

MANUAL BORING HEAD ASSEMBLY

FACING HEAD ASSEMBLY

SETUP

BORING BAR AND BEARING SUPPORT ASSEMBLY SETUP

END-MOUNT BEARING SUPPORT ASSEMBLY SETUP

ID-mount bearing support assembly setup

ROTATIONAL DRIVE ASSEMBLY SETUP

MOUNTING THE AXIAL FEED ASSEMBLY TO THE BAR

ATTACHING THE MECHANICAL RAPID FEED (OPTIONAL EQUIPMENT)

MOUNTING AN OPTIONAL ELECTRIC AXIAL FEED ASSEMBLY

Setting the Axial Feed Rate

SETTING THE FEED DIRECTION

Setting feed direction while the bar is rotating

Setting feed direction when the bar is stopped

Disengaging the feed

SETTING THE FEED RATE

TOOLING SETUP

Tool carrier setup

To lock the tool carrier on the bar for other operations

To remove the brass nut

BORING 31

Manual boring head assembly setup

P/N 57064, Rev. 9

Page i

Micro Adjustment Boring Head

BORING HEAD SETUP

FACING HEAD

Manual facing head assembly setup

Facing head radial feed

INSTALLING THE FACING SLIDE ARM ONTO THE TOOL CARRIER

Install the slide arm onto the tool carrier

Adjusting the tool carrier for perpendicularity

Feedbox assembly

INSTALL THE COUNTERWEIGHT ARM ONTO THE TOOL CARRIER

HYDRAULIC POWER PREPARATION AND CONNECTION

OPERATION

PRE-START CHECKS

Before operating the portable boring bar

USING THE REMOTE PENDANTS

Feed pendant

HPU PENDANT

MANUAL OVERRIDE (ELECTRICAL FEED ONLY)

CLAMP COLLARS

STARTING THE MACHINE

STOPPING THE MACHINE

REPETITIVE MACHINING

DISASSEMBLY

Standard disassembly

Alternative disassembly

MAINTENANCE

RECOMMENDED LUBRICANTS

BORING BAR/LEADSCREW

AXIAL FEED ASSEMBLY

ROTATIONAL DRIVE ASSEMBLY

BEARING SUPPORT ASSEMBLY

TOOL HEAD ASSEMBLY

Manual boring head assembly

Manual facing head assembly

Tool carrier 54

HYDRAULIC POWER UNIT AND MOTOR

General hydraulic system

Hydraulic motor

Hydraulic filter and fluid

TROUBLESHOOTING

STORAGE

SPECIFICATIONS

TOOL KIT AND SPARE PARTS

EXPLODED VIEWS AND PARTS

Page ii

BB8100 Operating Manual

INTRODUCTION

This manual describes how to use the Model BB8100 Portable Boring Bar. This precision

machine tool is designed for on-site boring without costly disassembly of equipment. All

parts and components meet CLIMAX’s strict quality standards. For maximum safety and

performance, read and understand the entire manual before operating the boring bar.

About this manual

Information in this manual is up-to-date at time of going to print. Because CLIMAX is

committed to continued product improvement, the machine you receive may differ slightly

from the one described here.

Safety Warning Symbols

The purpose of product safety signs and labels is to increase the level of awareness to

possible dangers.

Safety Alert Symbols indicate DANGER, WARNING or CAUTION. These symbols may be

used in conjunction with other symbols or pictographs. Failure to obey safety warnings can

result in serious injury. Always follow safety precautions to reduce the risk of hazards and

serious injury.

DANGER

Indicates a hazardous situation that could be fatal or cause serious injury.

WARNING

Indicates a potentially hazardous situation that could be fatal or cause

serious injury.

CAUTION

Indicates a potentially hazardous situation that could result in minor to

moderate injury, damage to the machine or interruption of an important

process.

NOTICE

Provides critical information for the completion of a task. There is no

associated hazard to people or the machine.

P/N 57064, Rev. 9

Page 1

General Safety

The primary challenge for most on-site maintenance is that repairs are often done under

difficult conditions.

CLIMAX leads the way in promoting the safe use of portable machine tools. Safety is a

joint effort. As the operator of this machine, you are expected to do your part by closely

examining the job site and following the operating procedures outlined in this manual, your

own company rules, and local regulations.

WARNING

For maximum safety and performance, read and understand this entire

manual and all other related safety instructions before using this equipment.

Failure to follow the instructions and guidelines in this manual could cause

personal injury, fatalities and property damage.

ROTATING MACHINERY

QUALIFIED PERSONNEL

Rotating machinery can seriously injure an

Before operating this machine, you must receive

operator. Lock out all power sources before you

training specific to this machine from a qualified

interact with the machine.

trainer. Do not operate the machine If you are

not familiar with the proper and safe operation.

KEEP YOUR WORK AREA CLEAN AND

TIDY

OBEY WARNING LABELS

Keep all cords and hoses away from moving

Obey all warning labels. Failure to follow

parts during operation. Do not clutter the area

instructions or heed warnings could result in

around the machine.

injury, or even be fatal. Proper care is your

responsibility. Contact CLIMAX immediately for

SECURE LOOSE CLOTHING AND LONG

replacement manuals or safety decals.

HAIR

INTENDED USE

Rotating machinery can cause serious injuries.

Do not wear loose fitting clothing or jewelry. Tie

Use this machine according to the instructions in

back long hair or wear a hat.

this operating manual. Do not use this machine

for any purpose other than its intended use as

HAZARDOUS ENVIRONMENTS

described in this manual.

Do not use the machine near explosive

STAY CLEAR OF MOVING PARTS

chemicals, toxic fumes, inappropriate radiation

hazards or other hazardous environments.

Keep clear of the machine during operation.

Never lean toward or reach into the machine to

remove chips or to adjust the machine while it is

FLYING CHIPS

running.

Flying metal chips can cut or burn. Do not

remove chips until after the machine has been

locked out, all power sources are off and the

machine has stopped.

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BB8100 Operating Manual

Machine Specific Safety Practices

All aspects of the machine have been designed with safety in mind. Following are

safety practices that you should keep in mind when using the CLIMAX BB8100

Boring Bar Machine.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

RADIATION HAZARDS

Eye and hearing protection must be worn while using

There are no systems or components on this machine

the machine. These safety items do not impose

that are capable of producing hazardous EMC, UV or

constraints to the safe operation of the machine.

other radiation hazards. The machine does not use

lasers nor does it create hazardous materials such as

OPERATING CONDITIONS

gasses or dust.

Do not operate the machine if it is not mounted to the

ADJUSTMENTS AND MAINTENANCE

workpiece as described in this manual.

All adjustments, lubrication and maintenance should

TOOLING

be done with the machine stopped, and disconnected

from power. The shut-off valve should be locked and

The machine is provided with all the tools for the setup

tagged out before any maintenance occurs.

and operation of the machine.

WARNING LABELS

LIFTING

Warning labels are attached to your machine upon

Avoid lifting heavy objects by yourself as serious injury

delivery. If any labels are defaced or missing, be sure

can result. Always follow your plant’s procedures for

to contact CLIMAX immediately for replacements.

lifting heavy objects.

MAINTENANCE

CUTTING FLUIDS

Check that the machine components are free of debris

There are no cutting or cooling fluids used with this

and properly lubricated prior to use.

machine.

CLAMP COLLARS

DANGER ZONE

To prevent the bar from sliding through the support

The operator and other persons can be anywhere in

bearings, or falling, use P/N 40708 - The collars are

the vicinity of the machine. The operator must make

made in matching sets and must be used to secure

sure there are no other persons in danger from the

the bar when the machine is in the vertical orientation.

machine.

Torque these collars to 100 ft-lbs (136 Nm), using the

clamp collars to prevent over tightening of the

METAL FRAGMENT HAZARD

bearings. Clamp collars should be positioned ABOVE

at least 2 support bearings when installed in a vertical

The machine dispenses metallic fragments during

orientation. Clamp collars should be shouldered

normal operation. You should wear eye protection and

against the bearing when in use.

gloves at all times when working with the machine.

HAZARDOUS ENVIRONMENTS

Do not use the machine in a hazardous environment,

such as near explosive chemicals, toxic fumes, or a

radiation hazard.

P/N 57064, Rev. 9

Page 3

Risk Assessment and Hazard Mitigation

Machine Tools are specifically designed to perform precise material-removal operations.

Stationary Machine Tools include lathes and milling machines and are typically found in a

machine shop. They are mounted in a fixed location during operation and are considered to be a

complete, self-contained machine. Stationary Machine Tools achieve the rigidity needed to

accomplish material-removal operations from the structure that is an integral part of the machine

tool.

In contrast, Portable Machine Tools are designed for on-site machining applications. They

typically attach directly to the workpiece itself, or to an adjacent structure, and achieve their

rigidity from the structure to which it is attached. The design intent is that the Portable Machine

Tool and the structure to which it is attached become one complete machine during the material-

removal process.

To achieve the intended results and to promote safety, the operator must under- stand and follow

the design intent, set-up, and operation practices that are unique to Portable Machine Tools.

The operator must perform an overall review and on-site risk assessment of the intended

application. Due to the unique nature of portable machining applications, identifying one or more

hazards that must be addressed is typical.

When performing the on-site risk assessment, it is important to consider the Portable Machine

Tool and the workpiece as a whole.

Page 4

BB8100 Operating Manual

Risk Assessment Checklist

The following checklist is not intended to be an all-inclusive list of things to watch out for

when setting up and operating this Portable Machine Tool. However, these checklists are

typical of the types of risks the assembler and operator should consider. Use these

checklists as part of your risk assessment:

TABLE 1-1. RISK ASSESSMENT CHECKLIST BEFORE SET-UP

Before set-up



I took note of all the warning labels on the machine.

I removed or mitigated all identified risks (such as tripping, cutting, crushing, entanglement,



shearing, or falling objects).

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



I read the machine assembly instructions.

I created a lift plan, including identifying the proper rigging, for each of the setup lifts required



during the setup of the support structure and machine.

I located the fall paths involved in lifting and rigging operations. I have taken pre- cautions to



keep workers away from the identified fall path.

I considered how this machine operates and identified the best placement for the controls,



cabling, and the operator.



I evaluated and mitigated any other potential risks specific to my work area.

TABLE 1-2. RISK ASSESSMENT CHECKLIST AFTER SET-UP

After set-up

I checked that the machine is safely installed and the potential fall path is clear. If the machine is



installed at an elevated position, I checked that the machine is safeguarded against falling.

I identified all possible pinch points, such as those caused by rotating parts, and informed the



affected personnel.



I planned for containment of any chips or swarf produced by the machine.



I followed the required maintenance with the recommended lubricants.

I checked that all affected personnel have the recommended personal protective equipment, as



well as any site-required or regulatory equipment.



I checked that all affected personnel understand and are clear of the danger zone.



I evaluated and mitigated any other potential risks specific to my work area.

P/N 57064, Rev. 9

Page 5

Inspecting the Machine

Your CLIMAX product was inspected and tested prior to shipment, and packaged for

normal shipment conditions. CLIMAX does not guarantee the condition of your machine

upon delivery. When you receive your CLIMAX product, perform the following receipt

checks.

1. Inspect the shipping container(s) for damage.

2. Check the contents of the shipping container(s) against the included invoice

to make sure that all components have been shipped.

3. Inspect all components for damage.

IMPORTANT

Contact CLIMAX immediately to report damaged or missing

components.

This is a highly configurable machine with many options and accessories. This manual

covers the use and operation of all of those possible options. The machine configuration

purchased by a customer may not contain all of the options and accessories detailed

herein. If a specific machine application requires additional options or accessories, contact

CLIMAX for assistance in obtaining the needed components.

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BB8100 Operating Manual

OVERVIEW

Model BB8100 Portable Boring Bar is a moving-head style line-boring machine. The 8"

(203 mm) diameter machine will bore 14.5-85.6" (368.3-2,174.2 mm) diameters and face

23.1-97.1" (586.7-2,466.3 mm) diameters.

Rotational drive assembly

The rotational drive assembly can be positioned anywhere along the bar.

Locking rings hold the assembly securely in place. Two torque arms

provide stability.

Mechanical axial feed assembly

Figure 2. Rotational

The tool head feeds axially along the bar using the mechanical axial

drive assembly

feed assembly.

CAUTION

If the mechanical axial feed unit is moved to the other end of

the bar, the machine will feed in the opposite direction. Check

the feed direction before operating the machine.

The 8" mechanical axial feed assembly can be

mounted to either end of the boring bar. Feed rate is

reversible and variable up to 0.040" (1.016 mm) per

revolution. Feed direction can be reversed or set to

Neutral by pulling or pushing the shifter knob.

Because the hand wheel component of the axial feed

assembly does not turn while the bar is rotating the

feed rate can be adjusted during operation.

Figure 3. Mechanical axial feed

The assembly includes a 15" (381 mm) trip rod.

assembly

P/N 57064, Rev. 9

Page 9

Hydraulic power

General description

The hydraulic power unit is an electrically driven piston pump with a horizontally mounted

motor. The unit has a 20-gpm pump and a 5-gallon (19 liter) reservoir.

Features include:

• Relief valve for system over pressure protection

• System pressure gage and shut-off valve

• Spin-on oil filter

• Combination fluid level and temperature gage

• Electric motor starter and motor overload heaters.

The hydraulic power unit connects to the rotational drive hydraulic motor with a pair of 25-

foot (7.6-meter) long hoses and quick disconnect fittings. A multi-function pendant controls

the power unit and the machine.

Several hydraulic power units are available. Obtain more information by calling CLIMAX.

CAUTION

To avoid damaging the power unit pump, connect the

hydraulic motor to the power unit before plugging in and

turning on the power unit.

Power unit pendant

The hydraulic power unit comes with a standard control pendant. The pendant, with

25-foot (7.6 m) cord, has the following controls:

• High/low volume control

• Jog/run

• Pressure start

• Pressure stop

• Power unit on

• Power unit off

Hydraulic motor

The high-torque low-speed hydraulic motor mounts directly to the rotational drive

assembly. Motor ports are 7/8-14 SAE O-ring type. Motor fittings are included with the

hydraulic power unit. A fitting kit may be purchased separately.

To reverse motor rotation, switch the hydraulic hoses at the motor. The hydraulic fluid that

passes through the motor lubricates the motor during operation.

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BB8100 Operating Manual

Motors with various displacement ratings are available. Contact your CLIMAX sales

representative for more information.

Bearing support assemblies

The portable boring bar can be set up using two ID-mount bearing assemblies, two end-

mount bearing assemblies, or a combination of bearing assemblies. Bearing support

assemblies can be placed anywhere along the bar.

NOTE

CLIMAX recommends using at least two bearing support

assemblies to ensure machine stability.

End-mount self-aligning bearing support assembly (with spider)

The end-mount bearing support assembly mounts to the end of the work piece through a

slotted spider. The bar is held in place by a self-aligning bearing which can compensate for

bar misalignment up to 1^o from perpendicular to the bearing housing.

The 2" (52 mm) thick support spider has four legs and a universal mounting-hole pattern.

The universal mounting-hole pattern allows you to set up the boring bar using existing bolt

holes (if available).

End-mount self-aligning bearing assembly (without spider)

The bearing assembly provides 4-way adjustable bar alignment. The assembly does not

include a spider; it mounts to any existing support structure. See Figure 40 on page 59 for

mounting pattern dimensions. A taper locking adapter secures the bar inside the bearing.

Figure 4. Self-aligning end mount with spider

Figure 5. Self-aligning end mount without spider

P/N 57064, Rev. 9

Page 11

ID-mount non self-aligning bearing support assembly (with spider)

The ID-mount bearing support assembly holds the bar in place with a taper locking

adapter. Center the bar by adjusting the four jaws on the spider. The jaws can be adjusted

from outside the bore.

Bearing support assemblies are available for bores with IDs from 23-77" (584-1,956 mm).

Figure 6. Non-self-aligning ID

Figure 7. Non-self-aligning ID

Figure 8. Non-self-aligning ID

mount with spider (20-35" 508-

mount with spider (34.25-49.25"

mount with spider (48.5-77"

889 mm)

870-1,251 mm)

1,232-1,956 mm)

Non self-aligning bearing assembly (without spider)

The bearing assembly does not include a spider; it mounts to any existing support

structure. See Figure 41 on page 59 for mounting dimensions. A taper locking adapter

secures the bar inside the bearing.

Clamp Collars

The clamp collars (P/N 40708) are made in

matching sets and must be used to secure the

bar when the machine is in the vertical

orientation. This will prevent the bar from sliding

through the support bearings or falling.

To prevent over tightening of the bearings, the

clamp collars should be placed above at least

two support bearings in a vertical orientation.

Figure 9. Clamp collar

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BB8100 Operating Manual

DANGER

To prevent the bar from sliding through the support

bearings, or falling, use the two clamp collars provided in

the tool kit when using the boring bar in a vertical

orientation. Torque to 100 ft.-lbs.

Boring bar and leadscrew assembly

Model BB8100 uses an 8" diameter bar. Standard bar lengths

are 8 feet to 20 feet (2.44 to 6.10 m) long in 2-foot (.61 m)

increments. Bars of other lengths are available upon request.

The chromed bars have full-length leadscrews. The bar end

caps have anti-friction leadscrew bearings. Because both bar

end caps are the same, the axial feed assembly can be

mounted to either end of the bar.

Figure 10. Boring bar

Axial tool carrier

The axial tool carrier holds the tool head assembly to the bar. The split-design carrier

mounts anywhere along the bar. Boring and facing head assemblies mount to the tool

carrier with screws and, if necessary, spacers. The tool carrier includes a brass nut and

drive key.

Manual boring head assembly

The boring head assembly includes spacers, leading and trailing cartridge holders, carbide

inserts and chip breakers. It requires an 8" (203 mm) tool carrier. Because the tool carrier

is split, the boring head can be mounted anywhere along the bar.

The boring head assembly will bore IDs in a range of 14.5-85.6" (368-2,174 mm),

depending on the number of stack blocks used. The carbide cartridges are micro

adjustable for precision boring. The range of diameters the boring head assembly will cut is

determined by the number of spacers mounted between the tool carrier and boring head.

See the boring head tool range in Table 2 on page 33 and Table 3 on page 34 to

determine how many spacers are needed for your application.

Facing head assembly

The facing head assembly mounts to the 8" (203 mm) tool carrier. Because the tool carrier

is split, the facing head can be mounted anywhere along the bar.

P/N 57064, Rev. 9

Page 13

Facing-head assemblies are available with 5" (127 mm), 8" (203.2 mm), or 12" (304.8 mm)

stroke. The range of diameters the machine can face is determined by both the number of

spacers used and the stroke of the facing head.

Feed rate is variable from 0.003-0.025" (0.076-0.635 mm) per revolution.

The facing head uses 1 square-inch tool bits.

Figure 11. Available facing heads and some mounting configurations

Refer to Table 5 on page 41, Table 6 on page 42, and Table 7 on page 43 (depending on

the travel head size) for the facing range of each.

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BB8100 Operating Manual

SETUP

WARNING

Rotating and moving parts can seriously injure the operator.

Turn off and lock out the machine before setting it up.

Before setting up the portable boring bar, decide where you will

place each assembly on the bar. Because the rotational drive

and tool head assemblies can be anywhere along the bar, make

sure to provide room for them when setting up the machine.

Boring bar and bearing support assembly

setup

Figure 12. Inserting the

bar into the bore

Clamp Collars

The clamp collars (P/N 40708) are made in matching sets and must be used to secure the

bar when the machine is in the vertical orientation.

P/N 57064, Rev. 9

Page 15

DANGER

To prevent the bar from sliding through the support bearings, or

falling, use the 2 clamp collars provided in the tool kit when using

the boring bar in a vertical orientation. Torque to 100 ft.-lbs (136

Nm).

CAUTION

At least two bearing support assemblies are needed to ensure

machine stability.

NOTE: The bearing mounts may be different styles, depending on application.

End-mount bearing support assembly setup

Though the end-mount bearing support assembly mounts to the outside of the work piece, it can

be placed anywhere along the boring bar.

CAUTION

Bearings placed too far apart allow the bar to deflect, reducing bore

accuracy.

1. Clean the bore of the work with solvent to remove grease, oil, and dirt.

2. Check the bar for nicks or cuts. Dress the bar smooth, if necessary. A bar

with nicks or gouges can damage mating parts (including the tool head

assembly and rotational drive unit) beyond repair. Clean the bar with solvent

to remove dirt and chips.

CAUTION

The bar is not hardened. To prevent damage to the bar, do not strike

it against the bearing supports or against the work piece.

3. Install the bearings at approximately the center

of the bar.

If using existing holes on your workpiece,

make sure they align with the slots in the

spider. Tap 5/8" (16 mm) or 1/2" (13 mm) new

holes if necessary.

If holes are to be tapped, hold the spider

against the work piece and mark the locations

of the slots in the spiders.

Figure 13. Attaching bearing

assemblies

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BB8100 Operating Manual

4. Slide the boring bar into the bearings to be machined (see Figure 15).

Figure 15. Boring bar into the bearings

5. Using a hoist, hold the bar and

bearings near the center of the

bore. Alignment should be within

1/8" (3 mm) (see Figure 14).

Figure 14. Centering and aligning the bar

WARNING

Swinging or falling machinery can seriously injure the

operator. Securely wrap the hoist around the bar and bearings

before lifting the machine.

6. If you want to mount the rotational drive assembly between the supports, do it

now. See the “Rotational drive assembly setup” on page 23 for mounting

information.

7. If mounting another end-mount bearing support assembly, repeat steps #4

through #10. If using an ID-mount bearing support assembly, see the “ID-

mount bearing support assembly setup” on page 19. At least two support

assemblies are needed to ensure machine stability.

8. Slide the boring bar through all bearing assemblies.

P/N 57064, Rev. 9

Page 17

NOTE

When completing the following steps, check after each

tightening of the socket set screw flat points (SSSFP) screws

for sufficient remaining set screw travel.

If there is insufficient travel remaining, loosen the SSSFP

screws. Remove the 1/4-28" hex heads (HHCS) and restart

from step a.

9. Lock the bar in place by tightening

the taper lock by doing the

following:

a) Tighten the taper lock nut onto

the bar.

b) Insert the 1/4-28" hex head

cap screws (HHCS) through

the lock nut and washer into

the taper. Leave them loose as

they are used to disassemble

the bearing after operation.

c) Tighten the 3/8-24" socket set

screw flat points (SSSFP) to

23 ft-lb. The purpose of this is

to tension the taper and nut to

clamp the bar.

Figure 16. Set screw and hex head screw

NOTE

The purpose of step c is to tension the taper and nut to clamp

the bar.

d) Rotate the bar one and a half rotations to seat the taper lock.

e) Repeat steps c and d until the torque remains at 23 ft-lb after one and a

half rotations.

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BB8100 Operating Manual

Figure 17. Tightening the bearing assemblies to the bar

NOTE

The six 1/4-28 hex head cap screws loosen the tapered lock

nut.

10. Precisely align the boring bar:

a) Position a dial indicator to check concentricity

between the boring bar and the bore.

b) Adjust the screws in the centering blocks until the

bar is centered.

Figure 18. Bearing

assembly

ID-mount bearing support assembly setup

Though the ID-mount bearing support assembly mounts inside the work piece, it can be placed

anywhere along the boring bar.

CAUTION

Bearings placed too far apart allow the bar to deflect, reducing

bore accuracy.

P/N 57064, Rev. 9

Page 19

Clean the bore with solvent to remove grease, oil, and dirt.

Examine the bar for nicks or cuts. Dress it smooth if necessary. A bar with

nicks or gouges can damage mating parts (including the tool carrier assembly

and rotational drive unit) beyond repair. Clean the bar with solvent to remove

dirt and chips.

CAUTION

The boring bar is not hardened. To prevent damage to the bar,

do not strike it against the bearing supports or the work piece.

Measure the diameter of the bore into which the bearing will fit. Using Table 1

on page 22, select the components required.

Position one bearing support

assembly on the bar. Tighten the

lock nut using the impact spanner

wrench in the tool kit.

a) Tighten the taper lock nut onto

the bar.

b) Insert the 1/4-28" hex head

cap screws (HHCS) through

the lock nut and washer into

the taper. Leave them loose as

they are used to disassemble

the bearing after operation.

c) Tighten the 3/8-24" socket set

screw flat points (SSSFP) to

23 ft-lb. The purpose of this is

to tension the taper and nut to

Figure 19. Positioning the bearing support

clamp the bar.

assembly on the bar

NOTE

The purpose of step c is to tension the taper and nut to clamp

the bar.

d) Rotate the bar one and a half rotations to seat the taper lock.

e) Repeat steps c and d until the torque remains at 23 ft-lb after one and a

half rotations.

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BB8100 Operating Manual

Slide the bar and bearing into the

workpiece.

Using a dial indicator and the jaw

crankshafts, center the bar in the

work piece. Turn the crankshafts

until the jaws are tight in the bore.

Do not exceed 22 ft-lbs (30 Nm) of

torque.

If you wish to mount the rotational

drive assembly between the

bearing supports, do it now. See

“Rotational drive assembly setup”

on page 23 for instructions.

If mounting another ID-mount

bearing, repeat Steps #3 through

#7. If mounting an end-mount

Figure 20. Insert the bar and bearing

bearing support assembly, see

“End-mount bearing support

assembly setup” on page 16.

CAUTION

Bearings placed too far apart allow the bar to deflect, reducing

bore accuracy.

Check that the bar is centered by sweeping a dial indicator inside the bore.

Adjust the jaws if necessary.

P/N 57064, Rev. 9

Page 21

Table 1. ID-mount bearing assembly bore diameter range

Bore diameter range inch (mm)

Parts required

Setup position

20.0 - 23.75 (508.0 - 603.3)

1, 2, 6

23.75 - 27.50 (603.3 - 698.5)

1, 2, 6

27.5 - 31.25 (689.5 - 793.8)

1, 2, 7

31.25 - 35.0 (793.8 - 889.0)

1, 2, 7

34.25 - 38.0 (870.0 - 965.2)

1, 3, 6

38.0 - 41.75 (965.2 - 1060.5)

1, 3, 6

41.75 - 45.5 (1060.5 - 1155.7)

1, 3, 7

45.5 - 49.25 (1155 - 1251.0)

1, 3, 7

48.5 - 52.25 (1231.9 - 1327.2)

1, 4, 6

52.25 - 56.0 (1327.2 - 1422.4)

1, 4, 6

56.0 - 59.75 (1422.4 - 1517.7)

1, 4, 7

59.75 - 63.5 (1517.7 - 1612.9)

1, 4, 7

62.75 - 66.5 (1593.9 - 1689.1)

1, 4, 5, 6

66.5 - 70.25 (1689.1 - 1784.4)

1, 4, 5, 6

70.25 - 74.0 (1784.4 - 1879.6)

1, 4, 5, 7

74.0 - 77.0 (1879.6 - 1955.8)

1, 4, 5, 7

Centering Block

Spider 20” - 35” (508 - 889 mm) diameter

Spider 34.75” - 49.25” (882.65 - 1250.95mm) diameter

Spider 48.5” - 63.5” (1231.9 - 1612.9mm)

Extension

Jaw 4.625 (117.47mm)

Jaw 8” (203.2mm)

Setup A

Setup B

Setup C

Setup D

Centering block

Extension closest to

Extension farthest

closest to the center

farthest from the

the center of the

from the center of

of the spider

center of the spider

spider

the spider

Page 22

BB8100 Operating Manual

Rotational drive assembly setup

The rotational drive assembly can be placed anywhere on the

boring bar.

Figure 21. Rotational drive

assembly

CAUTION

The boring bar is not hardened. To prevent damage, do not

strike it against the bearing supports or the work piece.

Mount the torque arms to the rotational drive housing

Mount the hydraulic motor to the rotational drive housing, if necessary. Check

that the mounting bolts are tight.

Loosen the socket-head screws. Push the locking rings out by screwing in

the four socket set screws.

Slide the rotational drive assembly along the boring bar.

Remove one of the locking rings to gain access to the RDU keyway.

Insert the drive key into the boring bar leadscrew groove. Check that the key

meshes with the leadscrew.

Slide the key along the groove and into the RDU keyway.

CAUTION

The rotational drive key must be in place before operating the

boring bar. Failure to do so may damage the machine.

Replace the locking ring after the key is installed.

Lock the rotational drive assembly to the bar by tightening the socket-head

cap screws.

NOTE

Tighten only the eight socket-head cap screws in the locking

rings, not the four setscrews. The setscrews loosen the

locking rings. Back out the setscrews before clamping the

rings to avoid damage to the rings.

P/N 57064, Rev. 9

Page 23

10. Secure the torque arms.

WARNING

Loose torque arms can swing uncontrollably injuring the

operator and damaging the machine. Secure the torque arms

to a stationary structure strong enough to withstand the full

torque of the rotational drive unit.

11. Connect the hydraulic motor lines to the hydraulic power unit.

CAUTION

To avoid damaging the hydraulic power unit pump, connect

the hydraulic motor to the power unit before plugging in and

turning on the power unit.

Mounting the axial feed assembly to the bar

The mechanical axial feed unit can be mounted to either end of the boring bar.

1. Place the axial feed unit in NEUTRAL so the leadscrew drive can rotate in

either direction. See “Setting the feed direction” for instructions.

2. While holding the axial feed unit against the bar end cap, turn the feed unit

output shaft until the hex in the end of the leadscrew engages

3. Tighten the two mounting bolts into the end cap to secure the feed assembly

to the bar.

4. Secure the axial feed unit stop rod to a stationary structure so it will trip the

feed mechanism. The rod should be sufficiently free to be removed if

necessary.

Page 24

BB8100 Operating Manual

Attaching the Mechanical Rapid Feed (optional equipment)

The optional mechanical rapid feed attachment fits between the axial feed assembly and the end

of the boring bar. It has a side port for a standard 7/16” drill socket, used to rapid advance the

feed. The lever engages and disengages the rapid feed system.

When engaged, access to the drill socket port is available. Access to this drill socket port opens

and closes when the lever is switched between servo and rapid feed mode. This prevents

operator error. When the servo is engaged, the drill socket will not fit into the port. Drawings and

part numbers are found in the following pages.

Rapid Advance is available using your hand drill and a 7/16" (11 mm) drive socket (included).

Typical rapid feed rates using your 0-400 RPM drill is 0.0-32" (0.0-813 mm)/min.

P/N 57064, Rev. 9

Page 25

Electric feed with rapid feed shown below for the BB7000/7100 model.

A special adaptor plate allows you to easily connect the electric feed/ mechanical gearbox

assembly to CLIMAX 3.5, 5, 6, and 8" (88.9, 127, 152.4, and 203.2 mm) boring bars. Adapters

are also available for competitive boring systems.

P/N 43735

Electric Feed Assembly for

3.5" (88.9 mm) diameter bar

BB6000/BB6100

P/N 43736

Electric Feed Assembly for

5 or 6" (127 or 152.4 mm) diameter

BB7000/BB7100 or BB8000/BB8100

bar

P/N 43734

Electric Feed Assembly for

8" (203.2 mm) diameter bar

BB8000/BB8100

Page 26

BB8100 Operating Manual

Mounting an optional electric axial feed assembly

The electric feed unit consists of the adaptor plate, manual override, electric motor assembly, and

remote pendant control.

The axial feed unit can be mounted to either end of the boring bar. The locating nose and hex nut

hole of the feed unit fit into the locating nose seat and protruding hex shaft of the boring bar end

cap.

1. Mount the adapter plate to the end of the bar using the ¾-10 cap screw and

two ½-13 cap screws.

2. Mount the mechanical override assembly to the adaptor plate. Make sure the

hex in the mechanical override is aligned with the hex on the lead screw.

3. Mount the electric axial feed assembly to the back of the mechanical override

with 4 cap screws.

4. Check that the keyway is aligned in the coupling.

5. Attach the pendant electrical cable to the rear of the electric axial feed.

NOTICE

If the axial feed unit is moved to the opposite end of

the bar, the feed direction will reverse. Check feed

direction before operating the machine.

Figure 22. Mounting the rapid feed electric axial feed assembly

P/N 57064, Rev. 9

Page 27

Setting the Axial Feed Rate

The feed potentiometer controls the axial feed rate. Turning the knob counterclockwise decreases

the feed rate; turning the knob clockwise increases the feed rate.

Axial feed rate is adjustable and variable from 0.010-0.500" (0.25-13 mm) per minute.

Setting the feed direction

Setting feed direction while the bar is rotating

The axial feed unit has three positions: NEUTRAL, FORWARD, and REVERSE.

1. To set the feed to FORWARD (tool feeds AWAY FROM the axial feed unit),

push and hold the shifter knob in toward the axial feed unit until you feel the

feed engage.

2. To set the feed to REVERSE, (tool feeds TOWARD the axial feed unit), pull

and hold the shifter knob out away from the axial feed unit until you feel the

feed engage.

3. To set the feed to NEUTRAL, position the shifter knob half way between

FORWARD and REVERSE.

NOTE

The higher the feed rate, the faster the axial feed unit will

engage.

Setting feed direction when the bar is stopped

1. Insert a 1/2" hex wrench into the hex hole in the dial.

2. While pushing or pulling the shifter handle, slightly turn the wrench 1/6 of a

turn or less.

3. When the feed is fully engaged, the hex wrench will turn only in the direction

the feed is set. If the feed is in NEUTRAL, the wrench will turn in either

direction.

WARNING

To avoid damage, check that the feed is fully engaged

before running the machine.

Disengaging the feed

1. Set the feed to zero or remove the axial feed stop rod to limit the tool feed.

2. If the bar is rotating, see ”Setting feed direction while the bar is rotating” on

page 28 for instructions to set the feed to NEUTRAL.

If the bar is not moving, see “Setting feed direction when the bar is stopped”

on page 28 for instructions to set the feed to NEUTRAL.

Page 28

BB8100 Operating Manual

3. Replace the stop rod, if necessary.

4. Check that the tooling is not moving.

Setting the feed rate

Axial feed rate is fully adjustable up to 0.040" (1.016 mm) per revolution.

Adjust the feed rate by lifting the spring plunger with one hand and turning the hand wheel with

the other. Turn clockwise to reduce the feed; counter-clockwise to increase the feed. The feed

can be adjusted while the bar is rotating.

CAUTION

The feed has solid stops at maximum and minimum feed

positions. To avoid damage, do not force the hand wheel past

the solid stops.

A feed dial on the axial feed unit shows the feed speed when the bar is rotating.

Tooling setup

Tool carrier setup

Tool head assemblies require a tool carrier to mount to the boring bar.

Do the following to mount the tool carrier:

1. Check the bar for nicks or cuts. Dress the bar smooth if necessary. A bar with

nicks or gouges can damage mating parts (including the tool head assembly

and the rotational drive unit) beyond repair. Clean the bar with solvent to

remove dirt and chips.

2. Position the carrier nut and carrier key inside the tool carrier.

3. Tighten the mounting screws.

4. Mount the two halves of the tool carrier onto the boring bar. Check that the

leadscrew nut engages with the leadscrew.

5. Tighten the socket-head cap screws.

6. Lightly oil the boring bar and leadscrew.

P/N 57064, Rev. 9

Page 29

To remove the brass nut

1. Do not remove all the screws.

2. Remove the screws on each corner of the brass nut.

3. If there is too much play in the brass nut, the center set screw can be

tightened.

To remove the brass nut

Figure 24. Screws to remove the brass nut

Boring

Manual boring head assembly setup

The manual boring assembly requires the tool carrier to mount it to the boring bar.

NOTE

The bar can rotate either direction. Check that the tooling

faces the correct direction.

Using the boring head tool range in Table 2 on page 33 and Table 3 on page 34, select

appropriate spacers and screws and assemble the tool carrier.

NOTE

Precision bores are best achieved by boring several rough

cuts and one shallow finish bore.

P/N 57064, Rev. 9

Page 31

NOTE

Parts listed are for one side of the carrier only. Identical

parts are required for the other side.

Micro Adjustment Boring Head

The micro-adjust boring head offers the possibility to micro-adjust readily available off-the-

shelf square shank tooling for boring. The micro-adjust travel is 0.5" (13 mm), and the

ability to slide the tool without having to change the setup provides a total tool travel of

more than 2" (per setup).

Figure 25. Micro-adjust boring head

To set the tool to the desired diameter, simply feed the dial screw until reaching it and then

lock the middle dove tail set screw with the provided T handle hex drive. Each division in

the dial screw resolves in 0.001" (0.025 mm) change in diameter. The dove tail adjustment

set screws are set to the correct load by CLIMAX and should not be necessary to re-adjust

them. These set screws have Vibratite-VC3 in order to avoid losing tension during

vibration. The lock also has this compound, and it might be necessary to re-apply some

every once in a while, if necessary.

The BB8100 comes with a 1 square-inch shank tool holder.

To set up leading and trailing, simply shift the boring heads against the mounting screws in

opposite directions.

There is a small set screw that stops the tool carriage from being removed from its holder,

and the boring head should never be operated without it on.

Page 32

BB8100 Operating Manual

Proper maintenance would involve cleaning and lubricating the dove tail surfaces and the

dial screw threads and groove, and if the lock set screw feels loose after a while, applying

the provided Vibrative vc-3.

Table 2. Micro adjust boring head tool range table

BB 8100 MICRO ADJUST BORING HEAD TOOL RANGE TABLE

14.5-85.6" (368-2,174 MM) DIAMETER

NUMBER OF SPACER BLOCKS REQUIRED

BORE RANGE DIAMETER

2.95" (76 mm)

5.9" (150 mm)

11.8" (300 mm)

block

14.5-21.5" (368-546 mm)¹

20.4-27.4" (518-696 mm)

26.3-33.3" (668-846 mm)

32.2-39.2" (818-996 mm)

38.1-45.1" (968-1,146 mm)

44-51" (1,118-1,295 mm)

49.9-56.9" (1,267-1,445 mm)

55.8-72.8" (1,417-1,849 mm)

61.7-68.7" (1,567-1,745 mm)

67.6-74.6" (1,717-1,895 mm)

73.5-80.5" (1,867-2,045 mm)

79.4-86.6" (2,017-2,200 mm)

¹ The tool holder must be shortened to avoid hitting the bar OD at the minimum diameter.

P/N 57064, Rev. 9

Page 33

Table 3. Solid tooling boring head tool range table

BB 8100 SOLID TOOLING BORING HEAD TOOL RANGE TABLE

14.5-86.6" (368-2,200 MM) DIAMETER

NUMBER OF SPACER BLOCKS REQUIRED

BORE RANGE DIAMETER

2.95" (76 mm)

5.9" (150 mm)

11.8" (300 mm)

block

14.5-22.5" (368-572 mm)²

20.4-28.4" (518-721 mm)

26.3-34.3" (668-871 mm)

32.2-40.2" (818-1,021 mm)

38.1-46.1" (968-1,171 mm)

44-52" (1,118-1,321 mm)

49.9-57.9" (1,267-1,471 mm)

55.8-73.8" (1,417-1,875 mm)

61.7-69.7" (1,567-1,770 mm)

67.6-75.6” (1,717-1,920 mm)

73.5-81.5" (1,867-2,070 mm)

79.4-86.6" (2,017-2,200 mm)

² The tool holder must be shortened to avoid hitting the bar OD at the minimum diameter.

Page 34

BB8100 Operating Manual

Facing head

Manual facing head assembly setup

The manual facing head attaches to the tool carrier on the boring bar.

1. Insert the tool holder into the facing head tool slide. Tighten the setscrews.

NOTE

The bar can rotate in either direction. Check that the tool bit is facing

the correct direction.

2. Adjust the tension of the gib by doing the following:

a) Crank the tool carrier until it is fully engaged with the slide.

b) Tighten the gib screws until there is noticeable drag on the slide. Unscrew

the setscrews slightly.

3. Retract the tool slide to protect the tool bit during setup.

4. Determine if spacers (from the boring head assembly) will be needed to face

the workpiece, referring to Table 5 on page 41, Table 6 on page 42, and

Table 7 on page 43 depending on the travel head size.

5. Mount the spacers, if necessary, to the tool carrier. CLIMAX recommends

using the same number of spacers on both sides of the tool carrier to ensure

smooth tool travel.

6. Mount the facing head to the tool carrier (or spacers) using mounting screws

from the boring head assembly. Secure the facing head with four 3/4-16

socket head cap screws (SHCSs), according to the following guidelines:

• Use 1.5" long SHCSs when bolting directly to the tool carrier or one of the

150- or 300-mm stack blocks.

• Use 4.5" long SHCSs when bolting with the 75-mm spacer.

7. Adjust the cutting tool depth. Precision cuts are best obtained by making

several rough cuts and one shallow finish pass.

Table 4 lists the available facing heads.

Table 4. Facing heads

Part number

Description

Range description

P/N 21115

5” travel

Table 5 on page 41

P/N 38654

8” travel heavy duty

Table 6 on page 42

P/N 22359

12” travel

Table 7 on page 43

Page 36

BB8100 Operating Manual

Figure 27. Facing head mounted directly to the tool

Figure 28. Facing head mounted with spacers to the

carrier

tool carrier

The facing head may mount directly to the tool carrier, or with spacers from the boring head stack

blocks as shown above.

Facing head radial feed

Radial feed is either manual or automatic. When the lid on the radial feed box is away from the

boring bar, the facing head will feed away from the center of the bar.

Setup

1. Select and assemble the appropriate configuration of spacers based on the

desired range, as specified in Table 5 on page 41.

2. Select the appropriate feed tools based on the following:

a) If no spacers are being used (see Figure 27), use the straight crank

handle and feed engagement knob to make manual adjustments and

engage the auto feed (see Figure 30 and Figure 31 on page 38).

b) If at least one spacer is being used (see Figure 28), use the feed box

crank to make manual adjustments and engage the auto feed. The feed

box crank is a combination tool that remains attached to the facing head

while in operation (see Figure 32 on page 38).

WARNING

Do not use the feed box crank if there are no spacers in the

configuration. This may damage the machine or the

workpiece if operated while attached.

P/N 57064, Rev. 9

Page 37

To manually feed the facing head

1. Disengage the feed box crank. The pins should

be retracted from the carrier feed ratchet slots

(see Figure 29).

NOTE

If the facing head is assembled without

spacers, remove the feed engagement knob

and mount the straight crank handle.

2. Turn the crank handle clockwise to feed the tool

Figure 29. Crank pins

out away from the center of the bar. Turn

disengaged

counter-clockwise to feed the tool in toward the

center of the bar. At the maximum recommended

torque rod angle of 15°, the automatic radial feed is infinitely variable up to

0.008" (0.2 mm) per trip.

NOTE

If the facing head is assembled without spacers, the straight crank

handle cannot turn a full revolution without striking the bar. Remove

and reattach as needed in order to complete each revolution.

Figure 30. Facing head

Figure 31. Facing head directly

Figure 32. Facing head mounted on

directly mounted with

mounted with feed engagement

spacers with feed box crank attached

straight crank handle

knob attached

attached

Page 38

BB8100 Operating Manual

To automatically feed the facing head

Engage the feed box crank handle. Push the pins firmly into the

carrier feed ratchet slots (see Figure 33).

NOTE

If the facing head is assembled without spacers,

first remove the straight crank handle, then mount

and engage the feed engagement knob.

To activate the feed ratchet, provide a trip mechanism for the steel

rod. Set the trip to move the rod no more than 15°. If a radial feed

Figure 33. Crank pins engaged

of more than 0.008" (0.2 mm) per revolution is desired, use multiple

trip mechanisms.

NOTE

CLIMAX recommends a maximum trip of 15^o.

To set the radial feed rate to less than 0.008" (0.2 mm) per revolution, move the trip mechanism

away from the center of the radial feed box. To increase the feed rate, move the trip mechanism

toward the center of the radial feed box.

Figure 34. Radial feed trip mechanism

P/N 57064, Rev. 9

Page 39

The feed trip arm must be tripped rotating clockwise relative to the feed box housing.

NOTICE

Actuating the feed trip arm in the opposite direction will result in machine

damage.

Use the feed trip arm according to the following principles:

• When the feed trip arm is oriented away from the boring bar, operate the bar in the

counter-clockwise direction (feed is radially in to out).

• When the feed trip arm is oriented toward the boring bar, operate the bar in the

clockwise direction (feed is radially out to in).

NOTICE

The trip arm must be facing away from the boring bar

when directly mounted to the tool carrier to ensure

clearance for the boring bar.

Figure 35. Feed trip arm and bar rotation

Page 40

BB8100 Operating Manual

Table 5 shows the facing range for the 5" (127 mm) travel head (P/N 21115).

Table 5. Facing Range for the 5" (127 mm) travel head (P/N 21115)

NUMBER OF BLOCKS REQUIRED FOR

THE THICKNESS SHOWN

USE 4.5" (114

RANGE

MM) SHCS

2.95"

5.9"

11.8"

(75 mm)

(150 mm)

(300 mm)

20.8-30.8"

(528.32-782.32 mm)

26.7-36.7"

Yes

(678.18-932.18 mm)

32.6--42.6"

(828.04-1,082.04 mm)

38.5--48.5"

Yes

(977.9-1,231.9 mm)

44.4--54.4"

(1,127.76-1,381.76 mm)

50.3--60.3"

Yes

(1,277.62-1,531.62 mm)

56.2--66.2"

(1,427.48-1,681.48 mm)

62.1--72.1"

Yes

(1,577.34-1,831.34 mm)

NOTICE

The facing ranges shown for these tables are calculated

with the tool feed radially out.

P/N 57064, Rev. 9

Page 41

Table 6 shows the facing range for the 8" (203 mm) travel head (P/N 38654).

Table 6. Facing range for the 8" (203 mm) travel head (P/N 38654)

NUMBER OF BLOCKS REQUIRED FOR

THE THICKNESS SHOWN

USE 4.5" (114

RANGE

MM) SHCS

2.95"

5.9"

11.8"

(75 mm)

(150 mm)

(300 mm)

20.8-36.8"

(528.32-934.72 mm)

26.7-42.7"

Yes

(678.18-1,084.58 mm)

32.6--48.6"

(828.04-1,234.44 mm)

38.5--54.5"

Yes

(977.9-1,384.3 mm)

44.4--60.4"

(1,127.76-1,534.16 mm)

50.3--66.3"

Yes

(1,277.62-1,684.02 mm)

56.2--72.2"

(1,427.48-1,833.88 mm)

62.1--78.1"

Yes

(1,577.34-1,983.74 mm)

NOTICE

The facing ranges shown for these tables are calculated

with the tool feed radially out.

Page 42

BB8100 Operating Manual

Table 7 shows the facing range for the 12" (305 mm) travel head (P/N 22359).

Table 7. Facing range for the 12" (305 mm) travel head (P/N 22359)

NUMBER OF BLOCKS REQUIRED FOR

THE THICKNESS SHOWN

USE 4.5" (114

RANGE

MM) SHCS

2.95"

5.9"

11.8"

(75 mm)

(150 mm)

(300 mm)

20.8-44.8"

(528.32-1,137.92 mm)

26.7-50.7"

Yes

(678.18-1,287.78 mm)

32.6--56.6"

(828.04-1,437.64 mm)

38.5--62.5"

Yes

(977.9-1,587.5 mm)

44.4--68.4"

(1,127.76-1,737.36 mm)

50.3--74.3"

Yes

(1,277.62-1,887.22 mm)

56.2--80.2"

(1,427.48-2,037.08 mm)

62.1--86.1"

Yes

(1,577.34-2,186.94 mm)

NOTICE

The facing ranges shown for these tables are calculated

with the tool feed radially out.

P/N 57064, Rev. 9

Page 43

Installing the facing slide arm onto the tool carrier

Figure 36. Facing slide arm dimensions

Install the slide arm onto the tool carrier

1. Using a device such as a crane, place arm onto tool carrier flush with carrier

surface as shown.

IMPORTANT

Always use the lifting eyes when lifting the arms. The

rotating lifting eyes provide the flexibility and safety

during setup operations.

2. Secure arm with the clamp bars (P/N 54551) with 3/4-16 x 2 screws (P/N

28757) - four per clamp bar and torque to 100 ft-lbs (135 Nm).

Page 44

BB8100 Operating Manual

DANGER

Failure to properly torque the four 3/4-16 x 2 SHCS (P/N 28757) to

150 ft-lb (210 Nm) can result in unexpected slippage of the tool

arm which can result in injury or be fatal.

Adjusting the tool carrier for

perpendicularity

The tool carrier is equipped with four set screws

that allow you to adjust the slide arm

perpendicularity if required.

Feedbox assembly

Mount and secure the feedbox with adapter plate

(P/N 54867), as shown in Figure 37.

Figure 37. Facing slide arm with feedbox

and adapter plate

Install the counterweight arm onto the tool carrier

1. Rotate the tool carrier on the bar to allow the counterweight arm to be

mounted on the receiving surface of the tool carrier.

2. Attach the lifting eye onto counterweight arm and install arm

IMPORTANT

Always use the lifting eyes when lifting the arms. The

rotating lifting eyes provide the flexibility and safety

during setup operations.

3. Using a lifting device such as a crane, lift the counterweight assembly to the

arm. Fasten the counterweight assembly to the arm using the 7/8-14 x 1-1/2

(P/N 53049).

Note that you can position the counterweight itself anywhere along the arm as needed to

balance the assembly.

P/N 57064, Rev. 9

Page 45

Hydraulic power preparation and connection

CAUTION

Before using the power unit, check pump rotation by jogging

the motor. The motor should rotate in the direction indicated

by the arrow on the pump.

1. Turn the power unit OFF.

2. Check that all fittings are clean.

3. Connect the hydraulic lines from the hydraulic motor to the power unit.

4. Jog the motor to see which direction the bar is rotating. Do the following to

reverse the bar rotation:

a) Turn off the hydraulic power unit.

b) Switch the hoses at the motor end.

5. Adjust the speed of the bar rotation by pressing the HIGH/LOW VOLUME

CONTROL button on the pendant.

CAUTION

To avoid damaging the pump and voiding the warranty,

connect the hydraulic motor to the power unit pump before

turning on the power unit.

Page 46

BB8100 Operating Manual

OPERATION

Pre-start checks

WARNING

Rotating machinery can cause serious injury. Turn off and lock

out power before making pre-start checks.

Before operating the portable boring bar

1. Tie down the rotational drive unit torque arms and the axial feed unit stop rod.

2. Check that all cutters are sharp and in good condition.

3. Secure fixed machine parts, including the tool carrier, tool head and cutting

tool. Check that moving parts move freely.

4. Check that the hydraulic power unit is OFF.

5. Check that the power unit wiring matches the electric power source. Plug the

power unit into a grounded outlet.

6. Check the power unit reservoir level. Fill the reservoir to above the red bar

with Mobil DTE-24 anti-wear hydraulic oil. Check that the power unit is level.

7. Clean the hydraulic hoses and fittings before connecting them.

8. Check that the electric pump motor on the hydraulic power unit is turning the

same way as the arrow on the case.

9. If the machine is setup in a vertical orientation, the clamp collars must be

installed for safety.

P/N 57064, Rev. 9

Page 47

Using the remote pendants

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

CAUTION

The bar rotation and the axial feed are independent of each

other. Check that the feed is OFF when the bar is not running.

Feed pendant

The following is a description of the Feed Pendant controls:

Symbol

Feature

Description

Feed speed

A momentary button which

override

overrides the feed rate

potentiometer and runs the axial

power feed at maximum rate,

regardless of the potentiometer

setting.

Feed Fwd /

A 3-position selector switch that

Rev

determines the direction of axial

feed. In neutral, power feed is

disengaged. The feed rate can

be adjusted or reversed during

Figure 38. Feedbox

operation.

pendant

Speed

The Feed potentiometer controls

the axial feed rate.

Counterclockwise decreases the

feed rate; clockwise increases

the feed rate.

CAUTION

Damage to the cutter, the boring machine and your work piece

may occur if the bar rotation is stopped while the power feed is

engaged and the cutting tool is in contact with the workpiece.

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BB8100 Operating Manual

HPU pendant

TIP

Additional information about the HPU function,

construction, and maintenance schedule can be

found in the HPU manual.

Feature

Description

Run/Jog

Runs or jogs the hydraulic power unit.

RPM

Increases or decreases the rotational speed.

Bar Off

Turns off the hydraulic power unit.

(red)

Bar On

Turns on the hydraulic power unit.

(green)

Off (red)

Turns off the electric motor.

On (blue)

Turns on the electric motor.

Figure 39. HPU pendant

Manual override (electrical feed only)

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

boring bar. When disengaged, a hand-drill can be installed for manual rapid operation. When the

gear box is in the manual override position, the pendant functions are not active.

CAUTION

Do not force the shift lever to engage. Forceful engagement

can damage the mechanical override mechanism.

To move the tool carrier rapidly, shift the feed lever on the top of the gearbox to the back position.

With a socket on the hexagon shaft, run with an electric drill or speed wrench. To re-engage the

feed, remove the socket, turn the feed on slow, and shift the feed lever to the forward position.

Clamp collars

The collars (P/N 40708) are made in matching sets and must be used to secure the bar when the

machine is in the vertical orientation.

P/N 57064, Rev. 9

Page 49

DANGER

To prevent the bar from sliding through the support bearings, or

falling, use the two clamp collars provided in the tool kit when

using the boring bar in a vertical orientation. Torque to 100 ft.-lbs

(13.6 Nm).

Starting the machine

WARNING

To avoid injury from flying chips or loud noise, wear

eye and ear protection while operating the machine.

1. Turn off and lock out the hydraulic power unit.

If boring:

a) Set the feed direction on the axial feed assembly. See “Setting the

feed direction” on page 29.

b) Set the feed rate on the axial feed assembly. See “Setting the feed

rate” on page 29.

If facing:

a) Set the feed direction on the axial feed assembly to NEUTRAL. See

“Setting the feed direction”

b) Adjust the automatic trip mechanism on the facing head. See “Facing

head radial feed”.

2. Press POWER UNITON at the hydraulic power unit pendant.

3. Press PRESSURE START at the pendant.

4. Adjust the bar rotation speed using the HIGH/LOW VOLUME CONTROL

knob on the pendant.

5. As cutting begins, lubricate the work piece and cutting tool with plenty of

cutting oil. Apply cutting oil with a squirt can or use an automatic mister.

Stopping the machine

WARNING

In case of emergency press POWER UNIT OFF on the

control pendant.

1. Press POWER UNIT OFF at the pendant to stop the power unit.

2. After all parts of the machine has stopped, use a brush to remove chips.

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BB8100 Operating Manual

WARNING

To avoid serious personal injury from flying chips, do not use

compressed air to remove chips.

3. If you will be machining the work piece again, see “Repetitive machining”. If

you are done machining, see “Disassembly”.

Repetitive machining

1. Reverse the tool head feed direction.

2. Manually or automatically feed the tool head back to where it started cutting.

3. Re-sharpen the tool bit or replace the carbide inserts, if necessary.

4. Using a dial indicator reset the tool bit cutting depth. Maximum recommended

cutting depth is 0.125" (3 mm).

5. Operate the boring bar as described in “Starting the machine” on page 50.

Disassembly

WARNING

The boring bar is not hardened. To prevent damage to the bar, do

not strike it against the bearing supports or the work piece.

Standard disassembly

1. Turn off and lock out the hydraulic power unit.

2. Unplug electrical cords and cables.

3. Disconnect the hydraulic hoses from the motor.

4. Remove the cutting tool from the tool head.

5. Remove the tool head and tool carrier.

6. Remove the axial feed assembly from the bar.

7. Securely support the boring bar, bearing supports, and rotational drive

assembly with hoists

8. If the rotational drive assembly is between bearing support assemblies,

remove one support first:

a) Loosen the bearing cartridge.

b) Loosen the support from the workpiece.

c) Remove the support from the bar.

9. Securing the rotational drive assembly with a hoist, loosen the eight socket-

head cap screws in the rotational drive assembly.

10. Push the locking rings out by screwing in the four setscrews.

P/N 57064, Rev. 9

Page 51

11. Remove one lock ring.

12. Remove the drive key.

13. Carefully slide the rotational drive assembly off the bar.

14. Loosen the bearing cartridges.

15. Remove the boring bar.

16. Remove all remaining bearing supports from the workpiece.

Alternative disassembly

In some cases, it is better to remove the bearings before removing the bar.

1. Turn off and lock out the hydraulic power unit.

2. Unplug all electric cords and cables, including the rotational drive assembly

fan cord.

3. Disconnect the hydraulic hoses from the motor.

4. Remove the tool bit or carbide cartridge from the tool head.

5. Remove the tool head and tool carrier.

6. Securely support the boring bar, bearing supports, and rotational drive

assembly with hoists.

7. Remove the axial feed assembly from the bar.

8. If the rotational drive assembly is between the bearing support assemblies,

remove one support first:

9. Loosen the bearing cartridge.

10. Loosen the bearing support from the workpiece.

11. Remove the bearing support from the bar.

12. Support the rotational drive assembly with a hoist. Loosen the eight socket-

head cap screws. Push out the locking rings by screwing in the four

setscrews. Remove one lock ring. Remove the drive key. Carefully slide the

rotational drive assembly off the bar.

13. Loosen the taper bore adapters in the bearings by doing the following:

a) Loosen the 3/8"-24 set screws (SSSFP).

b) Tighten the 1/4"-28 HHCS until the taper unseats.

c) Loosen and remove the 1/4"-28 HHCS. Note that the HHCS screws pull

the lock nut and taper out of the bearing mount.

d) Loosen and remove the taper nut.

14. Place a clean wooden “crib” in the bottom of the bore.

15. Remove the bearing supports from the workpiece.

16. Slide the bar out of the bore using the crib.

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BB8100 Operating Manual

MAINTENANCE

Recommended lubricants

LUBRICANT

BRAND

WHERE USED

Gear grease

UNOBA EP #0

Bearing cartridges

Rotation drive oil

Mobil SHC 634 Synthetic

Gear box cone drives

Light oil

LPS 2

Unpainted surfaces

Cutting oil

UNOCAL KOOLKUT

Tool bits, work piece

Way oil

Mobil VACTRA Heavy-Medium Way Oil

Dovetail ways

Hydraulic oil

Mobil DTE-24 Anti-wear hydraulic oil

Hydraulic power unit and motor

CAUTION

To avoid damage to the machine, only use recommended

lubricants.

Boring bar/leadscrew

Clean the leadscrew and boring bar frequently during operation. Keep chips away from the

leadscrew threads. Lubricate the leadscrew periodically with light oil to ensure smooth travel of

the rotational drive assembly. Before storage, lightly oil the bar to prevent rusting. Lightly grease

the leadscrew. Do not grease areas where chips can accumulate in the oils.

Axial feed assembly

Under normal conditions, the axial feed assembly is maintenance-free.

Rotational drive assembly

Under normal use, change the drive oil in the rotational drive gearbox every 500 hours with Mobil

600W Super Cylinder Oil (AGMA 7 Compounded) or equivalent.

Do the following to fill the gear box:

1. Using the lifting eye, set the gearbox upright. Secure the rotational drive unit

so it cannot move.

2. Remove the fill plug and oil plug.

3. Fill the rotational drive until oil overflows the oil plug hole.

4. Replace the oil plug.

5. Add one more quart of oil through the fill plug hole.

P/N 57064, Rev. 9

Page 53

6. Replace the fill plug.

Bearing support assembly

Under normal conditions, bearing assemblies are lubricated for life.

Before storage, lightly oil the assemblies to prevent rusting.

Tool head assembly

Manual boring head assembly

Lightly oil all parts to prevent rusting.

Manual facing head assembly

Before use and frequently during operation, lubricate the tool head carrier with way oil through the

grease fitting. Brush chips from the leadscrew frequently to prevent thread damage. Lightly oil the

leadscrew periodically to ensure smooth travel of the tool holder. When changing tool holders,

apply way oil to the dovetail ways.

Tool carrier

Lightly oil all parts with JET LUBE 550 to prevent rusting.

Hydraulic power unit and motor

General hydraulic system

After 72 hours of operation, do the following:

1. Replace the filter cartridge

2. Check the heat exchanger for leaks. Repair any leaks before running the

power unit.

3. Clean the filler/breather.

Hydraulic motor

The hydraulic motor is maintenance-free. Fluid passing through the motor lubricates internal

moving parts. To ensure long life and dependable operation, use high-quality clean hydraulic fluid

as described in “Hydraulic filter and fluid” on page 54.

Hydraulic filter and fluid

Though the hydraulic power unit requires little maintenance, changing the filter and fluid is

required for proper operation. Initially, change the filter after 72 hours of operation to remove

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BB8100 Operating Manual

impurities from the system. From then on, replace the filter every 150-200 hours. Use a high-

quality 10-micron industrial-grade filter. If the filtering system has a change-warning gage, replace

the filter whenever the gage indicates. Clean hydraulic fluid will help keep the power unit and

motor running properly.

The hydraulic fluid should be changed:

• When the oil becomes contaminated

• When the power unit is operated at high temperatures for a long time

• Every two years

Hydraulic fluid level should not drop below the red bar on the fluid level/temperature gage. Add

only filtered fluid to the system. Should hydraulic fluid leak out, do not put it back in the reservoir.

Use Mobil DTE-24 anti-wear hydraulic oil or equivalent. Recommended oil operating temperature

is 150^o F (66^o C).

WARNING

Connect the hydraulic motor to the power unit pump before turning on

the power unit. Failure to do so will damage the pump and void all

warranties.

P/N 57064, Rev. 9

Page 55

Troubleshooting

SYMPTOM

SOLUTION

Check the feed direction is set to the desired setting.

Clean the leadscrew.

Axial feed unit will not

Check that the feed rate is not too low.

advance the bar

Check that the axial feed unit is securely mounted to the

end of the bar.

Re-sharpen the tool bit or replace the carbide inserts.

Adjust the feed rate.

Chatter

Increase or decrease the hydraulic motor speed.

Change the cutter depth.

Tighten all clamps and hardware.

Machine is unstable

Provide additional support.

Check that the hydraulic power unit is turned on.

Check that the pump motor is turning in the correct

direction.

Rotational drive unit

will not rotate

Check the oil level in the power unit.

Check that the speed control is open.

Check the hydraulic hose connections.

Feeds in wrong

Check the handle position on the axial feed unit.

direction

Check the fluid level. Add more fluid if necessary.

Hydraulic power unit

Check that the pump motor is turning in the correct

fails to deliver fluid

direction.

Check hydraulic connections for plugs or leaks.

Check that the power unit and electrical supply are

compatible.

Hydraulic power unit

motor does not run

Check that the power unit is plugged in.

Check for faulty wiring.

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BB8100 Operating Manual

TOOL KIT AND SPARE PARTS

Table 8. Tool kit (P/N 54264)

P/N

DESCRIPTION

QTY

UOM

13052

WRENCH HEX BIT SOCKET 1/2 X 1/2 (KB)

Piece

14526

WRENCH SPEED HANDLE 1/2 DRIVE

Piece

14650

WRENCH END 1/2 COMBINATION LONG (KB)

Piece

15367

WRENCH STRAP 1-3/4 WIDE X 48 LONG

Piece

16793

WRENCH SOCKET 1/2 8 PT X 1/2 DRIVE

Piece

17437

WRENCH IMPACT SPANNER

Piece

19700

CONTAINER SHIPPING FLAT ROOF 20 X 8.75 X 10.5

Piece

20869

WRENCH HEX SET 5/64 TO 3/4 15 PIECES

Piece

40708

CLAMP COLLAR 8 ID TWO PIECE W/ SET SCREWS

Piece

57064

MANUAL INSTRUCTION BB8100

Piece

71729

WRENCH HEX 3/32 3.25 T-HANDLE

Piece

71730

WRENCH HEX 1/8 3.75 T-HANDLE

Piece

71731

WRENCH HEX 3/16 4.5 T-HANDLE

Piece

71732

WRENCH HEX 7/64 6.25 T-HANDLE

Piece

The listed spare parts are most frequently required due to wear, loss, or damage. To avoid

unscheduled down time, you may want to stock these items.

Table 9. Spare parts

PART NO.

DESCRIPTION

QTY

WHERE USED

17575

Nut leadscrew bearing adj.

11739

Thrust washer

10137

Thrust bearing

8" boring bar assembly

13179

Needle bearing

17616

O-ring

17617

O-ring

17448

4-5/8" Jaw

17449

8" Jaw

ID-mount bearing assembly

17700

Screw 5/8-18 x 5-1/2 SHCS

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BB8100 Operating Manual

PART NO.

DESCRIPTION

QTY

WHERE USED

11823

Thrust washer

10538

Thrust bearing

10858

Gear worm

17447

Crank shaft

10217

3/16 square key

14274

Thrust Washer

13174

Thrust bearing

17508

Worm nut

17520

Screw assembly jam feed

21053

Thrust washer

17007

Thrust washer

17507

Worm gear nut

10612

Snap ring

11739

Thrust washer

11158

5/8" Lifting eye

15208

5/8 Flat Washer

20390

Screw 5/8-11 x 6 SHCS

11696

Screw 1/2-13 x 3 SHCS

End-mount bearing assembly

26100

Screw 3/8-24 x 2 HHCS

26101

Screw 1/4-28 x 2 HHCS

20911

Screw 3/4-10 x 1-1/2 SSSFP

20133

Boring head cartridge size 10

15210

Screw 6-32 x 5/8 SHCS

15196

Clamp insert - size 10

15195

Chip breaker - size 10

Manual boring head assembly

17822

Carbide insert

23069

Tool holder - positive rake

23141

Chip breaker T3AE

18155

Carbide insert TPG 321 KC-850

13175

Thrust washer

13174

Thrust bearing

Manual Facing Head Assembly

14274

Thrust washer

P/N 57064, Rev. 9

Page 69

PART NO.

DESCRIPTION

QTY

WHERE USED

11165

Thrust washer

10538

Thrust bearing

10532

Bearing roller clutch

22357

Carbide insert SPU

23046

Chip breaker

25807

Filter element

Hydraulic power unit

14420

Hydraulic fluid

5 gal.

23662

Axial feed bar fuse

Mechanical Unit Axial feed

assembly Electric Unit

14303

Stop rod

17825

Carrier nut

10453

Screw 3/8-16 x 1-1/4 SHCS

17864

Carrier key

Tool carrier

10191

Screw 3/8-16 x 1 SHCS

11678

Screw 10-32 x 3/8 BHSCS

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BB8100 Operating Manual