Climax BW2600 Bedienungsanleitung
BW2600
AUTOBOREWELDER
BW2600 OPERATING MANUAL
ORIGINAL INSTRUCTIONS
P/N 85555
January 2019
Revision 6
P/N 85555, Rev. 6 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted, dissem-
inated, downloaded, or stored in any storage medium, without the express prior written consent of CLIMAX.
CLIMAX hereby grants permission to download a single copy of this manual and of any revision hereto onto
an electronic storage medium to be viewed and to print one copy of this manual or any revision hereto, pro-
vided that such electronic or printed copy of this manual or revision must contain the complete text of this
copyright notice and provided further that any unauthorized commercial distribution of this manual or any
revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
documentation@cpmt.com.
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected]. For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street
Newberg, Oregon 97132 USA
Telephone (worldwide): +1-503-538-2815
Toll-free (North America): 1-800-333-8311
Fax: 503-538-7600
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: +1-330-336-4550
Fax: 1-330-336-9159
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate
Bredbury Industrial Park
Horsfield Way
Stockport SK6 2SU, UK
Telephone: +44 (0) 161-406-1720
CLIMAX | H&S Tool (European Headquarters)
Am Langen Graben 8
52353 Düren, Germany
Telephone: +49 (0) 24-219-1770
E-mail: ClimaxEurope@cpmt.com
CLIMAX | H&S Tool (Asia Pacific
Headquarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: +65-9647-2289
Fax: +65-6801-0699
CLIMAX | H&S Tool (Middle East Headquarters)
Warehouse #5, Plot: 369 272
Um Sequim Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: +971-04-321-0328
Page B BW2600 Operating Manual
CLIMAX GLOBAL LOCATIONS
P/N 85555, Rev. 6 Page C
CE DOCUMENTATION
Page D BW2600 Operating Manual
LIMITED WARRANTY
CLIMAX Portable Machining & Welding Systems, Inc. (hereafter referred to as “CLIMAX”) warrants that
all new machines are free from defects in materials and workmanship. This warranty is available to the orig-
inal purchaser for a period of one year after delivery. If the original purchaser finds any defect in materials or
workmanship within the warranty period, the original purchaser should contact its factory representative and
return the entire machine, shipping prepaid, to the factory. CLIMAX will, at its option, either repair or
replace the defective machine at no charge and will return the machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor has
been performed properly. This warranty is available to the customer purchasing parts or labor for a period of
90 days after delivery of the part or repaired machine or 180 days on used machines and components. If the
customer purchasing parts or labor finds any defect in materials or workmanship within the warranty period,
the purchaser should contact its factory representative and return the part or repaired machine, shipping
prepaid, to the factory. CLIMAX will, at its option, either repair or replace the defective part and/or correct
any defect in the labor performed, both at no charge, and return the part or repaired machine shipping
prepaid.
These warranties do not apply to the following:
• Damage after the date of shipment not caused by defects in materials or workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability and
fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms control and
limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX cannot
guarantee that the information contained in this manual is correct for applications other than the application
described in this manual. Product specifications are subject to change without notice.
P/N 85555, Rev. 6 Page i
TABLE OF CONTENTS
CHAPTER/SECTION PAGE
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 HOW TO USE THIS MANUAL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.2 SAFETY ALERTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
1.3 GENERAL SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.4 MACHINE-SPECIFIC SAFETY PRECAUTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
1.5 RISK ASSESSMENT AND HAZARD MITIGATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.6 RISK ASSESSMENT CHECKLIST - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
1.7 LABELS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
1.8 LABEL LOCATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
2 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 FEATURES AND COMPONENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
2.1.1 Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
2.1.2 Stock components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
2.1.3 Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
2.2 CONTROLS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
2.3 MACHINE SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25
2.4 ITEMS REQUIRED BUT NOT SUPPLIED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26
3 SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 PREPARING THE MACHINE FOR USE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
3.1.1 Inspecting the machine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27
3.1.2 Assessing the work area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.2 LIFTING AND RIGGING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.3 INSTALLING THE BORE WELDER - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28
3.3.1 Mounting to a boring bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29
3.3.2 Installing the bore welder with an adjustable base - - - - - - - - - - - - - - - - - - - - - 38
3.3.3 Finishing the installation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42
3.4 INSTALLING ACCESSORIES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
3.4.1 Standard torch adapter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
3.4.2 Torch #00 and #0 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47
3.4.3 Torch extension support kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 48
4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 OPERATION MODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51
4.2 PRINCIPLES OF OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.3 PRE-OPERATION CHECKS- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
4.4 PREPARING THE BORE WELDER FOR WELDING - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.4.1 Setting the rotation speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
Page ii BW2600 Operating Manual
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
4.4.2 Setting the gas flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53
4.4.3 Setting the wire speed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.4.4 Checking the step setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
4.4.5 Attaching the weld ground clamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55
4.5 WELDING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.5.1 Welding safety during adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56
4.5.2 Weld interrupt options - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57
4.6 WELDING POINTERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.6.1 Arc voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58
4.6.2 Using 0.035" wire- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
4.6.3 Shielding gas- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
4.6.4 Wire and gas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
4.6.5 Spindle feed and wire location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
4.6.6 Welding in the horizontal axis - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 60
5 MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
5.1 OVERVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
5.2 MAINTENANCE INTERVALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.3 MAINTENANCE TASKS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.4 REPLACING LINERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
5.5 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.1 If the feed will not work - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.2 If there is a lack of fusion to the bore surface - - - - - - - - - - - - - - - - - - - - - - - 65
5.5.3 If the wire feeding stops and wire burns back to tip - - - - - - - - - - - - - - - - - - - - 65
5.5.4 If weld beads are “ropey” - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
5.5.5 If there is too much spatter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
5.5.6 If the weld is porous - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
5.5.7 If experiencing wire flip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 67
5.5.8 If steel weld deposits are too hard to machine - - - - - - - - - - - - - - - - - - - - - - - 68
5.5.9 If the weld is “graping” in the horizontal axis - - - - - - - - - - - - - - - - - - - - - - - - 68
5.5.10 If the weld voltage is hard to control - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
5.6 TRAINING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69
5.7 DECOMMISSIONING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 70
5.8 TOOL KIT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 71
6 STORAGE AND SHIPPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
6.1 STORAGE- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
6.1.1 Short-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
P/N 85555, Rev. 6 Page iii
TABLE OF CONTENTS (CONTINUED)
CHAPTER/SECTION PAGE
6.1.2 Long-term storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
6.2 SHIPPING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 73
APPENDIX A EXPLODED VIEWS AND PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
APPENDIX B SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Page iv BW2600 Operating Manual
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Inhaltsverzeichnis
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