BW3000 52815 Climax - MANUAL ENGLISH

BW
W3000 AutoBo
A oreWeld
der
OPE
ERATIO
ON & MA
AINTEN
NANCE MANUAL
Part No. 52
2815
July 2015
2
Serial Number:
N
BW30000 AutoBoreWeelder
BW
W3000
Table of
o Conten
nts
Safety Prrecautions .......................................................................................................................... 5
Warrantyy Information n ...................................................................................................................... 8
Introducttion to the BW W3000 ............................................................................................................ 9
Product Features
F .......................................................................................................................... 12
ations ................................................................................................................................ 13
Specifica
Major Asssemblies .......................................................................................................................... 14
Getting Started
S with the BW3000 0 .................................................................................................. 19
Setting Up
U the BW30 000 ................................................................................................................ 21
Operating the BW3000 ................................................................................................................. 30
Pre-Weld d Checklist ....................................................................................................................... 36
Starting, Stopping, and Interruptiing the Weld d Process ................................................................ 37
Using Auuto Skip ............................................................................................................................ 38
Using Piee Mode and Carriage Re eturn ........................................................................................... 39
Welding Pointers ........................................................................................................................... 41
Welding in the Horizo ontal Axis ....................................................................................................... 43
Optional Equipment ...................................................................................................................... 46
Torches and Torch Accessories
A ................................................................................................... 48
Consuma ables ................................................................................................................................ 51
Wirefeedder Accessorries ................................................................................................................ 52
Mountingg Accessorie es ................................................................................................................... 53
Cables and
a Conduits s ..................................................................................................................... 54
BoreWelder Accesso ories ............................................................................................................... 55
Maintenaance & Adjus stments ......................................................................................................... 56
Troublesshooting the BW3000 ....................................................................................................... 62
Troublesshooting Sum mmary ............................................................................................................ 67
Preparation for Shipp ping ............................................................................................................... 69
Storage ...................
. ...................................................................................................................... 70
Glossaryy ........................................................................................................................................ 71
Exploded d Views and Parts Lists .................................................................................................... 73
Quick Reeference ........................................................................................................................... 74
WARNING
For maximum
m sa
afety and peerformance, read and un nderstand the entire man nual
and all related sa afety instrucctions before
e using this equipment.
e Failure to fo
ollow
the instructions and guidelines in this manual co ould cause personal injjury,
fataliities or prope
erty damage e.
Copy
yright © 2015 Climax Porta
able Machinin
ng & Welding Systems, Incc.
Page 3 Parrt No. 52815 www.cclimaxportable
e.com
BW3000
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Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Page 4 Part No. 52815 www.climaxportable.com
BW3000
Safety Precautions
The primary challenge for most on-site maintenance is that repairs are often done under difficult
conditions.
Climax Portable Machining and Welding Systems, Inc. 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 scrutinizing the job site and closely following the operating procedures outlined in this
manual, your own company rules, and local regulations.
General Safety Practices

QUALIFIED PERSONNEL! AMBIENT LIGHTING
Before operating this machine, you must receive Do not operate this machine in ambient lighting
training specific to this machine from a qualified that is less than normal intensity.
trainer. If you are not familiar with the proper and
SECURE LOOSE CLOTHING AND LONG HAIR!
safe operation, do not use the machine.
OBEY WARNING LABELS! Rotating machinery can seriously injure an
operator as well as others close by. Don’t wear
Obey all warnings and warning labels. Failure to loose fitting clothing or jewelry. Tie back long
follow instructions or heed warnings could result hair or wear a hat.
in injury, or even be fatal. Proper care is your
HAZARDOUS ENVIRONMENTS
responsibility. Contact Climax immediately for
replacement of damaged or lost manuals or Do not use the machine in a hazardous
safety decals. 1-800-333-8311 environment, such as near explosive chemicals,
INTENDED USE flammable liquids, gasses, toxic fumes, or
inappropriate radiation hazards.
Only use the machine according to the
HOSES, PENDANT AND ELECTRICAL CABLES
instructions in this operating manual. Do not use
this machine for any purpose other than the Do not abuse the pendant cable as this can
intended use as described in this manual. When damage the cable and pedant. Never use the
using the tools, machine, accessories and/or cord for carrying, pulling or unplugging. Remove
tool bits, you must determine the proper working any and all kinks before straightening the cable.
conditions and the work to be performed. Keep cords and hoses away from heat, oil,
STAY CLEAR OF MOVING PARTS! sharp edges or moving parts. Plugs must match
the outlet. Never modify the plugs in any way.
Keep clear of the machine during operation. Do not use an adapter plug with grounded
Never lean toward or reach into the machine to power tools. Do not expose the machine to rain
remove chips or to adjust the machine while it is or wet conditions. Always examine hoses and
running. Keep bystanders away while operating cables for damage before use. Be cautious and
this machinery. never drop electrical equipment, this will
damage the components.
ROTATING MACHINERY
REPETITIVE MOTION
Rotating machinery can seriously injure an
operator. Lock out all power sources before you Individuals can be susceptible to disorders of the
interact with the machine. hands and arms when exposed to tasks that
involve highly repetitive motions and/or vibration.
KEEP YOUR WORK AREA CLEAN AND TIDY!
STAY ALERT
Keep all cords and hoses away from moving
parts during operation. Do not clutter the area Stay alert, watch what you are doing and use
around the machine. Keep the work area clean common sense when operating machinery. Do
and well lit. not operate machinery while you are tired or
under the influence of drugs, alcohol or
medication.

www.climaxportable.com Part No. 52815 Page 5
BW3000
Machine Specific Safety Practices

All aspects of the machine have been designed with safety in mind. Rotating parts are not always
shielded by machine components or by the work piece. Do not force the machine.
PERSONAL PROTECTIVE EQUIPMENT
Do not use the machine in a hazardous
Eye and hearing protection must be worn while environment, such as near explosive chemicals,
using the machine. These safety items do not toxic fumes, or a radiation hazard.
impose constraints to the safe operation of the RADIATION HAZARDS
machine.
There are no systems or components on this
OPERATING CONDITIONS
machine that are capable of producing hazardous
Do not operate the machine if it is not mounted to EMC, UV or other radiation hazards. The machine
the work piece as described in this manual. does not use lasers nor does it create hazardous
materials such as gasses or dust.
TOOLING
ADJUSTMENTS AND MAINTENANCE
The machine is provided with all the tools for the
setup and operation of the machine. Remove all All adjustments, lubrication and maintenance
adjustment tools before starting the machine. should be done with the machine stopped, and
locked out from all power sources. The shut-off
LIFTING valves should be locked and tagged out before
Most of the machine components are heavy and performing any maintenance. Do not operate the
must be moved or lifted with approved rigging and machine if moving parts are misaligned, binding or
practices. Climax accepts no responsibility for the broken. If the machine or parts are damaged,
selection of lifting equipment. Always follow your have the machine repaired before use.
plant’s procedures for lifting heavy objects. Do not WARNING LABELS
lift heavy objects by yourself as serious injury can
result. Warning labels are already attached to your
machine. Contact Climax immediately if
CUTTING TOOLS AND FLUIDS replacements are required.
There are no cutting or cooling fluids supplied with MAINTENANCE
this machine. Keep cutting tools sharp and clean.
Be sure the machine components are free of
CONTROLS debris and properly lubricated prior to use. Have
The machine controls are designed to withstand your machine serviced by a qualified repair
the rigors of normal use and external factors. The person using only identical replacement parts
on-off switches are clearly visible and identifiable. NOISE LEVEL
If hydraulic power supply failure occurs, be sure to
turn off the supply before leaving the machine. 85 dB(A) or higher – Hearing Protection is
required.
DANGER ZONE
STORED ENERGY
The operator and other persons can be anywhere
in the vicinity of the machine. The operator must Hydraulic fluids could still be under pressure!
ensure there are no other persons in danger from Make sure the HPU is shut off and locked out
the machine. properly.
METAL FRAGMENT HAZARD MSDS
The machine produces metallic fragments during Material Data Safety Sheets are included in the
normal operation. You should wear eye protection maintenance manual.
at all times when working with the machine. Only UNINTENTIONAL STARTING
remove fragments with a brush after the machine
has stopped completely. Prevent unintentional starting. The machine must
be properly locked out and/or shut down before
HAZARDOUS ENVIRONMENTS
maintenance.

BW
W3000
Safety Sign and

d Symboll Guidelin
nes
The purppose of product safety signs and sym
mbols is to in
ncrease the level of awa
areness to
possible dangers.
Safety alert symbols indicate DA ANGER, WA ARNING or CAUTION.
C T
These symbo ols may be used
u
nction with otther symbolss or pictogra
in conjun aphs. Failure
e to obey saffety warninggs can resultt in
serious in
njury or deatth. Always fo
ollow safety precautionss to reduce the risk of ha
azards and
serious in
njury.
DANGER
Indic
cates a haza
ardous situattion that could be fatal or cause serious injury.
WARNING
Indic
cates a potentially hazarrdous situatiion that could be fatal or
o cause serious
injury
y.
CAUTION
Indic
cates a pottentially hazzardous situ
uation that could resu
ult in minorr to
moderate injuryy, damage to the macchine or intterruption ofo an imporrtant
process.
IMPORTANT
Prov
vides critica
al informatio
on for the completion of a taskk. There is no
asso
ociated hazaard to people
e or the mach
hine.
INFORMATION
Prov
vides importa
ant informatiion regarding
g the machin
ne.
Copyyright © 2015 Climax Porta

able Machinin
www.climaxportable.co
om Parrt No. 52815 Page 7
BW3000
Warranty Information
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 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.
For quick and accurate service, please provide your factory representative with your name,
shipping address and telephone number, the machine model, serial number, and date of
purchase.
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.
Be sure to review the terms and conditions of sale which appear on the reverse side of your
invoice. Those provisions control and limit your rights with respect to the goods purchased from
Climax.
DISCLAIMER
Climax Portable Machining & Welding Systems, Inc. (hereafter referred to as “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.
All trademarks mentioned in this manual or other documentation provided with your Climax
product are trademarks or registered trademarks of their respective holders.

BW3000
Introduction to the BW3000
The BW3000 BoreWelder is an automated bore welding system with the following features:
 Variable step control for extended weld coverage.
 Auto Skip for designating weld-only or skip-only areas.
 Auto Stop and Position Indicator Collar to set stop and restart points.
 Quick disconnect system for quick setup and takedown.
 Dedicated wire feeder.
 Remote control of the power supply.
 High current limit.
 Precise angle control.
This chapter contains important safety information and a description of the product, its features,
its basic operation, and specifications. It also describes the parts of the BoreWelder.
Product Description and Basic Operation

The BW3000 BoreWelder is an automated welding device. It passes current, welding wire, and
metal inert gas (MIG) to a torch that moves in both rotary and axial directions. As the torch
moves, it deposits a continuous layer of metal (contiguous weld beads) around the bore’s
circumference to build up the surface. You can adjust the BoreWelder to differences in the bore
diameter by selecting a different torch and/or adjusting the Offset Head.
In addition, the BoreWelder has an Auto Skip function. With this function, you can set up the
BoreWelder to not weld a portion of the bore, such as a keyway, or to weld only a portion of the
bore, such as a worn section.
When you are setting up the BoreWelder you must:

 Attach the BoreWelder to the part to be welded.
 Align the BoreWelder to the bore.
 Determine the proper torch/bore clearance.
 Make the initial control settings.
When you are welding, you must:

 Start and stop the machine.
 Make minor adjustments in the rotational speed, voltage, and wire speed to maintain good
weld quality.

BW3000
Safety
As you would
w with alll welding pro
ocesses, ma ake sure thatt your skin an
nd eyes are properly
protectedd before usin
ng this equipment. Dama age to the skkin and eyes can result frrom both dire
rect
and indirrect exposuree to arc rayss. Protect you
urself and otthers accorddingly.
CAUTION
You must use protective eyee wear, protective
p clothing, weld d curtains, and
shiellds when ussing the BorreWelder to
o protect youurself and others
o from eye
and skin damage e. Damage can
c result frrom both dire
ect and indirrect exposurre to
arc rays.
r
Operatorrs are respon

nsible for pro
otecting them
mselves and
d others whe
en they are welding.
w Clim
max
strongly recommend
r s:
 The
e use of weld curtains and shields.
 Shade 3 sungla
asses with side
s shields for
f operatorss.
 A handheld
h we
eld helmet fo
or operators.
The handdheld helmet is held betwween the pro
ocess and thhe operator, allowing the e operator to
o
view the control box without raising a conven
ntional helme
et. It’s also easier
e to insp
pect the proccess
with a ha
andheld helm met, as you can
c hold the helmet nearr the process without bu umping into the
t
BoreWeld der or the pa
art you’re we
elding.
Generall Safety Precautions
 Set-up, maintenance, and operation
o of the BW3000
0 BoreWelde
er should be attempted by
b
qua
alified individ
duals only.
 Alte his machine must not be
erations to th e made witho
out written approval
a from
m Climax.
 Any parts need
ded for special applicatioons, alteratio
ons, repair, or
o servicing must
m be
app
proved in wrriting by Clim
max to avoid creating hazzardous con nditions.
 To ensure that nothing getss caught in rotating
r mem
mbers, avoid wearing loo
ose fitting
clo
othing and ke
eep hair back or in a capp when opera
ating the ma
achine.
 Turrn off the inp
put power be
efore changin
ng torches or working on
n the machin
ne.
 Re w all instructtions for the power supp
ead and follow ply unit you have
h chosen
n to use with the
BoreWelder.
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BW3000
Welding Safety Precautions

 The operator and any personnel observing the machine when in use must use a protective
shield with a filter and cover plates that conform to ANSI Z87.1 standards.
 The operator needs protective clothing, such as heavy shirts and cuffless pants made of a
durable flame-resistant material for protection from sparks and flame. Other personnel in
the area need to be protected from the arc rays by a screen and/or a warning not to watch
or otherwise expose themselves to the rays or to any hot spatter.
 Practice good housekeeping in the area around the BoreWelder.
 Keep combustibles or any other fire hazards well away from the work area. For in-shop
use, have a fire extinguisher readily available.

BW3000
Product Features
Patented “Step” Process
 Complete weld coverage at the start and finish of the bore.
 Infinite step size (and weld bead) adjustment from 0.025 inch (0.6 mm) to 0.220 inch (5.6
mm).
 Ability to step in either direction.
 Adjustable step location.
Auto Skip
 Ability to designate weld-only or skip-weld areas up to 180 degrees.
 Automatic skipping of keyways and intersecting bores.
 Automatic repair of out of round bores without pre-machining.
 Reduced repair, machining, and pre-machining time.
 Lower consumable and labor costs.
 Elimination of re-welding by skipping good sections of the bore.
Auto Stop and Position Marker

 The Auto Stop function lets you set a stop point so that the BoreWelder stops when the
bore is complete.
 The Position Marker recalls the last stop point.
Control Box
 When a Climax wire feeder is used, the control box provides:
 One central location for adjusting all BoreWelder functions.
 Remote control of the welding power supply.
Patented Torch and Extension System

 Quick disconnect system with a captive liner allowing for fast setup and takedown.
 Easy replacement of consumables without moving the BoreWelder.
 Quick readjustment for bores longer than the stroke of the machine.
175 Amp Current Limit

 Extended arc time for high productivity.
 Up to 5 pounds per hour of weld deposition.

BW
W3000
Speciification
ns
Specification Descrip
ption
WELDING PR
ROCESS Metal inert ga
as (MIG)
WIRE DIAMET
TER RANGE 0.023 to 0.04
45 inch (0.6 to 1 mm)
Bore: 0.88 to 27 inches (22 to 686 mm)
BUILDUP DIA
AMETER RANG
GES
Outside: 0.88
8 to 14 inches (22
( to 356 mm))
(STANDARD MODEL)
Face: 0.88 to
o 20 inches (22
2 to 508 mm)
UNSUPPORT TED TORCH REACH
R IN
60 inches (1.5 meter)
VERTICAL AX
XIS
LENGTH OF STROKE 6 inches (152
2 mm) and 12 inches (305 mm
m)
STEP RANGE
E 0.025 to 0.20
00 inch (0.6 to 5 mm)
MAXIMUM CO
ONTINUOUS WELDING
W
175 A
CURRENT
Constant volttage (CV)
WELDING PO
OWER REQUIR
RED 200 A minimu um
100% duty cyycle
CONTROL BO
OX POWER
100 to 120 VA
AC, 5 A, 60/50
0 Hz
REQUIREMENTS
REMOTE VOL
LTAGE AND CONTACTOR
C
10 K ohm pottentiometer and dry contact
CONTROL
TYPICAL WEL
LD VOLTAGE OPERATING
16 to 17.5 V
RANGE (SHO
ORT ARC/0.035
5 WIRE)
BoreWelder: 6 in. (152 mm)) stroke, 22 lb. (9.4 kg)
COMPONENT
T WEIGHTS Control Box: 18 lb. (8.10 kg)
Wirefeeder: 32
3 lb. (14.40 kgg)
Table 1: BW3000 BoreWelder

B Specifications (6-inch
h Stroke Mo
odel)
able Machinin
BW3000
Majorr Assem
mblies
BoreW
Welder
The Bore eWelder prov vides the circcular and axial motion ne
eeded to build up a bore. It also provvides
for the ro
otational pass
sage of curre hielding gas to the weldiing torch. Th
ent, welding wire, and sh he
figure below shows the BW3000 BoreWelderr and its major assemblie g the control box,
es, including
wirefeede er, and adjus
stable base..
Figure 1: BoreWeld
der and Majo
or Assembllies
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BW
W3000
Figure 2: Parts of th
he BoreWellder

able Machinin
BW3000
Contro
ol Box
The conttrol box conttrols all the welding
w functions. It conttains the mo
otor controlle
ers for the
wirefeedeer step and rotation, plus relays for gas solenoid d and powerr supply contactor contro ol.
entiometers allow you to
Four pote w speed, step size, and weld volttage.
o adjust rotation speed, wire
Control Cables. Theese cables connect

c the control
c box to
t the BoreW
Welder, wireffeeder, weld
ding
upply, and th
power su he 100 to 120V AC powe er.
Wirefeeder
The wireffeeder supports a standard 12 inch (305 mm) ro oll. The four- roll assemb
bly and shield
ding
gas solennoid are ope erated by the
e control boxx. wirefeederrs may be ennclosed (below left) or sh
hop
style (bellow right).
Wirefeedd Conduit. The

T wirefeed d conduit allo
ows passage e of wire and
d shielding gas
g from the
wirefeedeer to the BorreWelder. It’ss available in
n 2, 3, 4, 5, 10, and 15-fo 0.6, 0.9, 1.2, 1.5,
oot lengths (0
3, and 4.6 meters).
se. The gas hose
Gas Hos h conneccts the shield
ding gas (ine
ert gas) regullator to the wirefeeder.
w
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BW
W3000
Adjusttable Bas
se
The adjustable base enables quick setup and d provides support
s for th
he BoreWeld
der while also
o
allowing you to adjus st parallelism
m and centerring. The jack screws help keep the BoreWelder
parallel to
o the bore; the slider permits one axxis of fine centering adjusstments. The
e mounting rod
r
supports the BoreWe elder.
Figure 3: Adjustable Base & Mounting

M Ha
ardware
Radial Mount.
M The radial
r mountt is used to extend
e the diistance of the BoreWelder from the
mounting
g rod to the bore
b being welded.
w It’s also
a used to help center the
t BoreWellder.
ar, installed on the moun

Locking Collar. The locking colla nting rod, pre
events the BoreWelder
B from
own the mou
sliding do unting rod wh
hen the bore e axis is vertiical.

able Machinin
BW3000
Torche
es
The torch
hes attach too the Offset Head
H assem mbly using th
he Orientatio
on Fitting. Torches are
available
e to let you weld
w holes fro
om 0.5 to 56
6 inches (13 to 1422 mmm) in diamete er.
Torch Exxtensions. Torch
T extenssions allow th
he torch to enter
e into deep or remoteely located
holes. Th
he extension
ns come in 3-inch, 6-inchh, 12- inch, and
a 18-inch lengths
l (76, 152, 305, and
457 mm)). The extens a an indicator for setting the BoreW
sions can alsso be used as Welder paralle
el to
the bore.
Offset Head As
ssembly
The Offse et Head lets
s you change e the torch diameter with
hout changin ng the torch angle.
a By
allowing you to slide the torch an
nd change itss orientation, the Offset Head
H Assemmbly adjusts the
torch’s diameter rangge up to 3 incches (76 mmm).
Carryin
ng Case
The Bore
eWelder commes with an all-weather
a c
case that hass a customizzed interior to
t protect your
BoreWeld
der during sttorage or tra
ansportation..
Power Supply
To use th
he full potenttial of the BW
W3000 BoreW Welder, you should use a power sup pply that
generatees a continuo
ous welding current
c of 20
00 amps. Thee power suppply must bee a constant
voltage (CV) supply and
a should be b fitted with
h a remote voltage control receptacle
e.
The BW3 3000 comes equipped with
w a power supply contrrol cable tha
at interfaces the control box
b
and the power
p supply
y.
The powe
er cable (#2 welding cab
ble) transmitss welding current from th
he power sup
pply to the
BoreWeld
der.
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BW
W3000
Gettin
ng Startted with
h the BW
W3000
This chapter presentts procedure
es for setting
g up your BW
W3000 BoreW
Welder inclu
uding additio
onal
tools and
d equipment needed for setup. It expplains:
 The
e contents of
o the carryin
ng case.
 The
e type of mo
ounting syste
em used.
 Attaching the BoreWelder
B t the part to
to o be welded..
 Attaching the control
c box.
 Adjjusting paralllelism using
g the torch exxtension as a guide.
 Ce arse center).
entering with the torch exxtension (coa
 Insstalling a wellding torch and
a setting th
he clearance
e.
 Fin
ne centering with the adjustable base
e.
 Understanding
g the boring bar
b interface
e.
 Adjjusting the re
each.
 Attaching the wirefeed
w conduit and loading wire.
 Attaching the weld
w cables and
a gas hosse.
 Setting the axia
al and rotatio
onal start po
ositions.
Inspec
ction for in-shipme
ent dama
age
 Up
pon receiving
g your machine inspect the
t containe
ers for shippiing damage..
 Op
pen the conta
ainers and in
nspect the machine
m for shipping
s dam
mage.
 Check the item
ms you receivved against the items lissted on the in
nvoice.
IMPORTANT
Conttact Climaxx immediate
ely at 1-80
00-333-8311 concerning
g damaged
d or
miss
sing components.
Unpac
cking insttructions
 Wh
hen unpackin
ng the mach
hine, take ca
are not to dro
op or damag
ge the compo
onents.
 Use lifting eyes
s or slings to
o lift the com
mponents outt of the shipp
ping crate.
 Save the shipp
ping crate to store the machine when
n not in use..
CAUTION
The containers are designe ed to be lifte
ed only with
h the provided lifting po
oints
and with the con
ntainer fully closed. DO O NOT LIFT T with the container
c covvers
remo
oved.

able Machinin
BW3000
INFORMATION
Surfa
aces subjecct to corrosio
on were sprrayed with a rust preveentative prio
or to
shipm
ment (and possibly
p wra
apped in oil impregnate
ed paper). The
T user shoould
exercise caution
n while handdling the com
mponents provided
p sincce they mayy be
greasy and/or slippery.
Additio
onal Required Too
ols and Equipmen
E nt
The follow
wing list des
scribes the minimum
m add
ditional toolss required to
o complete a job. These tools
are not provided
p with
h the BoreWWelder.
 Ha
and-held welding helmet, shade #9.
 Safety glasses
s with side sh
hields, shade
e #3.
 Dia
agonal cutters.
 Adjjustable wre
ench.
 Sto
opwatch or wristwatch
w w second hand.
with h
 Shielding gas regulator.
r
 Shielding gas (for
( mild steeel, Climax reecommends mixtures of 75% argon//25% carbon n
dio
oxide for welding in the horizontal
h axxis and 92% argon/8% carbon
c dioxid
de for weldin
ng in
the
e vertical axis
s).
 We
elding wire (tthis chapter assumes the use of ER
R-70S-6).
 Ne
egative cable
e and “C” typ
pe clamp to connect
c the power supp
ply to the work piece.
 Sticck electrode
e holder and stick weldin
ng rod.
 We
eld power su
upply CC/CV
V 300 amp.
Conten
nts of the
e Carrying
g Case
The all-w
weather case e protects the
e BoreWelde ng you quickk access to the equipment.
er while givin
From thee top tray, rem
move the co ontrol box, ca
ables, gas ho olator pad. Frrom the bottom
ose, and iso
tray, remove the adju ustable basee, mounting rod,
r radial mount,
m lockingg collar, 1/2--13x3 inch bolt,
nut, and four spring washers.
w
Mounting Syste
em (When
n Not Usiing the Boring Barr Interfac
ce)
A 1/2-13xx3 inch bolt attaches the e BoreWelde er adjustablee base to the part being welded.
w Firstt,
you mustt weld the bo olt to the parrt. Climax reccommends stick
s weldingg, which provvides quick
setup and reliable pe erformance in rough envvironments. The T optional A-1086 sticck electrode
holder fitss quickly into
o the A-1097 7 positive weeld cable to allow stick welding.
w After the bolt is
welded to o the part, yoou secure th he adjustable e base to it as
a described d later.
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Setting Up the BW3000

Attaching the BW3000 using the Adjustable Base.
Figure 4: Attaching BoreWelder Using Adjustable Base
1. If you are using a radial mount, weld the 1/2-13x3 inch mounting bolt to a spot
approximately 14 inches (36 mm) from the center of the bore to be built up (the workpiece
bore).
2. If you aren’t using a radial mount, weld the mounting bolt to a spot approximately 11 inches
(28 mm) from the center of the bore.
3. Place the adjustable base plate over the mounting bolt as shown in the figure above.
4. Secure the adjustable base to the part by installing the four spring washers and nut (see
below). Tighten the nut one-half turn past finger tight with the 3/4 wrench provided.

BW3000
The sprin ng washers maintain con

nsistent presssure on the
e leveling scrrews while you
y adjust the
parallelissm.
1. Screw the mou
unting rod intto the slider hole and tig
ghten firmly. Torque
T to 15
5 foot pound
ds (2
kg--m).
2. Insstall the lockiing collar (10
0140) 8 inch
hes from the top of the mounting
m rod. This sets th
he
heiight of the BoreWelder and a preventss the equipmment from inaadvertently sliding down the
moounting rod.
3. If you
y are using
g a radial mo
ount (A-1023
3) (see below
w), install it over
o mountin
ng rod.
4. Slip
p the BoreW
Welder over th
he radial mo
ount.
5. Mo
ove the Bore
eWelder and radial moun
nt to bring the ad directly ovver the bore to
e Offset Hea
be welded.
Attach
hing the Control
C Box
1. Co
onnect the co
ontrol cabless as shown on
o Figure 1.
 Wirefeederr control cable.
 BoreWelde
er control cab
ble.
 Power supply control cable.
2. Co
onnect the AC
C power cab
ble to 115 VA
AC 60 Hz witth ground.
3. Swwitch the POW e control boxx to the ON position to
WER switch on the frontt panel of the
enssure operatioon. In the no he LEDs on the control bo
ormal power up cycle, th ox flash thre
ee
tim
mes, and thenn only the red
d LED and the arc interrrupt blue LEDD stay lit. If the
t control
cabbles aren’t plugged in, th
he LEDs con
ntinue to flash.
Adjustting Paralllelism Us
sing the Torch
T Ex
xtension as
a a Guid
de
1. Set the Offset Head
H assemmbly to zero offset
o by lining up the large hash ma
ark on the sid
de
pla
ate with the edge
e of the offset
o side (sshown beloww).
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2. To adjust paralllelism, install an extensiion into the Orientation

O F
Fitting, long enough
e to prroject
throough the borre to be weld
ded. Move th he BoreWeld der left or righ
ht until the attached
a
exttension nearrs the bore surface
s at the
e 3 o’clock or
o 9 o’clock position.
p Adju
ust the forwa ard
jacck screws on the adjustab ble base (see below) as necessary to o make the extension
e
parrallel to the bore.
b
3. Moove the BoreeWelder forw ward or back until the atta

ached extension nears the bore surfface
at the
t 6 o’clockk or 12 o’clocck position. Adjust
A the re
ear jack scre
ew as neede
ed to make th
he
exttension para
allel to the bo
ore.

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BW3000
Centerring the BoreWeld

B der with th
he Torch Extensio
on (Coars
se Centerr)
1. Maake slight adjjustments to
o the BoreWeelder and rad
dial mount too move the attached
a
exttension to the center of bore.
b Estima
ate the cente
er by eye or measure
m witth a scale.
2. Locck the BoreWWelder to the
e radial mount by tighten
ning the clam
mp knob on the
t BoreWelder
(15 mum torque).
5 ft/lb. maxim
3. Lig
ghtly tighten the
t radial mo
ount clamp knob
k to the mounting
m rod
d.
4. Re
emove the ex
xtension from
m the Orienta
ation Fitting..
Installiing a Wellding Torrch and Setting

S the
e Clearan
nce
1. Select the apprropriate torch
h for your pro
oject.
TORCCH WITH STAANDARD

TORCH WIT
TH 52FN DIF
FFUSER
TORCH USE
ED DIFFUSERR
ES IN INCHES (MM)
BORE SIZE
BORE SIZES
S IN INC
CHES (MM)
00 0.875–1.75 (22–44) –––

0 1.75–
–3 (4
44–76) –––
1 2.75–
–5.5 (70–140) 4.25–7.00 (10
08–178)
2 4.5–7.5 (114–191) 6.00–9.00 (15

52–229)
3 6–9 (152–229) 7.5–10.5 (19

91–267)
4 8–11 (2
203–279) 9.5–12.5 (24
41–318)
5 10–13
3 (2
254–330) 11.5–14.5 (29
92–368)
6 12–15
5 (305–381) 13.5–16.5 (34
43–419)
7 14–17
7 (356–432) 15.5–18.5 (39
94–470)
8 16–19
9 (4
406–483) 17.5–20.5 (44
45–521)
9 18–21
1 (4
457–533) 19.5–22.5 (49
95–572)
10 20–23
3 (508–584) 21.5–24.5 (54
46–622)
11 22–25
5 (559–635) 23.5–26.5 (59
97–673)
12 24–27
7 (610–686) 25.5–28.5 (64
48–724)
T
Table 2: Ava
ailable Torch
hes
WARNING
Rotaating machin nery can cauuse serious injury to the
e operator and
a bystand
ders.
Turnn off and locck out the machine
m befo
ore making the
t pre-startt checks. When
W
operrating the machine,
m alw
ways be awa are of the loocation of all people in the
vicinity of the ma
achine.
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2. Attach the torch (and exten nsions, if neeeded) to the BoreWelderr Orientation
n Fitting and
seccure the torc
ch in position
n with the 1.5
5 inch (38 mmm) Orientatio
on Nut, as sh
hown in the
figu
ure below.
IMPORTANT
Climax recomme ends that yo ou remove the Orientation Fitting from the Offfset
Head d when chan nging torche es. Spinning the Orientation Fitting onto
o the torcch is
easieer than rotatting the torch he fitting is fixed
h into the Orrientation Fittting when th
to the head.
CAUTION
Neveer use a wre ench or plierrs to adjust the
t knob on the Offset Head.
H A wre
ench
or pliers could da
amage the equipment.
e
The rangge of the torc

ch changes depending
d on
n which side of the offsett head the to
orch is orientted
toward.
3. Alig
gn the torch to the Offse et Head dove etail travel. Using
U the adjjustment kno
ob on the Offfset
Heead, shift the offset of the
e torch to adjjust the diammeter range. If the torch doesn’t fit th
he
borre as shown in the figure e, turn the to
orch and Orie entation Fitting clockwisee 180 degrees in
the
e slide. Thenn re-adjust thhe Offset Hea ad to its oppposite extrem
me to change e the range ofo
the
e torch.
4. Use the adjustment knob ono the Offsett Head to adjust the torch clearance to 1/4 inch (6
(
mm
m) from nozzzle to bore su
urface.

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INFORMATION
Turn
n the adjustm
ment knob with
w one hand while help
ping the slide
e along with the
thum
mb and finger of your oth
her hand.
Fine Centering with the Adjustab

ble Base
To center the BoreW Welder to the bore, you must work in two
t axes, onne after the other
o (we’ll refer
r
to them as
a X and Y forf this discuussion). The adjustable base
b lets you
u adjust the X-axis
X using a
slide and
d lead screw arrangemen nt and adjust the Y-axis by
b pivoting from
f the mouunting rod. For
F
the purpooses of this discussion,
d a
assume the adjustable base
b is pointting in the 6 o’clock posittion
when vieewed from the top.
1. Pre
ess the ROT TATE JOG bu utton or mannually rotate the Offset Head
H to rotate
e the torch frrom
the
e 6 o’clock po nt A) to the 12 o’clock po
osition (Poin osition (Pointt B). Make a mental note e of
the
e distance fro
om the torchh nozzle to th
he bore surfaace at these positions.
2. Turrn the adjusttment screw on the adjusstable base to
t center the
e torch betweeen Points A and
B. Move the sc crew clockwiise to move the
t slider awway from thee base and counterclockw
c wise
to move
m the slider toward the
t base. Acccuracy within 1/16 inch (1.6 mm) is sufficient forr
moost applicatioons.
3. Preess the ROT TATE JOG bu utton or man nually rotate the Offset Head
H to rotate
e the torch frrom
the osition (Pointt C) to the 9 o’clock position (Point D).
e 3 o’clock po D Make a mental
m note of
o the
disstance from the
t torch nozzzle to the bo ore surface at these possitions.
4. Looosen the raddial mount cla
amp knob an
nd pivot on the mountingg rod to cente er the torch
bettween Points s C and D. Accuracy
A within 1/16 inch
h (1.6 mm) is sufficient for
f most
appplications.
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5. Lock the radial mount clamp knob (15 ft/lb. maximum torque) to prevent movement of the
BoreWelder and subsequent loss of centering.
Understanding the Boring Bar Interface

A boring bar interface may be used instead of the Climax adjustable base (for full details, please
consult the operating manual from the boring bar manufacturer).
When using a boring bar interface in the horizontal axis, it’s helpful to position the interface so
the mounting rod is above the hole to be welded. This will ease centering adjustments since the
BoreWelder will be hanging from the mounting rod.
Centrality adjustment is normally limited to one axis: the Y or swing axis from the mounting rod.
The instructions above explain how to center on the Y axis.
In most cases the boring bar interface eliminates the need for parallelism adjustment, since the
interface is trued to the boring bar and, consequently, the bore. In situations where parallelism is
inaccurate, please refer to your boring bar manual for adjustment information or contact Climax
directly.
Adjusting the Reach

The BoreWelder should be positioned on the mounting rod so that the axial torch travel will reach
the beginning and end of the bore (if the bore is shorter than the stroke of the BoreWelder). You
have two options for positioning the BoreWelder.
Option 1: Add or remove extensions to change the reach without moving the BoreWelder on the
mounting rod.
Option 2: Slide the BoreWelder up or down the mounting rod.
Attaching the Wirefeed Conduit and Loading Wire

1. Attach the BoreWelder end of the wirefeed conduit to the swivel connector located at the
top of the BoreWelder by engaging the attachment nut. Tighten by hand only, as the seal is
obtained with an O-ring.
2. Open the wirefeeder case.

3. Loosen the thumb screw of the feeder conduit fitting.

BW3000
INFORMATION
If the
e wire does not feed fre eely: (a) Esp
pecially with the #00 an nd #0 torch, you
may need to mo omentarily inncrease the feed
f roll pre
essure by sqqueezing the
e roll
down n and forcin ng the feed wire
w through h the bent tiip. Apply pre
essure by hand
h
only.. (b) In otherr cases (not with the #0 and #00 torrches), the wire
w gets cau ught
at the “funnel” en ntrance of th
he contact tip
p. Stop presssing the WIRRE JOG switch.
Insteead, turn the e spindle a revolution or
o two. You’’ll hear a sn nap as the wire
w
work ks its way intto the contacct hole. Noww press the WIRE
W JOG switch.
s The wire
w
will pass
p freely th
hrough the torch.
t
4. Attach the wire efeeder end ofo the wirefe

eed conduit by
b inserting the
t end into the feeder
con
nduit fitting to
o a positive stop.
5. Secure the feeder conduit fitting with th
he thumb screw.
ace the roll of
6. Pla o wire on thee spool holde eed from the bottom of th
er so that the wire will fe he
rolll. Straighten about 6 inch
hes (152 mmm) of wire at the end of the roll to pre
epare for
fee
eding.
7. If your
y wirefeed
der is equipp
ped with the push/pull op
ption, place the
t toggle sw
witch in the
n before you go through the following steps.
norrmal position
8. Dissengage the pressure ro

olls on the wiirefeeder by flipping the lever(s) off the
t pressure
e roll
arm
m.
9. Thread the wire into the feed mechanissm inlet guid
de. Push the
e wire past th
he feed rollss and
into
o the conduiit fitting.
10. Engage the fee
ed roll presssure lever(s)..
ake sure the control box is ON, and press the WIRE
11. Ma W JOG sw
witch. The wire
w will be
pusshed through the wirefee
ed conduit and
a the BoreeWelder and on to the to
orch.
Attach
hing the Weld
W Cables and Gas
G Hose
e
Refer to Figure 1: Bo
oreWelder an
nd Major Asssemblies.
1. Attach one endd of the positive weld cable to the Bo
oreWelder quick
q connecct, and the other
endd to the pow
wer supply.
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2. Attach the negative weld cable

c to the part
p to be weelded. The ground
g clampp should be
atta
ached to cle
ean, bare me eing welded.
etal, and be located nearr the bore be
3. Attach one end
d of the gas hose to a re
egulated sou
urce of shield
ding gas, and the other end
e
to the
t quick connect at the
e wirefeeder.
4. Onn the control box, press the
t PURGE button to ch heck the gass flow rate an
nd clear the
sysstem of unwa 3 cfh (l m3/h
anted gasess. A flow of 35 hour) is good
d.
CAUTION
Alwaays use #2 weld cable. Do not use e a larger size
s to get a higher currrent
capaacity. Higherr currents wiill damage th
he BoreWelder. Make sures you havve a
goodd ground. Poor ground leads to po oor arc quaality, poor arrc stability, and
incre
eased risk off electrical sh
hock.
Setting
g the Axia
al and Ro
otational Start Pos
sitions
1. To set the axia al start position, jog the torch
t along its long axis until the nozzzle is positio
oned
pro t hole farthest from the BoreWeld
operly to starrt welding att the end of the der. Typicallyy, the
wirre is 1/16 to 1/8 inch (1.66 to 3.2 mm)) from the ennd. Welding always prog gresses towa ard
the
e BoreWelde er.
2. To set the rotation start po osition, push and hold the e ROTATION INITIALIZ ZE button on the
conntrol box unttil the torch stops
s rotatin
ng. This will be
b the rotatioon starting position
p for th
he
weeld. Starting here
h ensurees a complete e revolution of the torch before the step
s occurs,
the
ereby providiing complete e buildup at the very end d of the hole
e.
3. To change the rotation initialize point, reach into th
he square ho ole on the side of the red
d
shrroud and turrn the knurle
ed adjustablee step collar to the desire
ed location.
INFORMATION
If you are weldin
ng horizontaally, be sure
e to retract the starting point
p to rem
move
backklash from th
he gear train.
Afterr the step point
p is reacched, feed a foot or so
o of wire out of the to
orch,
remo d wire from inside the Bo
oving twisted oreWelder.
Do Not
N adjust th
he step collar while the machine
m is welding.
w

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Opera
ating the BW30
000
This chap
pter presentts procedure
es for welding
g with your BW3000
B BorreWelder:
 Understanding
g the control box.
 Choosing the control
c settin
ngs (including
g rotation sp
peed, wire sp
peed, step, arc
a voltage, and
shielding gas fllow rate).
 Pre
e-weld check
klist.
 Sta
arting, stopping, and inte
errupting the weld processs.
 Using Auto Skiip.
 Using Pie Mode and Carria
age Return.
 We
elding pointe
ers.
 We
elding in the horizontal axxis.
Unders
standing the Conttrol Box
Figure 5:
5 Control Box Panel
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PRESS THIS PRESS WITH FUNCTION KEY

TO DO THIS…
ALONE… TO…
Function Access the second function of a button

Purge Purge shielding gas
Jog wire at the speed set by the Wire Speed

Wire Jog Retract wire
dial
Rotate the spindle at the speed set by the

Rotate Reverse the direction of rotation
Rotation Speed dial
Rotate the spindle to the step point (start

Rotation Initialize Cycle step
Buttons
point)
Retract Jog the quill/spindle/torch away from the bore Toggle step enable
Extend Jog the quill/spindle/torch towards the bore Reverse step
Cycle through Auto Skip, Pie, and

Weld
Carriage Return
Follow all safety Start welding/stop welding.
Note: When Auto Skip is on, the Arc
instructions!
Interrupt light is blue.
Disable Auto Skip

Briefly stop welding, but maintain the
Arc Interrupt Note: When Auto Skip is off, the
motion of the BoreWelder
Arc Interrupt light is off.
Emergency Stop Disconnect the mains power
Step Size Sets the step size from 0.025 in. to 0.220 in. (0.6 mm to 5.6 mm)
Knobs
Rotation Speed Sets the rotation speed from 0.875 in. to 28 in. (22 mm to 711 mm) diameter bores
Wire Speed Sets the wire speed from 0.50 to 750 IPM
Arc Voltage Remotely controls the power supply arc voltage
Auto Skip RED when Auto Skip is On

Lights
Pie Mode BLUE when Pie Mode is On
Carriage Return GREEN when Carriage Return is On

Meter
Arc Voltmeter Reads the arc voltage at the BoreWelder head

BW3000
Choos
sing the Control
C Se
ettings
Setting Rotation Speed
S Usin
ng Travel Speed
S and SPR
Understa anding Rota ation Speedd. Rotation speed
s is how
w fast the sp
pindle of the BoreWelderr is
turning. Spindle
S spee
eds for the BoreWelder
B a so slow that they are
are e measured in seconds per
rotation (SPR),
( rathe
er than revolu
utions per minute
m (RPM).
Understa anding Travvel Speed. Travel
T speedd describes the speed at
a which the torch travelss
along the
e surface of the part bein
ng welded. The
T unit of measuremen
m nt is inches per
p minute (IIPM).
Typical trravel speeds
s for MIG bo
orewelding are
a between 18 and 22 IP PM.
When the e rotation sp
peed is corre
ectly set, the
e relationship
p between wire
w speed an nd step remaains
almost unchanged th hrough a widde range of applications.
a bles is important
. This reducttion of variab
to the success and speed
s of commpletion of a weld.
Estimating Rotation n Speed (SPPR). As a rule of thumb, in a 1 inch diameter
d bore, at 20 IPM
M
travel spe
eed, the SPR is 10 seco
onds. For evvery inch of bore
b diameteer, add 10 se
econds to yoour
SPR.
Example
e: 3.5 inch diiameter x 10
0 = 35 SPR @ 20 IPM
Calculatting Rotatio
on Speed (SPR) Exactly y. The diameeter of the bore and the target travel
PM) provide the information necessa
speed (IP ary to exactlly determine n speed (SPR).
e the rotation
Below is simple form
mula for quickkly determining SPR.
Diameterr x 10.4 = SP
PR @ 18 IPM
M [Vertical axis]
a
Diameterr x 9.4 = SPR @ 20 IPM
M
M [Horizontal axis]
Diameterr x 8.4 = SPR @ 22 IPM
Setting Rotation
R Sppeed on the Control Bo ox. To attain
n the correct ROTATION N SPEED dia al
setting fo
or the bore th
hat you are welding,
w Clim
max provide es a chart to show the cooarse settingg of
rotation speed.
s As a final check, a quick calcculation of SPR will provvide you with
h the actual
seconds per revolutio on. By holdin
ng down the e ROTATE button,
b c time the spindle rota
you can ation
easily annd make finaal adjustmentts to rotation
n speed.
INFORMATION
Operrators familiar with typiccal manual MIG
M welding g are used tot high curre
ents
and voltages, co ombined witth torch lead d angles annd weave movements.
m The
Bore
eWelder runss with lowerr currents an nd voltages,, neutral gun
n angle, and
d no
weavve motion. Therefore, travel spee ed is very important. Also since the
operrator is not in manual co t process, the norma
ontact with the al feedback loop
l
has been
b removed.
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DIAL SE
ETTING 0 1 2 3 4 5 6 7 8 9 10
SECOND
DS PER
290 254 173 110 72 49 3
32 22 1
15.5 11 8.5
REVOLU
UTION
BORE SIZE
S @20 IPM
M 31 30 18.3 11.6 7.6 5.2 3.3 2.3 1.6 1.2 0.9
Table 3: Rotation Speed Table
Setting
g Wire Sp
peed
Understa anding Wire e Speed. Wire
W speed is the rate at whichw the wire travels th
hrough the
BoreWelder system. The unit of measure is typically in in nches per minute
m (IPM). The amoun nt of
wire bein
ng used in th
he weld proccess requiress a certain amount of am mperage to create
c the arrc
and melt the wire. Wire
W speed an nd amperage e are directlyy proportional to each other. Most weld
w
power suupplies havee an ammete er, which rea
ads the amou unt of curren
nt (amperes)) being
generateed by the powwer supply while
w weldingg.
DIAL SE
ETTING 0 1 2 3 4 5 6 7 8 9 10
WIRE S PEED (IPM) 190 340

FOR STAANDARD 0 30 510 670
(120A) (
(160A)
WIREFEEEDER
WIRE SP
PEED (IPM) 160 24
40 330
FOR P USH/P
U ULL 0 10 90 400 490 580 630 630
(
(100A) (125
5A) (155A)
WIREFEEEDER
Table 4: Wire Speed

d Settings and
a Ampera
age (0.035 Diameter
D Wire)
Setting of
o Wire Spe eed. To measure the IPM
M of wire, se
et the WIRE SPEED dial to “2” (for
example)), depress th OG button forr 6 seconds,, and multiply that result by 10.
he WIRE JO
Examplee: 6 seconds of WIRE JO
OG equals 19 inches of wire
w in 10 minutes.
m Multtiply 19 by 10
0 to
get 190 IPM
I of wire.
If you sta
art welding at
a this dial se
etting, your amperage
a will be approxximately 120
0 amperes,
referencing the chartt above.
e BoreWelde
While the er can use different
d size welding wirres, Climax recommends
r s using 0.03
35-
inch weld
ding wire in most
m cases.
Typical Startup
S Wirre Speed Pa
arameters. The
T startup parameters
p address thee first one or two
rotations. After this, you
y increase
e wire speed
d and step to
o increase de
eposition.
INFORMATION
Regaardless of welding
w wire size, the 1775 amp currrent limit of the
t BoreWe
elder
sets the limit of deposition
d ra
ates for wire.

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BW3000
A
AXIS DIAL SETT
TING A
AMPERAGE WIRES PEED (IPM)
VER
RTICAL 2.0 to 3..0 120 to 160 190
0 to 340
HORIZONTAL 1.8 to 2..5 100 to 130 160

0 to 265
Table 5: Wire Speed

d at Startup
p (with 0.035
5 Diameter Wire)
Setting
g the Step
p
Understaanding Step p. Step is the amount off distance the BoreWelder automaticcally retractss
during on
ne revolution
n.
The rangge of step on
n the BW300 00 is infinitelyy adjustable
e from 0.025 inch (0.6 mm) to 0.220 inch
(5.6 mm)).You must verify
v by visu
ual inspectio on that the sttep value is correct, afte
er welding ha
as
been initiated. The ve
erification method
m is expplained below w.
ng Step. Step is set to an estimated
Estimatin e valuue before weldding.
STEP DIA
AL SETTING 1 2 3 4 5 6 7 8 9 10
STEP VALUE (INCH) 0.045 0.0

065 0.080 0.100 0.12
20 0.140 0
0.160 0.180
0 0.200 0.220
AMPERAGE 100 120

0 140 160
Table 6: Estimated Step Settin

ngs at a Trav
vel Speed of
o 20 IPM
INFORMATION
If the
e travel spee
ed is 20 inch
hes per minu
ute, the ampe
erage and step value in
inchees are nearlyy equal.
How to Tell
T If Step Is I Set Rightt. To visuallyy verify whetther step is set
s correctlyy, watch the
leading edge
e of the weld
w processs. The intentt is to have the
t weld bea ad lying direcctly in betwe
een
the previous bead an nd the base metal. If the e step is too short, lack of
o fusion to th
he base mettal
can result. If the stepp is too long,, lack of fusio
on to the pre
evious bead can result.
Setting
g Arc Voltage
Understaanding Arc Voltage. Arrc voltage is the length of
o the arc be
etween the molten
m puddle
and the end
e of the electrode, in this
t case, MIG wire.
The MIG process has four opera ating modes:: stubbing, short arc, glo obular transfeer, and spra ay. In
boreweldding, it is imp
portant to remmain in shorrt arc. This iss the lowest voltage posssible to attaain a
consistennt dynamic weld
w processs. If the volta
age is lowere ed below short arc mode e, stubbing will
w
occur (indicated by a very unstab ble inconsisttent weld pro ocess). To enter
e short arc mode, raiise
the voltag
ge. Any voltaage higher than
t short arrc mode can n result in sh
hortened tip life,
l loss of
current density,
d and possible lacck of fusion.
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W3000
Weld Po ower Supply y Remote Control Settings. When interfacing with

w weld po ower suppliess,
the follow
wing settings e addressed. Due to the wide variatio
s need to be on of power supplies it may
m
be necesssary to conssult the operrator’s manu
ual for your power
p supplyy or call Clim
max Techniccal
Support.
 Set the voltage
e control on the power supply to REMOTE.
 Set the contacttor control on
o the powerr supply to REMOTE,
R wh
here applicable.
Setting Arc
A Voltage e. The Clima ax control bo
ox interfaces with most power
p supplies, allowing
remote control
c of voltage at all times.
If your po
ower supply has digital readouts,
r se
et the arc voltage to 18.5
5 volts as a startup
s value
e.
If your po
ower supply has no digittal readouts,, wait until th
he arc is stru
uck and then
n adjust the
voltage to
o between 17 and 19 voolts.
You mayy need to re-adjust the ARC
A VOLTAG
GE dial as soon
s as you begin weldin
ng.
INFORMATION
The Climax mou unting mech hanism must be in conttact with the
e negative weld
w
potential to actua
ate the voltm
meter.
Choos
sing Shiellding Gas
s and Settting the Gas Flow
w Rate
Shielding Gas Typee. Shielding gas mixturess between 75%
7 argon/25% CO2 and 92% argon/8%
CO2 are normally us
sed with mild
d steel buildu
up.
GAS TY
YPE BEST USE
E PR
ROS CONS
Good control
c for
75/25
5 Weld
ding in horizo
ontal axis Generattes more spattter
uphill/downhill welding
Low spattter for long More fluiid puddle; harrder

92/8
8 Weld
ding in the verrtical axis
duration
n welding t control
to
Checking Flow Rate e. The shield

ding gas flow
w rates shou uld not excee
ed 35 cfh. To check the flow
rate, presss the PURG GE button. The
T gas sole enoid will ope
en for 10 secconds, allow
wing you to check
c
the flow rate
r and also
o clear unwaanted gasess from the syystem.

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BW3000
Pre-Weld Checklist
Now that all of your parameters are set on the control, take a minute to review the setup and
connections.
ITEM CHECK BOX
Weld positive connected to BoreWelder and weld power supply 

Weld negative connected to part and weld power supply 
Rotation speed set (ROTATION SPEED) 
Wire speed set (WIRE SPEED) 
Step set (STEP SIZE) 
Voltage set (ARC VOLTAGE) 
Shielding gas connected and on (PURGE) 
Torch at rotation initialize point (step point) 
Twisted wire fed out from BoreWelder (WIRE JOG) 
Quill retracted to correct position to start weld (RETRACT) 

BW
W3000
Startiing, Sto
opping, and Inte
erruptin
ng the Weld
W Pro
ocess
Startin
ng
To start welding,
w press the WELD button on the control box.
b
If stubbin
ng occurs, ra
aise the volta
age until the
e process sta
abilizes.
After the first rotation
n you should
d be able to view
v the placement of thhe weld bead d in relation to
the previous bead an nd the base metal. As mentioned
m ea t Tell If Step Is Set Right”
arlier (“How to
on page 32), the corrrect step is attained
a wheen the weld is
i evenly pla
aced betwee en the previoous
bead and d base meta al.
Normallyy, only adjusttments to ste
ep, wire spe
eed, and volttage are neccessary to maintain
m the
required weld deposits and feed necessary for f successfful boreweldiing.
WARNING
As with
w any arcc welding prrocess, you must use the
t approprriate light sh
hield
when n you make any visual inspection.
i A
Avoid both direct
d and in
ndirect expossure
to arrc rays.
Stoppiing
To stop welding,
w pres
ss the WELD
D button aga
ain.
Using Arc Interrrupt

Arc interrrupt lets you
u briefly stop the weld prrocess yet maintain
m all other weld mode function
ns.
For exammple, you can manually stop s the process when welding
w overr a grease hole.
1. Whhen your torcch approach hes an area you
y don’t wa
ant to weld, press the AR
RC INTERR
RUPT
buttton on the control
c box. Welding
W stops.
2. Re
elease the AR
RC INTERR
RUPT button. Welding re
esumes.
This proccedure mustt be repeated
d for each re
evolution until the area where
w weld is
i not to be
depositedd is passed. When you observe
o arc interrupt, make
m sure yo
ou use an ap
ppropriate lig
ght
shield.

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BW3000
Using Auto Skip

Auto Skip is, first, a way to automatically skip keyways. However, with a quick keystroke, the
Auto Skip system lets you fill in an out-of-round or worn section of a bore.
This function greatly increases productivity, as you can fix a worn section of the bore without
excessive pre-machining and subsequent borewelding to fill in the over-bored area.
You program the skip area using two cam disks on the top of the BoreWelder.
If keyways are to be avoided or worn sections are to be welded:
1. Make sure the BoreWelder is centered and parallel to the bore.
2. Rotate the torch manually or press the ROTATE button. Rotate to the beginning of the
“interrupt” or weld area.
3. Squeeze the outside diameter of the cam discs with the thumb and forefinger, and pull
away from the spindle, opening a low spot in the cam discs.
4. Rotate the discs until the AUTO SKIP switch just falls into the low area.
5. Rotate the torch as in Step 2 to the end of the interrupt area.
6. Hold the first disc where you set it in Step 3. Then move the other disc until the AUTO
SKIP switch actuates (that is, the switch rides up on the “high” leaving the low “interrupt”
area).
7. Re-check the disc settings by rotating the spindle through the “interrupt” zone in the
welding rotation direction.
Listen to the switch click or visually watch the switch actuate to verify the accuracy of your stops
and starts. Make all final adjustments before welding.

BW
W3000
Using
g Pie Mo
ode and
d Carriage Retu
urn
Hold dowwn the FUNC
CTION key and
a press the WELD buttton to cycle
e through three settings in
i
this order:
For exammple, if you wanted

w to go
o from the Auto Skip (the
e default pow
wer up settin
ng) to Carria
age
Return, you
y would ho old down thee FUNCTION N key and press the WE wice. To go from
ELD button tw
Carriage Return to Auto
A ou would hold down the FUNCTION key and pre
Skip, yo ess the WEL LD
button on
nce.
Pie Mo
ode
Pie mode
e is used to weld up worrn areas of bore
b in the vertical axis.
The follow
wing proceddure assume
es you have just powered up the con
ntrol and are
e in the Auto
o Skip
mode. To o use Pie Mo
ode:
1. Set up the BoreWelder as described in
n Chapter 2 and in this chapter.
c
2. Set the Auto Skip cams ass if you were going to skiip the worn section.
s
3. Wh hile you are not welding,, hold down the FUNCTIION key and
d press WEL
LD once (to cycle
c
from Auto Skip p to Pie Mode).
esume weldin
4. Re ng as you would for norm
mal borewelding.
The BoreeWelder will now weld back and fortth inside the worn area, stopping the e weld proce
ess,
stepping, then beginning weld ag gain in the opposite
o dire
ection at each end point. The weld
parameteers are contrrolled exactly the same as for norma al borewelding.
If multiple
e passes are e needed to ensure com mplete correcction of the worn
w bore, Climax
C
recomme ends startingg with a smaall pie section ening the pie for the seco
n for the first pass, wide ond
pass, and d so on. In this way, the stops and starts
s are hiddden undernneath the subbsequent be eads,
ng the machining processs.
simplifyin

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BW3000
Carriage Return
Carriage Return is used to weld up a worn area of a bore in the horizontal axis, when the worn
section occurs on the uphill or downhill side of the bore.
The following procedure assumes you have just powered up the control and are in the Auto Skip
mode. To use Carriage Return:
1. Set up the BoreWelder as described in Chapter 2 and in this chapter.
2. Set the Auto Skip cams as if you were going to skip the worn section.
3. While you are not welding, hold down the FUNCTION key and press WELD twice (to cycle
from Auto Skip to Carriage Return).
4. Set the rotation direction to the preferred weld direction for your application by holding
down the FUNCTION key and pressing the ROTATE button to toggle the rotation
direction.
5. Resume welding as you would for normal borewelding.
The BoreWelder welds in the rotation direction inside the worn area, until it reaches the end of
the set cam limit. It then stops welding and reverses rotation at full speed to the original starting
point while stepping. The weld and rotation begin again. All parameters are set as you would
with normal borewelding.

BW
W3000
Weldiing Poin
nters
Achiev
ving the Smoothes
S st and Le
east Viole
ent Arc Action
A
The length of time the BoreWeld der can be ussed continuo ously depends mostly on n spatter buildup
in the we
elding nozzle
e. Therefore, a main objeective when deciding wh hat kind of wire,
w gas, andd
power suupply to use is to choose
e the combin nation that produces the smoothest and least vio olent
arc action. Such a co
ombination tyypically prod
duces less spatter
s buildu
up and longe er welding times.
Wires witth higher deoxidizer con ntents usually work best.. Wires ER-7 70S-6 and ER-70S-2
E wo
ork
well. Anyy common in nert gas can be used; bu ut those with high argon contents aree preferred. A
mixture of
o 92% argon n/8% CO2 works
w well, as
a does 75% % argon/25% CO2. The former
f generally
is preferrred. Straightt argon or he
elium should not be used d for steel, and
a straight CO2
C producces
excessive spatter.
INFORMATION
ER-7
70S-2 is probably the better choice for multtilayer buildups becausse it
osits less silicon dioxide..
depo
Avoiding Wire Flip

F by Using a Wire
W with a Large Cast
C
The termm “wire flip” is
s used to describe an inherent condition in borewelding. The e spindle annd
t BoreWelder rotate around a non
torch of the nrotating wiree. Torque is applied to th
he wire by th
he
rotating torch,
t and is affected by a number ofo variables including, buut not limited
d to, extensio
on
lengths, stroke
s of maachine, cond
duit length, conduit
c shappe and configguration, orie
entation of
wirefeede er in relation
n to BoreWelder, and the e cast of the
e wire.
As the Bo oreWelder tu
urns, the wirre is twisted slightly betw
ween the torrch and the wirefeeder.
w T
This
twist (in extreme
e ses), unwinds once per revolution
cas r ass the torch progresses around the bo ore,
and prod duces a channge in the tra
ack of the we eld in a sma e bore. In exxtreme cases,
all area of the
“flip” can cause a voiid in the weld. Typically, there are no detrimenta al effects to the finished
product.
To avoid this problem
m, use a wire e with a larg
ge arc or “casst.” Cast is the
t diameterr of the circle
e that
akes on the floor in its re
a wire ma elaxed statee.
To checkk cast, cut ab
bout 4 feet (1.2 meters) from your ro oll of wire an
nd toss it on the floor. Th
he
cast diam
meter should d be as largee as possiblee and at leasst 40 inches (1 meter). Casts
C below 30
inches (0 ause difficulties. A cast of 40 inchess (1 meter) or
0.8 meter) arre likely to ca o more will
reduce or t effect of wire flip. Co
o eliminate the onsult with Climax if you are unable to t find large cast
wires.

able Machinin
BW3000
To reduce the chances of wire flip, take these steps:

1. Avoid an “S” shape in the conduit. A “C” shape is preferred.
2. Alternately, position the conduit as shown in the figure below. This method works
particularly well with long conduits.
3. If the wire has a tight cast and it still flips in this configuration, try tightening up the curve.
Long torch extensions tend to negate any benefit that this conduit shape (see figure
below) may have.
Cleaning Glass Inclusions from the Bore

Welding wire usually contains some silicon as a deoxidizer. During the welding process, this
changes to silicon dioxide (glass) and solidifies in clumps on the surface of the weld. These
clumps normally do not cause a problem; but when many layers of buildup are applied one on
top of another, the glass from the lower level is re-melted and added to the new glass, forming
larger glass clumps. It is therefore a good practice to clean the glass from the bore after two
layers have been applied.
Providing Appropriate Axial Movement Each Revolution

During welding, check that the STEP SIZE setting is providing appropriate axial movement
during each revolution. If the step is too great, the bead will appear ropy, and spaces may
appear between the beads. If the step is too little, the surface of the weld may appear smooth
and flaw-free but it may have fused poorly to the base metal. Make sure the arc is directed
slightly above the intersection point between the base metal and the previous bead.
At the beginning of the welding process, the first circular bead has no previously laid bead to
rely on for support and, therefore, is a different shape than those that follow. It is best if the first
step (at the end of the first revolution) is made slightly smaller than those that follow. An
alternative is to use a slightly slower wire speed or slightly higher rotation speed during the first
revolution.

BW
W3000
Weldiing in th
he Horiz
zontal Axis
A
Welding in the horizo ontal axis reqquires that you
y pay more attention to t the machine settings than
t
when we elding in the vertical axiss. In the horizzontal axis, the
t weld beaad must travvel through the
flat, verticcal-up, overhead, and vertical-down n positions. Flat
F and ove erhead positions of the bore
b
present non problems s for the BoreeWelder. Ho owever, vertiical-up and vertical-dow
v n positions may
m
be challe enging.
This secttion begins with
w a procedure for horizontal welding. This is followed
f by practical
p
suggestioons for vertic
cal-up and vertical-down
v n welding.
INFORMATION
Makee sure you’vve mastered vertical axiss bore buildu
up before yo
ou try weldin
ng in
the horizontal
h axxis.
Proced
dure for Horizonta
H al Axis Welding
W
Use the short
s arc MIG weld proccess. In most cases, it is the only pra
actical mode
e in which the
BoreWelder can be used
u successsfully for ho
orizontal weldding.
1. Alw
ways retract to the startin
ng location to
t eliminate backlash in the gear train.
2. The e first few beeads are the
e most critica
al. If the firstt bead is nott against a sh
houlder (or a
pre evious bead)), you must take
t special care to ensure that this
firsst bead is smmooth and evven. At the start,
s a reducced current
(wire speed) is s advisable (about 95 ammps for 0.030 0- inch wire
and d 110 amps for 0.035-inch wire). A normal
n to slightly fast
rota ational traveel speed is appropriate to
o promote fa ast freezing.
3. It also
a is advisa
able to set th
he step to a lower value for the first
steep because thet first bead d is smaller and
a flatter th
han those
thaat follow. Forr example:
 Set the step to 2.2.
 Set the first rotation to a wire speed of 110 amps.
 When the machine
m steps (at the be
eginning of the
t second
rotation), in
ncrease the wire
w speed to t 130 ampss.
 Before the next step, in
ncrease the step to 2.6.
 When the machine
m steps, increase
e the wire sp
peed to 150 amps.
a
 Before the next step, in
ncrease the step to 3.1.
 After the sttep occurs, visually
v verify
fy that the va
alue is correcct.

able Machinin
BW3000
Make any fine adjusttments need

ded to the ste
ep, then let the
t machine
e finish applyying the beads.
ginning of the weld is tre
If the beg eated in this manner, the
e weld can be
b deposited into the “V”
formed byb the bore surface
s and the
t previoussly depositedd weld metal. This “V” he
elps the weld
d
bead to stay
s in place
e by:
 Pro
oviding incre
eased heat sink
s area to freeze
f the weld.
w
 Forcing the bead into a mo
ore controllable shape so
o its surface
e tension can
n hold it in place.
Once thee buildup is started
s in this way, you can
c increase
e the weld cu
urrent. You should
s be ab
ble
to weld smoothly
s at 150
1 amps ussing 0.035- inch wire.
A shielding gas of 75
5% argon/255% CO2 help ps to control the weld pu
uddle by incrreasing the
freeze ra
ate. The CO22 increases the penetrattion into the workpiece. To
T decrease e spatter,
decreasee the CO2 inn the gas mixxture as low as 8%. (The b more difficult for the
e bead will be
beginnerr to manage..)
INFORMATION
Whe en doing mulltiple passess in the horizzontal axis, be
b sure to alternate rotaation
direc
ction betwee
en passes. This
T makes the uphill we eld of the seccond pass tra
avel
up ov oth downhill section of th
ver the smoo he first pass.
When bu uilding up a horizontal

h axxis bore, it’s important to
o eliminate any
a dirt or rust in the borre.
Rust tend ds to make the
t puddle more
m fluid annd harder to control. Thiss causes bead-to-bead
fusion prroblems that are accentuuated in the horizontal axxis.
Make surre the step size
s is large enough. Inssufficient step is one of the causes fo or lack of fussion
ase material. To be safe,, be sure the
to the ba e step size iss, if anything
g, too great rather
r than tooo
small.
Make surre rotation speed is fast enough to prevent
p the puddle
p from flowing ahead of the arcc. If
the weld puddle flowws ahead of thet arc on th he downhill, the
t weld bea ad may not adhere
a to the
base metal. This is a common ca ause for lackk of fusion on the downh peeds of 22 IPM
hill. Travel sp
are gene
erally sufficie
ent to prevennt this from happening.
h H
However, impurities in thhe base metal,
choices of
o shielding gas,
g excessive voltage, excessive amperage,
a o a combina
or ation of all the
above caan contributee to lack of fu
usion on thee downhill seection of the bore.
Do not alllow the arc voltage to climb too high
h. An arc voltage of 17 volts
v is norm
mal. A high
voltage (above 19) will
w make the e weld bead difficult to co
ontrol, especcially on the downhill sid
de.
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W3000
The inductance of the power sup pply plays an

n important part
p in horizo ontal buildup
p also. If the
e
power su upply has an
n INDUCTAN NCE control,, you can inccrease the innductance too help flatten
n out
the bead, make it bleend better, and,
a most important, kee e uphill side and
ep it from piling up on the
forming a tall narrow
w bead. Thesse tall narrow
w beads tend d to spill and
d expose neww base meta al for
the arc to
o gouge andd spill again.
Offset Head Settings Wh

hen Using Extens
sions in th
he Horizo
ontal Axis
s
In horizontal axis welding, when reaching with extension ns over 3 fee et (0.9 meterr), the weigh
ht of
the torch and extensions can pryy the slide fro
om its seat. In this case, the clampinng screws
should bee tightened to
t no greate
er that 20 incch pounds too lock the slid
de and bodyy together.
Considerr using the Torch

T Extenssion Supportt Kit when re
each extendss past 4 feett (1.2 meterss).

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BW3000
Optional Equipment
This chapter presents a brief overview of optional equipment for the BoreWelder and its major
components. The following table lists the optional equipment and related part numbers.
ITEM OPTIONAL EQUIPMENT PART NO.

TORCHES AND TORCH
Face Welding Torch 28186
ACCESSORIES
Compact Face Torch Consult Climax
Trammel Torch: standard 27013
Trammel Torch: 28 inches 38506

Trammel Torch: 56 inches 53004
Conical Seat Torch 28020
Extended Range Torch 13/24 34473
Adapter, Standard Torch to Trammel 36170
Counterbalance Kit 30756
Torch Extension Support Kit 33256
#1A Torch 39723
#000 Torch 39724
CONSUMABLES EZ Feed #0 and #00 Tips 35486
Heavy Duty Tips, Nozzles, and Diffusers Consult Climax
WIREFEEDER ACCESSORIES Push/Pull Option 44992
Wire Straightener (shop-style wirefeeder only) 35357
MOUNTING ACCESSORIES Radial Mount 5 Inch 31411
Radial Mount 10 Inch 35006
Mounting Rod Extender 30831
CABLES AND CONDUITS Stick Electrode Holder 36169
Positive Weld Cable, 90 Degree Connector 34345
2, 3, 4, 5, 10, and 15-Foot Conduits Consult Climax
Other Feeder Conduits Consult Climax
BoreWelder Cable Remote Step, No Rotate Consult Climax

BW3000
ITEM OPTIONAL EQUIPMENT PART NO.
BORE WELDER
Auto Skip Option (factory installed) 28000
ACCESSORIES
Slow Rotation Pulley and Belt 32574
Fast Rotation Motor Consult Climax
Plate, Offset Head Protector (Inverted Operation) Consult Climax

BW3000
Torches and Torch Accessories

Face Welding Torch
The Face Welding Torch is used to apply weld buildup on faces up to20 inches (508 mm) in
diameter. It welds in a spiral pattern, starting at the outside and working inward 0.166 inch (4
mm) with each revolution of the torch. It requires the use of two radial mounts and a mounting
rod extender.
It comes with:
 An alternate leadscrew for a finer spiral pattern (for horizontal axis applications)
 An over-center extension for reaching through a bore to weld inside faces
 A 2-inch (51-mm) torch extender to vary the range of the Face Torch
 Straight and angled torch heads
 Extra conduit and liner.
Compact Face Torch

The Compact Face Torch is designed with the boring bar user in mind.
The clearances required to operate this torch are reduced to 6 inches (152 mm) axial and 6
inches (152 mm) radial. The basis of operation is the same as for the Face Welding Torch.
Trammel Torch
The Trammel Torch can be used for both bore buildup and OD buildup.
The diameter range of the Trammel Torch when used for bore buildup is 9 to 18 inches (229 to
457 mm). The diameter range of the standard Trammel Torch when used for OD buildup is 0 to
14 inches (0 to 356 mm). Torch limitations when doing OD buildup restrict such buildup to about
10 inches (254 mm) from the end.
This torch can be ordered for 28 and 56-inch (0.7 and 1.4 meter) diameters. Radial mounts
equal to the radius of the bore should be fitted between the mounting rod and the BoreWelder.
The Trammel Torch requires a mounting rod extender.
The Trammel Torch is supplied with:
 A standard torch adapter for fitting of BW3000 torches and extensions (The standard torch
adapter fits the standard BW3000 torches to the Trammel Torch. This allows for a longer
reach.)
 A 2-inch (51 mm) torch extender for changing the Trammel Torch head location.
 Straight and angled torch heads.
 Extra conduit hose and liner.

BW3000
Conical Seat Torch

The Conical Seat Torch is designed to weld tapered bores from 10degrees taper to negative 10
degrees cone. The stroke of this torch is 4 inches (102 mm). The operation of this torch is
similar to the operation of the Face Torch, except for its variable angle of feed.
The diameter capability in its stock form is 3 to 20 inches (76 to 508 mm).
Use of one 10-inch (254 mm) or two 5-inch (127 mm) radial mounts is required for swing
clearance
Use of the mounting rod extender is required for axial clearance. Consult Climax for the
clearance required to use this torch.
Extended Range Torch #13/#24

This is a combination torch designed to span borewelding range of 28 to 56 inches (0.7 to 1.4
m).
Radial mount lengths equal to the radius of the bore must be used to provide swing clearance.
The slow rotation belt and pulley must be fitted to the BW3000 in order to attain correct output
spindle speeds.
Counterbalance Kit
This accessory provides counterbalance for the rotation drive when operating in the horizontal
axis. Use the counterbalance with BoreWelder torch #6 and with Face Welding, Trammel,
Extended Range, and Conical Seat Torches. This accessory maintains a consistent rotation
speed for the torch.
The counterbalance is normally installed on a 3-inch (76 mm) extension that is fitted between
the Offset Head and the torch being used. The weight is oriented opposite the torch, and should
be moved in or out on its arm until it balances the weight of the torch.
Torch Extension Support Kit

The Torch Extension Support Kit is used to provide extension and torch support when the
distance from the BoreWelder to the torch is far enough to make torch stability questionable and
alignment difficult.
This accessory is advisable when torch extensions reach over 4 feet (1.2 m) in the horizontal
axis.
The kit comes with a remote Offset Head and steady-rest.
#1A torch
This torch has an internal diameter of 3 to 5.5 inches (76 to 140 mm).
It’s designed to replace the #1 torch when exotic or highly alloyed wires and/or high preheats
are being used. This torch consists of a one- piece bronze body with the diffuser machined
directly into the torch body, enhancing heat transfer away from the contact tip.

BW3000
#000 Torch
The #000 torch is designed to work down to bore sizes of 0.5 inch (13 mm). The maximum
working depth of this torch is 5 inches (127 mm). The recommended wire has a 0.023 to 0.025-
inch (0.58 to 0.64-mm) diameter. Typical parameters are 60 to 80 amps and 13 to 14 volts.
Shielding gas can be fed from the opposite end of bore if applicable, or though the torch body if
the bore is blind.
The BW3000 BoreWelder must be fitted with a fast rotation motor to attain correct travel
speeds.
Climax recommends fitting the BW3000 with a push/pull wirefeeder to aid in feeding wire with
low column strength.

BW3000
Consumables
EZ Feed #0 and #00 Tips
EZ feed tips are used when feeding wire through the #0 or #00 torch is difficult.
Installation and use of these tips is the same as for the standard #0 and #00 tips.
Heavy-Duty Tips, Nozzles, and Diffusers

These parts can be fitted to bore torches and specialty torches to increase weld time when
you’re using wires other than mild steel.
These parts are available for all torches except the #0, #00, #000, and #1A torch.
Diffusers affect the maximum and minimum diameter ranges of the torches that they are fitted
to, as detailed on the torch range chart (Table 2).
Consumable Kit P/N 66947

PART NO. DESCRIPTION QTY UoM
36530 NOZZLE #00 TORCH END 1 Piece
36531 NOZZLE #0 BW TORCH 1 Piece
BOX PLASTIC TRANSLUCENT W/ ADJUSTABLE COMPARTMENTS 7 X

67174 1 Piece
3-5/8 X 1-5/8
69520 TIP WELDING #0 STANDARD (.035/.9mm) (KB) 5 Piece
69521 TIP WELDING #00 (.035/.9mm) (KB) 5 Piece
69778 DIFFUSER WELDING 5 Piece
69865 TIP WELDING (.035/.9mm) 25 Piece
70763 LABEL CONSUMABLES KIT BW3000 1 Piece

BW3000
Wireffeeder Accesso
A ories
Push/P
Pull Wireffeeder
The push h/pull option is an extra wirefeeder
w m
mounted to the
t top of the e BW3000. This
T wirefee
eder
is a single drive roll feeder
f that assists
a the main
m wirefeedder in feedin
ng wires with
h low column n
strength or wires that are difficultt to feed. To er must be push/
o use this opttion, the main wirefeede
pull capaable. The folllowing picturre shows a BoreWelder
B equipped with
w a push/p pull feeder.
Wire Straighten
S ner
The wire straightener is intended
d to reduce the
t bend (“ca ast”) in the welding
w wire to prevent wire
w
flip, which causes the
e weld to de
eviate from itts intended track.
t
With the wirefeed conduit discon nnected from
m the wirefee eder, the wire
e straightener is inserted
d
into the wirefeed
w mottor, oriented
d, and adjustted to attain a 60 to 70-in
nch (1.5 to 1.8
1 m) cast.
INFORMATION
The wire straighttener can be
e used only with
w the sho
op style wireffeeder.
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BW3000
Mounting Accessories
Radial Mounts (5 and 10 inch) (127 and 254 mm)
The radial mount accessory is used to distance the center line of the BoreWelder away from the
mounting rod. This is helpful when building up large diameter bores or pins. The mount is also
used when the accessory attached needs radial clearance to rotate without hitting the mounting
rod. Two lengths are available: 5 inches (127 mm) and 10 inches (254 mm).
Mounting Rod Extender

The mounting rod extender is used with the mounting rod to extend its length. This item is
commonly used when using the Face, Conical, or Trammel Torch to provide axial clearance
between the BoreWelder and the part.

BW3000
Cables and Conduits

Stick Electrode Holder
This cable plugs directly into the standard positive weld cable supplied with your BW3000. This
cable allows very quick changeover from borewelding to stick welding. As most modern power
supplies have both CV and CC capability, this attachment is very handy. This cable is essential
for attaching the adjustable base bolt, welding down boring bar bearing mounts, or touching up
un-welded sections of the bore.
Positive Weld Cable, 90 degree Connector

When attached to the BW3000, the positive weld cable with a 90 degree connector has an
overhead clearance of under 1/2 inch (13 mm), compared to 6 inches (152 mm) with the
standard positive weld cable. This cable is intended to plug into the standard positive weld
cable.
2, 3, 4, 5, 10, and 15 Foot Conduits (0.6 to 68.6 m)

There are multiple conduit lengths available for your borewelding application. Consider the
shortest conduit possible to lessen wire flip. Custom conduits are available for special
applications.
Non-Climax Feeder Conduits

Many different styles of conduits are available to attach the BoreWelder to wirefeeders other
than the Climax feeder. Most common brands of wirefeeders can be integrated with the Climax
BoreWelder. These conduits change the stock BW3000 system in the following ways:
 The weld current is transmitted through the conduit itself, to a junction block at the
BoreWelder end of the conduit. From the junction block there is a weld cable shunt that
transmits weld current to the positive weld connector.
 The wire speed control, voltage control, purge, and wire jog are inoperative when using a
non-Climax feeder.
 Conduit lengths range from 8 feet (1.8 m) to 15 feet (4.6 m).
 The Climax push/pull wirefeeder cannot be used with non-Climax feeders.

BW
W3000
BoreW
Welder Access
sories
Slow Rotation
R Pulley
P an
nd Belt
The slow
w rotation pulley and beltt are fitted to
o the BoreWelder rotatio
on drive when the diameter to
be welde
ed is over 27
7 inches (686 6 mm) in dia ameter. Wheen these partts are installed, the rotattion
speed (spindle speedd) is 50 perccent of the original speedd. The final output
o dle speed allows
spind
welding of
o diameterss from 1.75 innches to 54 inches (44 mm m to 1372 mm).
INFORMATION
Insta
allation requ
uires partiall disassemb bly and should be haandled onlyy by
nnel with insstruction from Climax to
qualiified person o prevent damage
d to your
y
BoreeWelder.
Fast Rotation
R Motor
M
The fast rotation mottor can be fittted to the BoreWelder
B r
rotation drive
e when the diameter
d to be
b
welded iss under 0.87
75 inches (22 2 mm). Whe en installed, the spindle speed
s ple the original
is trip
speed. The
T final outp put spindle speed
s allowss welding of diameters frrom 0.5 inchhes to 9.3 incches
(13 mm to
t 236 mm) at a a travel sp peed of 20 IPM.
INFORMATION
Insta
allation requ
uires partiall disassemb bly and should be haandled onlyy by
nnel with insstruction from Climax to
qualiified person o prevent damage
d to your
y
BoreeWelder.
Plate, Offset
O He
ead Prote
ector (Inv
verted Op
peration)
This shie
eld is designed to protecct the rack an
nd rack slot from
f spatterr when the BoreWelder
B i
is
used in the inverted position.
eld mounts over
This shie o the Orie
entation Fittin
ng on the Offfset Head slide.

able Machinin
BW3000
Mainttenance
e & Adju
ustmentts
CAUTION
Failu
ure to propeerly maintain the mach
hine will ressult in prem
mature wear or
damage to the machine.
m Damaged caussed by impro oper or inade
equate mach
hine
mainntenance is not
n covered by the machhine limited warranty.
w
This chapter presentts routine ma

aintenance and
a adjustments for the BoreWelderr, wirefeederr,
torches, conduits, ca
ables, and co
ontrol box.
BoreW
Welder Ma
aintenanc
ce
The BoreeWelder requires little maintenance
m when prope erly cared forr. Preventative maintena
ance
is the mo
ost effective means of atttaining a lon
ng service liffe.
Daily Maintenance
e
Daily maintenance consists prim marily of keep ping the Bore eWelder clean and prote ected. The
BoreWelder is designned to survivve in industrrial environm ments that arre usually du
usty and grittty;
however, it has close
e fitting partss and will lasst longer if ke
ept clean.
The quill and Offset Head
H provid
de sliding mo
ovement. For this reason
n, you should clean both
h
items daily under norrmal use.
Quill. A clean
c shop towel
t lightly sprayed withh a lubricantt such as WD D-
40™, can n be used to
o remove iron oxide (and d any other foreign
f
materialss) deposited on the quill from the we eld process. Be sure to wipew
off any exxcess lubric
cant with a cllean cloth. This
T p the quill sliding
will keep
freely in the
t quill possitioner. Avoiid using an excessive
e am
mount of a sticky
s
lubricant that may tra
ap foreign materials.
m Avo oid spraying Anti Spatter on
the quill tube.
t
Offset Head. After use, use a cle
ean shop tow wel, lightly sprayed
s with
lubricant such as WDD-40™, to clean the matting surface of the Offse et
Head asssembly. It’s best to move
e the slide to ent of travel in both direcctions and clean
o its full exte
the exposed area of the body doovetail face.
Orientation Fitting and
a Nut. Ma ake sure tha g area of the Orientation Fitting and Nut
at the mating
ee of spatter and dirt.
is kept fre
Replacing the BorreWelder Liner
L
1. Set the Offset Head to zero
o offset.
emove the sw
2. Re wivel couplin
ng and loose
en the liner set
s screw in the Offset Head
H slide.
3. Push the liner out of the to
op of the spin
ndle.
emove the sp
4. Re pindle condu
uit fitting from
m the old line
er and install it onto a ne
ew liner of th
he
corrrect length.
5. Slid
de the liner into
i the spin
ndle and then n into the Offfset Head. The
T liner sho ould be flushh in
the
e Offset Head slide, Orie entation Fittin
ng counterbo ore. At the to
op of the spiindle, the sp
pindle
connduit fitting should
s rest 1/8
1 inch (3 mm)
m below th he top of thee spindle.
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BW
W3000
6. Re
einstall the sw
wivel couplin
ng, and torqu
ue to 20 foot pounds.
BoreW
Welder Ad
djustmentts
There are
e only two adjustments
a that require your attentio
on: the Offse
et Head and
d the quick
f the positive weld atta
connect for achment.
Offset Head
H Dovetail Adjusttments
The dove etail of the Offset
O Head must
m be adju
usted so thee slide memb ber
presses snugly
s again
nst its seat and
a yet can still
s slide from m side to sid
de.
The Offset Head con nducts weld current throu
ugh this sliding seat, and
d
also prevvents shielding gas from T adjustment is made by
m escaping. The
tightening
g the two up pper 10-32 socket
s head cap “binder screws” that
secure thhe side platee.
You shou uld adjust the binder scrrews so that the head sliides with
moderate e resistance. You should d need exterrnal hand pressure, in
addition to
t turning the knob to move the slide e. The tensio
on of the Offfset
Head is correct
c when n the slide ca
an be moved d only by a combination
c of
turning th
he knob withh one hand while
w assistin
ng with the other.
o
If the binder screws are

a too loose e, the Offsett Head assembly may ovverheat from m increased
resistancce across thee slide and body
b interfacce. Also poro
osity in the weld
w can ressult from
contamin nation of the shielding ga
as.
Quick Couple
C Adjustments
The quick couple con nducts all the welding cuurrent that iss used in the
e welding pro ocess. The quick
q
couple iss rigged from
m the factory to have an interference e fit with the mating fema ale connectoor.
The tanggs of the quic
ck couple sh hould be spreead slightly wider
w than the female co onnector, to
ensure good electrical contact when
w assemb bled. The axxial force required to assemble this
connecto or should be 5 to 10 pounds. If the feemale conne n easily, it iss a sign that the
ector slips on
quick couuple needs to
t be spread d open slighttly. You can spread the quick
q couple e by sliding a flat
head scrrewdriver bettween the ta angs and twisting slightlyy.

able Machinin
BW3000
Wirefeeder Maintenance and Adjustments

Wirefeeder Maintenance
The wirefeeders are built to last for years of service. If you keep the machine clean, you’ll more
easily find and correct wear or maintenance issues.
Inspect the following items for signs of wear:
 Drive rolls
 Pressure rolls
 Geared drive roll adapters
 Axles
 Rubber isolator feet on a shop-style wirefeeder.
For the shop-style wirefeeder, make sure the inside of the case is clean and free of metallic
objects. Also check that the wire feed motor is secure in the frame of the wirefeeder. Damage to
the system can result if the wire feed motor is allowed to make contact with the frame of the
wirefeeder.
Wirefeeder Adjustments
The wire feed drive roll pressure has a wide range of acceptable settings. However, when the
force transmitted to the wire exceeds its column strength, the wire collapses in the conduit (seen
as a crinkle or wave in the wire), causing the wire to resist movement in its intended direction.
Typically, the operator diagnoses this as a problem with wire feeding and quickly turns up the
feed roll pressure, making the situation worse. The following procedure should help determine
the maximum possible feed roll pressure. In practice, it is advisable to operate the feed roll
pressure below the maximum capable pressure, because of variations in the physical
characteristics of the wire.
1. Attach the conduit to the wirefeeder only.
2. Jog the welding wire until it exits the free end of the conduit.
3. Clip off any excess wire flush with the end of the conduit fitting.
4. Hold the free end of the wire feed conduit up to a hard surface (like a table edge) and jog
the wire feed rolls momentarily (2 to 3 seconds). The rolls should spin on the wire.
5. Remove the conduit end from the hard surface.
6. Jog the full length of wire out of the conduit, watching closely for any distortion in the wire.
7. If the feed roll pressure is just right, the wire that was inside the conduit should not have
any “sine wave” effects—it should be “crinkle” free. Tighten the feed rolls slightly. Then,
recheck for the sine wave effect. Repeat this until the effect appears.
8. If the feed roll pressure is too tight, the wire column will fail just after the feed rolls. You’ll
see a noticeable crinkle or sine wave in the wire. Back off the pressure on the rolls until
the effect disappears. This setting will be the highest possible feed roll pressure.

BW
W3000
In other words,
w the wirefeeder
w drrive rolls sho
ould be set so
s that, whenn a stoppage e occurs, the
e
wire feed
d rolls slip an
nd the wire does
d not crin
nkle. As menntioned earlie
er, this is the
e highest
possible tension. In most
m cases, Climax reco ommends a wirefeed settting well below this.
For mild steel, 0.035 diameter wire, set the feed
f roll presssure from 2.5
2 to 3 on th
he adjuster
barrels.
INFORMATION
Weld
ding wire vaaries in conssistency, so a feed roll pressure that was rightt for
one wire may beb too much h for anotheer wire. With
h each neww wire, you may
m
have
e to re-adjust the feed ro
oll pressure.
Torche
es, Condu
uits, and Cables
Maintain
ning Torch
hes and Ex
xtensions
Torch maaintenance includes clea aning or replacing the lin
ners and inspecting diffu
users, tips, and
a
nozzles for
f wear. Ins spect the torcch and exten
nsion thread ded ends whhere they ma ate for “dingss”
and burrss. These are
eas require complete
c ele
ectrical conta
act and gas seal.
Maintain
ning Cond
duits
Conduit maintenance
m e includes an inspectionn of the O-rin
ngs that seall each end of
o the conduiit in
T O-rings should be lu
its part. The ubricated to allow easy assembly
a an
nd disassembly. If the O--
rings aree cracked, wo
orn or otherw
wise compro omised, replace them.
The cond duit liner can
n be blown out
o to remove e foreign ma
atter that mig
ght restrict fe
eeding. If the
e
liner needs to be rep placed, see below
b for the
e procedure..
Replace
ement of Liners
L
The replaacement schhedule for linners in the BoreWelder
B t
torches and conduits de
epends on many
m
factors. These
T factorrs include, bu
ut are not lim
mited to, worrkplace environment, we
elding wire used,
u
welding parameters,
p feed roll pre
essure, and maintenancce schedule.
When liner replacemment is requirred, you sho
ould observee the followin
ng procedure
e. This
procedurre is importa
ant to mainta
ain proper op
peration of th
he BoreWeld der.
1. Whhen replacing g the liner in
n any compo onent which forms a curvve that the liner has to
follow, it is imp
portant to pre er. The linerr is pressed into the torch or conduitt until
eload the line
the
e liner is felt to be making contact with the outer wall of the bend
b in the torch
t or condduit.
This pressure should
s not exceed
e 5 pouunds.
2. Wh hen replacing g the liner in
n a wirefeedeer conduit, coil
c the conduit into a 24-inch (60 mm m)
circcle and pushh the liner in so it makess contact with h the outer wall
w of the co onduit. Thenn
seccure it in place with the set
s screws while
w it’s in th
his coiled po
osition. Do not over- tigh
hten
the
e set screws when securring the linerr.
3. Alwways clip the
e liner with a sharp set of
o diagonal cutters, in succh a way tha at the end off the
line
er is recesse
ed at the end d of the condduit or torch.. The distancce of recesssion should not
n
excceed one co oil, or approxximately 0.05
50 inch (1 mm). This pro ocedure prevvents sharp liner
endds from beinng exposed.

able Machinin
BW3000
Replace
ement of Contact
C Tip
ps for Torches #00 an
nd #0
When replacing the contact
c tips of torches #00 and #0, make
m sure thhat the conta
act tip is
ed correctly in the nozzle
positione e. The tip should not be centrally loccated axially. Instead, thee tip
should be e secured soo its exit end
d is closer to
o the end of the torch no ozzle. To dettermine the
proper lo
ocation and as
a a gauge between
b thee tip and the cup, use thee same Allen n wrench tha at
you usedd to tighten the set screw w holding the e tip in place
e. Do not pre
eload the line
er in either of
o
these torrches.
If replaceement of the e contact tip is required, it is not neceessary to rem
move the lin
ner. Instead,
loosen th he screw tha at holds the contact
c tip, remove
r t and insert a new tip over the line
the tip, er
that is insstalled in the
e torch.
An altern
native proceddure is to rem
move the tip p and the line
er, and use a piece of welding
w wire as
a a
“snake”. The weldingg wire is inseerted into the
e liner hole in the threadded end of th
he torch, outt
through the
t nozzle. Then
T the commbination off new tip and d old liner ca
an be slid on
nto the “snakke”
from the nozzle end, and the line er can easilyy be piloted into the linerr attachmentt area on the
e
threadedd end of the torch.
t
When replacing the liner on the #0
# and #00 torches:
t
emove the old tip and line
1. Re er.
2. Using a length of liner that is too long, insert the ne
ew liner from
m the threaded attachme
ent
end
d of the torch, out throug
gh the nozzle.
3. Insstall the conttact tip on the liner, and move the co
ombination up
u into the to
orch until corrrect
pla
acement is re eached.
4. Lig
ghtly tighten the tip hold--down set sccrew, making
g sure your
pla
acement is as shown in the t figure.
5. Trim the liner to the correcct length by pulling
p the lin
ner out two
coils, and cuttin
ng in betwee en the two.
6. Push the liner back into thee torch with the 3/32 hexx wrench
use
ed to tighten
n the liner ho
old-down sett screw.
7. Tig
ghten the line
er and tip in place. The tip
t hold-dow
wn torque
sho
ould not excceed 25 inch pounds.
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BW
W3000
Contro
ol Box Ma
aintenanc
ce
The conttrol box is de
esigned to withstand
w the
e rigors of the
e work envirronment withh minimal
maintena
ance. Howev ver, care sho en to avoid direct contactt with water, weld spatte
ould be take er,
high heat, and exces ssive impact.
The conttrol box is prrovided with a cover to completely
c enclose the case
c when not in use and to
partially protect
p the case
c when inn use.
To clean the control overlay and buttons, use
e a shop tow
wel lightly sp
prayed with WD-40™.
W
CAUTION
The control boxx enclosure is made from f polypro
opylene coppolymer, soo be
carefful not to set it on prehe
eated parts or
o on parts that
t have be
een or are be
eing
weld
ded.
Tool Kit
K P/N 699
971
PART NO. DESCRIPTION QTY U
UoM
10600
0 WRENC
CH HEX 5/32 SHORT ARM
M 1 P
Piece
11082
2 WRENC
M 1 P
Piece
11094
4 WRENC
M 1 P
Piece
SPLINER STAINLES
SS STEEL .06
65 ID X .144 OD
O X 16 FT FOR
F .023/.045
5
40424
4 1 P
Piece
WIRE
52815
5 MANUA
AL INSTRUCT
TION MODEL
L BW3000 BO
OREWELDER
R 1 P
Piece
63846
6 WRENC
CH SPANNER
R 2 INCH 1 P
Piece
63847
7 WRENC
CH SPANNER
R 1.5 INCH 1 P
Piece
63848
8 WRENC
CH SPANNER
R 1/2 - 7/8 INC
CH MODEL Z 1 P
Piece
66947
7 KIT CON
NSUMABLE PACKAGE
P BW
W3000 .035/..9MM TIPS (K
KB) 1 P
Piece
67082
2 GLOVES
S WELDING CLIMAX BRA
ANDED SIZE LARGE 1 P
Piece
67313
3 WELD SAMPLE
S 2.75
50 ID X 3.500 OD X 2.000 (KB) 1 P
Piece
67337
7 LUBRIC
CANT 3 OZ WD-40
W 1 P
Piece
69866
6 NOZZLE
E WELDING (ALL
( EXCEPT
T #00 & #0) (1
( EA) STAND
DARD 21-62 5 P
Piece

able Machinin
BW3000
Troubleshooting the BW3000

This chapter explains how to troubleshoot the BoreWelder BW3000 for both welding and
mechanical problems, including lack of fusion, tip seizure, ropy beads, excessive spatter, a hot
torch nozzle, porosity, a deposit that’s too hard to machine, cutting tools that break, and weld
graping.
Appendix A contains a list of spare parts and support libraries to assist with troubleshooting.
If you are still having problems after trying the remedies in this chapter, please contact Climax’s
knowledgeable and experienced technical staff.
PHONE 503.538.2185
FAX 503.538.7600
E-MAIL info@cpmt.com
Common Welding Problems and Their Cures

Lack of Fusion to the Bore Surface
Lack of fusion to the bore surface can be caused by the step being too small. If you are directing
the welding arc mostly against the previously deposited bead, the newly deposited weld metal is
likely to “cold lap” against the bore surface. It will fuse well with the previously deposited bead
but not with the base metal. To cure the problem, set the step to direct the arc precisely at the
intersection between the bore surface and the previously laid weld deposit or at an angle that
slightly favors the base metal.
Another possible reason for lack of fusion is that the rotation speed is too slow. If rotation is too
slow, the welding arc is directed on top of the currently melted weld puddle, preventing the arc
from making direct contact with the base metal.
Lack of Fusion to the Previous Weld Bead of the Same Layer
Lack of fusion to the previous weld bead is usually caused by too much step. The welding arc is
playing too much on the bore surface and not enough on the previously deposited bead. To
prevent this problem, direct the arc at the exact intersection of the previous bead and the bore
surface.
Wire Feeding Stops and Wire Burns Back to Tip
This problem is also referred to as tip seizure, and is usually caused by one of two reasons:
1. A mechanical blockage of debris at the “cone” entrance to the contact tip. This debris jams
between the wire and contact tip bore. When the wire stops and the welding power supply
remains on, the wire burns back to the contact tip and the contact tip melts.
2. Overheated or exhausted contact tip. When the contact tip is overheated or spent, the
wire may seize to it. The contact tip is a consumable, so replacement is required at
intervals that are determined by, but not limited to, the following factors: dimensions of
bore, arc voltage, welding current, welding wire, shielding gas, preheat of part, quality of
weld connections, and type of power supply used.

BW
W3000
Refer to “Wirefeederr Adjustmentts” section fo

or informatio
on on setting the feed rolll pressure.
Weld Be
eads Are “Ropy”
“
To make
e the beads wet
w out more
e and becom
me less ropyy, you should
d try the follo
owing:
 Inccrease in the
e arc voltage
e up to 18 vo
olts.
 Use less CO2 in the mixturre of shieldin
ng gas.
 Verify that the travel speed arameters (18 to 22 IPM).
d is within accceptable pa
 Ma
ake sure thatt your weldin
ng wire is no
ot contamina
ated with russt.
 Maake sure thatt the base metal
m is not contaminated
c d with rust, grease,
g or sccale. A
san
ndblasted prre-machined d or ground part
p is desiraable for bestt results.
If your we
eld power su
upply is equipped with in
nductance control, anoth
her strategy is to increasse
inductancce. More ind
ductance flatttens the we
eld puddle.
INFORMATION
On Lincoln pow
wer supplies, turning the
t knob counterclock
c kwise increa
ases
induc
ctance.
Too Much Spatterr

The usua
al cause for too much sp patter is an arc
a voltage that’s too higgh. The arc should
s have an
even sou
und that is no
ot violent. A setting of 15
5½ to 18 vollts is normal.
The shielding gas als so has a ma
arked effect on
o weld spatter. For spa
atter control, a shielding of
argon witth less than 15% CO2 iss recommended (for exaample, 92% argon/8% CO2).C More CO2
C
causes excessive
e sp
patter.
Certain tyypes of weld
ding wire cre eate more sp
patter than others.
o If all other
o optionss have been
n
exhausteed, try wire frrom a differe
ent manufaccturer. Conta
act Climax fo or information on alterna
ative
wires.
Torch Nozzle
N Bec
comes Too Hot
oltage that’s too high. Ke
A hot torcch nozzle is usually the result of using an arc vo eep the volta
age
between 15½ and 18 8 volts.
Porosity
y in the We
eld
Porosity is indicated by a spongee-like appea
arance of thee weld bead. Porosity is commonly
caused by
b two factorrs: Lack or contaminatio
c n of shieldin
ng gas; and a contamina ated bore
surface.
Spatter buildup
b in the
e nozzle can n restrict flow
w, resulting in a lack of shielding
s gass. A gas floww
that’s tooo high can ca ause ambien nt air to conttaminate the e shielding gas. A flow raate of 20 to 40
4
CFH is re ecommende ed. If wind is a problem in the field, make
m wind blocking
b damms out of leatther
and alum minum foil. Use leather on o the BoreW o the bore, as leather does not conduct
Welder side of
electricityy. A 3-foot sq
quare piece of leather withw a slit fromm the centerr out to one edge provides
easy insttallation over the extension. You can n use small magnets
m to hold the leatther in place
e.
Aluminum m foil is usedd on the oppposite end off the bore. Fold
F the alumminum foil arround the pa art to
hold it in place to shield the bore e, then make e a hole to view the process.

able Machinin
BW3000
Excessivve oil, rust, dirt, and grea

ase can conttaminate the e bore surfacce and cause
e porosity.
Sandblassting, pre-ma achining, annd preheatingg may be required. In ca ases where the
t base me etal is
deeply coontaminated d, you may need
n to run a flux cored wire
w to mana age the exce
essive
contaminnants.
In some cases, lamin nated sections in heavy equipment bores
b can haave grease deposited
d in
n the
spaces between
b the layers. You have a few options to handle
h this problem. Youu could pre-g grind
the laminnation line, and
a pre-weld d with stick welding
w rod to
t seal the la
amination. This is very
effective,, but is time consuming and difficult on small bores. You cou uld preheat in an attemp pt to
drive out the grease. However, itt’s likely thatt grease will continue to leak out while welding
continuess. It’s also possible to weld
w up to thee lamination, stop the weeld process,, retract the
machine over the lam mination, and e weld process. The unfinished section can then be
d restart the
stick weldded after bo orewelding iss complete.
Steel Weld
W Depos
sit Is Too Hard
H to Mac
chine
Assuming the wire iss a mild steel wire (such as the 70s-sseries), the ability
a to harrden must be
e
attained from the basse material. If the depossit is hard, it must have obtained
o carrbon and
possibly other alloys from the ba
ase material which cause e it to be sussceptible to heat
h treatme
ent
hardening.
Generallyy, to preventt hardening, slow down the cooling rate. To do so,
s increase e the preheatt of
the part and/or
a decre ational travel speed of th
ease the rota he torch. Fasst travel speeds produceea
rapid queench of the weld
w beads.
If hard weld beads are encounte ered, you ma
ay be able to
o temper the hardened bead
b by weld
ding
another pass
p directly
y over it.
If the buildup is still too hard, posst-heat to a temperature
t e of about 1100°F to tem
mper the weld
d
bead and d allow mach hining.
INFORMATION
Be sure to allow the part to cool
c below 400°F
4 before
e reheating. Do not allow
w
any part
p of the weld
w to rise above
a the critical temperrature (about 1300°F) evven
for a short time, unless you are
a prepared d to do a fulll anneal with
h the
assoociated heat soaking and d slow coolin
ng.
Weld Brreaks Cutting Tools When

W Mac
chined
A tungste
en carbide toool bit edge can be “hon ned” to make e it less suscceptible to brreakage. If you
y
create a 45 degree chamfer
c that’s 0.005- incch to 0.007-inch wide (0..127 mm to 0.178 mm), the
toughnesss of the tool bit is increa
ased.
Weld “G
Graping”
Graping occurs when n the moltenn puddle oveercomes the surface tenssion that hollds it in place
e.
The term
m “graping” re
efers to the drooping
d glo
obs of weld metal
m hangin
ng from the bore
b surfacee.
Typicallyy, this occurs
s on the uphill section wh
hen the Bore
eWelder is in
n the horizon
ntal axis.
To remed dy this problem, use lowwer currents and voltages for the firsst revolution and build a shelf
that can support subsequent welld beads. So ome operato ors weld two low ampera age rotationss
directly on
o top of eac e shelf. This shelf suppo
ch other to create a large orts the third and subseqquent
rows of much
m larger beads. Stepp adjustmentts are required to provide the desired results.
Copy
able Machinin
e.com
BW3000
In any case, step has a marked effect on graping. A step that’s too great or too little reduces the
required support for the molten puddle.
During most BoreWelder buildup operations in the vertical axis, graping should not be
experienced within the current limits of the BW3000. If graping is experienced during the buildup
operation, the weld current may be too high or the travel speed too slow. Again, it’s possible for
graping to occur if the step is too great or too little. In these cases, the bead will be unsupported
and its surface tension will no longer hold it in place.
Mechanical/Electrical Troubleshooting
Machine Does Not Step
The default setting on power up is step enabled. Step can be turned on and off by pressing the
FUNCTION key, then RETRACT on the control box.
The STEP switch inside the BoreWelder head unit may not be working properly. To check it,
hold ROTATION INITIALIZE and wait for the spindle to rotate and stop at the step point. As an
alternate means of checking the switch, separate the BoreWelder from the control system.
Consult the schematic and test the ohms across the pins relevant for the STEP switch. At the
same time, rotate the BoreWelder spindle by hand until the step switch drops into the step
detent. The meter should read continuity at this point. If not, remove the red shroud and check
the switch directly. The wiring or switch may be at fault.
Check the control cable for continuity.
Check that the RETRACT and EXTEND buttons move the quill. If not, refer to “Machine Cannot
be Retracted or Extended” below.
Machine Cannot be Retracted or Extended
1. Check for a motor failure. Can you hear the motor operate when you press either the
RETRACT or EXTEND button? If you can, then skip to Step 3.
There should be continuity (through the motor armature). If there is no continuity, a light tap on
the side of the motor may restore operation. If the light tap works, contact Climax for a new style
of motor brush. Or give the brush springs a slight kink to ensure electrical contact when at rest.
2. Check the cable for continuity.
3. Check whether the worm roll pin is sheared. If the motor operates but the quill does not
move, it’s likely that the roll pin is sheared or the gear train is otherwise damaged.

BW3000
Machine Does Not Rotate

First, verify motor continuity by checking BoreWelder receptacle pins (25 to 35 ohms) (check the
schematic).
Then check the cable for continuity
If you still have a problem, contact Climax.
Wirefeeder Does Not Feed Wire
First, check the motor for continuity (20 ohms) (check the schematic).
Then check the cable for continuity (check the schematic).
If you still have a problem, contact Climax.
Nothing Happens When the WELD Button Is Pressed
First, check if the machine is completely retracted. Press EXTEND to move the quill off its limit,
and try again.
Then check the AC power inlet fuse.
Machine Rotates, Steps, and Feeds Wire Out But Does Not Weld
Check the continuity of the power supply control cable (check the schematic).
Check the positive and negative ground leads for proper connection.
No Voltage Control
Check the continuity of the power supply control cable (check the schematic).
Check the positive and negative ground leads for proper connection
No Arc, No Wire Feed, But Rotates at Full Speed
Check that the AUTO SKIP switch is horizontally aligned to cams (that is, the switch roller
contacts both cams).
Check that the AUTO SKIP switch is radially engaging the cams properly (that is, the switch
roller is actuated by the high spot on the cams).
No Arc, No Wire Feed, But Rotates at Dial Speed
Make sure the control is not in Pie Mode or Carriage Return.

BW3000
Troubleshooting Summary
The following table summarizes the troubleshooting information in this chapter. Problems are
presented in alphabetical order by keyword. If you are still having problems after trying these
remedies, please contact Climax.
SEE
PROBLEM QUICK SOLUTION
PAGE
See “Wire feed: No arc, no wire feed, but rotates
Arc: No arc at full speed” and “Wire feed: No arc, no wire
feed, but rotates at dial speed” in this table.
See “Weld breaks cutting tools when machined”
Broken machining tools
in this table.
Buildup: Separation of the buildup from
See “Fusion: Lack of fusion to bore surface”
the underlying base material due to lack of
in this table.
fusion
Direct the arc at the precise intersection between
the bore surface and the previously laid weld
Fusion: Lack of fusion to bore surface 64
deposit.
Increase rotation speed.
Direct the arc at the precise intersection between
Fusion: Lack of fusion to the previous the bore surface and the previously laid weld
64
weld bead of the same layer deposit.
Increase arc voltage.
Graping See “Weld graping” in this table.
See “Weld: Steel weld deposit is too hard to
Hardening of weld deposit
machine” in this table.
Check for motor failure.
Check for continuity of motor circuit (check the
schematic).
Machine cannot be retracted or extended 67
Check cable for continuity.
Determine if worm roll pin is sheared or gear
train is otherwise damaged.
Verify motor continuity by checking BoreWelder
Machine does not rotate receptacle pins (check the schematic). 68
Protect shielding gas from contamination from
bore surface by lowering gas flow, preventing
Porosity: Porosity in the weld 65
spatter buildup, cleaning bore surface, and/or
using stick welding on laminated surfaces.
Ropy beads See “Weld beads are ropy” in this table.
See “Machine does not rotate” in this table. Also
Rotation
see references under “Weld” and “Wire feed”.
Spatter: Too much spatter Lower arc voltage. 65
Make sure step is enabled.
Make sure the STEP switch is working properly.
Step: Machine does not step Check the control cable for continuity. Make sure 67
the RETRACT and EXTEND
buttons move the quill.

BW3000
SEE
PROBLEM QUICK SOLUTION
PAGE
See “Wire feed: Wire feeding stops and wire
Tip seizure
burns back to tip” in this table
Check continuity of the power supply control
cable.
Voltage control: No voltage control 68
Check positive and negative ground leads for
proper connection.
Increase arc voltage.
Weld beads are ropy Use less CO2 in the shielding gas. Increase 65
inductance.
Hone the cutting edge of the tool.
Weld breaks cutting tools when machined Make sure the nose radius is not too small or too 66
large.
Lower weld current and voltage for the first
Weld graping during horizontal axis
revolution. 66
borewelding
Make sure the step is not too great or too little.
Weld graping during vertical axis Lower weld current. Increase travel speed.
66
borewelding Make sure the step is not too great or too little.
Check continuity of the power supply control
Weld: Machine rotates, steps, and feeds cable.
68
wire out but does not weld Check positive and negative ground leads for
proper connection.
Press EXTEND to move the quill off its limit and
Weld: Nothing happens when the WELD
try again. 68
button is pressed
Check the inlet fuse.
Slow down the cooling rate by increasing the
preheat of the part and/or decreasing the
rotational travel speed of the torch.
Weld: Steel weld deposit is too hard to
Deposit another weld layer on top of the hard 66
machine
layer to temper it.
Post-heat the buildup after welding and allow to
cool.
Wire feed: No arc, no wire feed, but Make sure the control box is not in Pie Mode or
68
rotates at dial speed Carriage Return.
Check that the AUTO SKIP switch is horizontally
Wire feed: No arc, no wire feed, but
aligned to the cams and engaging the cams 68
rotates at full speed
properly.
Check the motor for continuity (check the
schematic).
Wire feed: Wirefeeder does not feed wire 28, 68
Check whether wire is caught in torch.
Replace the contact tip.
Wire feed: Wire feeding stops and wire Make sure the feed roll pressure is not too tight.
64
burns back to tip (tip seizure) Remove blockage of debris at the cone entrance
of the contact tip.
Use short conduits and extensions. Avoid an “S”
Wire flip shape in the conduit. Tighten the curve of the 42
wire.

BW3000
Preparation for Shipping

The crate the machine arrived in is designed for safe shipment of the machine. Use the crate
and packing components that the machine arrived in for repackaging the machine.
Package the machine as shown in the photos.

BW3000
Storage
This equipment is intended to be stored indoors in a temperature and humidity controlled
environment.
Prepare the Machine for Storage
 Ensure the machine is free from dirt, grease, chips and other debris before storage.
 Apply a moisture preventative material to unpainted surfaces (WD-40 for short-term
storage, LPS-3 for long-term storage) to prevent corrosion.
 Store the machine in the crates provided.
 Place desiccant bags or vapor wrap around the machine to absorb moisture.
Climax advises changing the desiccant bags in the storage crate every 18 months.
Ideal Long-Term Storage Conditions
Ideal long-term storage conditions are cool and dry indoors (50°F and 20% relative humidity).
While such conditions may not be realistic for your setting, do not let temperatures exceed 70°F,
and if possible, keep the relative humidity below 40%. Make every effort to keep temperature
and relative humidity levels constant.

BW3000
Glossary
Arc Interrupt A BoreWelder function that lets you briefly stop the weld process yet
maintain all other weld mode functions.
Arc Voltage The length of the arc between the molten puddle and the end of the
electrode, in this case, MIG wire.
Articulate The hinging motion of the BoreWelder and radial mount to accommodate
movement of the BoreWelder spindle towards and away from the
mounting rod.
Auto Skip A BoreWelder function that lets you automatically skip keyways or fill in
an out-of-round or worn section of a bore.
Carriage Return A BoreWelder function that lets you weld up a worn area of a bore in the
horizontal axis, when the worn section occurs on the uphill or downhill
side of the bore.
Cast The diameter of the circle that a welding wire makes on the floor in its
relaxed state.
Centering Positioning the BoreWelder so that it’s centered over the bore.
Complete centering is called “centrality.”
DIP Transfer See short arc.
ESO Electrical Stickout. See Stickout.
HAZ Heat Affected Zone.
Leveling The process of aligning the axis of the BoreWelder to the axis of the bore
to be welded.
MIG Welding Metal inert gas welding, where the consumable metal electrode (wire) is
mechanically fed into the arc, shielded by an inert gas.
Parallelism Positioning the BoreWelder so that it’s parallel to the axis of the bore to
be welded.
Pie Mode A BoreWelder function that lets you weld up a worn area of a bore in the
vertical axis.
Porosity The condition that results when the weld bead becomes sponge-like in
appearance. Porosity is typically associated with loss of shielding gas
coverage, excessive contaminants in or on the base metal, or excessive
voltage.
Rotation Speed How fast the spindle of the BoreWelder is turning, measured in seconds
per rotation (SPR). It’s calculated from the diameter of the bore and the
target travel speed.

BW3000
Short Arc One of the operating modes of the MIG welding process that’s relevant to
this manual (others are stubbing, globular transfer, and spray). In
borewelding, it is important to remain in short arc (also known as DIP
transfer).
Spring Washer A Belleville or disc spring washer acts as an axial spring.
Step Step is the amount of distance the BoreWelder automatically feeds or
retracts during one revolution.
Stickout Electrical Stickout (ESO). The distance between the end of the contact tip
and the workpiece.
Stubbing The undesirable MIG weld mode. Stubbing results in incomplete melting
of wire and erratic arc formation, providing inadequate heat to properly
bond or form a weld puddle. The weld wire drives into the workpiece, and
then the arc disintegrates the wire. Excessive spatter and noise
accompany this mode.
Travel Speed The speed at which the torch travels along the surface of the part being
welded, measured in inches per minute (IPM).
Wire Flip As the BoreWelder turns, the wire is twisted slightly between the torch
and the wirefeeder. This twist (in extreme cases), unwinds once per
revolution as the torch progresses around the bore, and produces a
change in the track of the weld in a small area of the bore.
Wire Speed The rate at which the wire travels through the BoreWelder system,
measured in inches per minute (IPM). Wire speed and amperage are
directly proportional to each other.

BW3000
Exploded Views and Parts Lists

The following diagrams and parts lists are for your reference purposes only. The machine
Limited Warranty is void if the machine has been tampered with by anyone who has not been
authorized in writing by Climax Portable Machining and Welding Systems, Inc. to perform
service on the machine.
Drawing List
1. 54421 – Welding Head Assembly, 6 inch & 12 inch
2. 54273 – Spindle Head Assembly, 6 inch & 12 inch
3. 68374 – Shroud Assembly, Metal Connector
4. 68379 – Shroud Assembly, Plastic Connector
5. 28208 – Radial Mount Assembly, 5 inch
6. 29037 – Adjustable Base Assembly
7. 65054 – Wirefeeder Assembly, Shop Style
8. 35357 – Wire Straightner Assembly, Shop Style Wirefeeder
9. 69018 – Wirefeeder Assembly, Enclosed
10. 44992 – Feed System Assembly, Top Mount, P/P, 24VDC
11. 66946 – Wirefeeder Assembly, Enclosed, P/P, 24VDC
12. 48013 – Facing Torch Assembly, Compact, 6 in Swing
13. 28186 – Facing Torch Assembly, 8 in Swing
14. 34473 – Torch Assembly, #13 / 24
15. 70132 – Torch Assembly, Bearing Mount Clearance, #6 - #12
16. 38506 – Trammel Torch Assembly
17. 40554 – Hub Assembly, Trammel Torch
18. 64058 – Torch Hub Assembly, Bearing Clearance, #6 - #12
19. 69895 – Torch Extensions, 3 in – 18 in
20. 30756 – Torch Counterbalance Assembly
21. 28020 – Conical Torch Assembly
22. 39723 – Torch Assembly, #1A
23. 29032 – Torch Assembly, Standard, #2 – #12
24. 31894 – Conduit Assembly, Wire Feed, 2 ft – 15 ft
25. 30774 – Hose Assembly, Shielding Gas
26. 36169 – Electrode Stick Holder Assembly
27. 72101 – Cable Assembly Power Supply Lincoln 14 Pin Plastic Connectors 25 ft
28. 72138 – Cable Assembly Power Supply Lincoln Multi Weld 6 Pin Plastic Connectors

BW3000

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Q
Quick Refe
erence
I SET UP THE BW3000 BORE
I. EWELDER 19. Align torch to th
he Offset Head dov vetail travel.
A
Attach the Contrrol Box Shift the offset of the torch to adjust the
You must use the appropriate
Y a safety equipment,
e
diameter range.
i
including a hand-heeld welding helmet and safety 8.
8 Connect the co ontrol cables.
g
glasses, when settiing up the BoreWellder. 2 Adjust torch cle
20. earance to 1/4 in. (6
6 mm) from
9
9. Switch POWER R switch to ON. LEDs on the nozzle to bore ssurface.
control box flas
sh three times; then n only red and
blue LEDs stay y lit. If the control ca
ables aren’t F
Fine Center
plugged in, LEDDs continue to flash h.
2 Press ROTATE
21. E JOG or manually rotate the
A
Adjust Parallelis
sm Offset Head to rotate torch from 6 o’clock
(Point A) to 12 o’clock (Point B).
10. Set Offset Head assembly to zero
1 o offset.
2 Turn the adjustment screw on the adjustable
22.
1 Install extensio
11. on to help adjust parallelism. base to center ttorch between Poin nts A & B.
1 On the adjustable base, adjust the
12. e forward jack 2 Rotate torch ass in Step 21 but go from
23. f 3
screws first, us
sing the extension too reference o’clock (Point C
C) to 9 o’clock (Poin
nt D).
the 3 or 9 o’clock location of bore..
2 Loosen the radial mount clamp kn
24. nob & pivot on
1 Adjust the rear jackscrew, using th
13. he extension the mounting rod to center to orch between
to reference thee 6 or 12 o’clock location of Points C & D.
bore.
A
Attach BoreWeld
der to Part to Be
e Welded 2 Lock the radial mount and the BorreWelder
25.
clamp knob.
1
1. If using a radiaal mount, weld the 1/2-13x3
1 N
NOTE: A boring barr interface may be used
u instead
mounting bolt to t a spot approxima ately 14 in. o the Climax adjusttable base.
of
(36 mm) from the t center of the bo ore. Otherwise
(no radial mount), weld the mountting bolt to a A
Adjust the Reach
h
spot approxima ately 11 in. (28 mm m) from the
center. 2 Add or remove extensions to chan
26. nge the reach
C
Center the BoreW
Welder (Coarse))
2
2. Place the adjus stable base plate over
o the without moving BoreWelder. Or slide
mounting bolt. Secure it to the part by installing 1 Adjust BoreWe
14. elder & radial mount to move the BoreWelder up or down the mounting rod.
the 4 spring wa ashers & nut. Tighte en the nut. attached extension to the center of
o the bore.
3
3. Screw the mou unting rod into the slider
s hole & 1 Lock BoreWeld
15. der to radial mount.
A
Attach Wirefeed Conduit & Load
d Wire
tighten firmly.
1 Lightly tighten radial
16. r mount clampp knob to the 2 Attach BoreWe
27. elder end of the wirefeed conduit
4
4. Install the lockiing collar 8 in. from
m the top of the mounting rod. to swivel conne ector at the top of BoreWelder
mounting rod. by engaging atttachment nut. Tighten by hand
1 Remove the ex
17. xtension from the Orientation
O
5
5. If you’re using a radial mount (A-1 1005), install it Fitting. only.
over mounting rod. 2 Open the wirefe
28. eeder case. Loosen n the thumb
6.
6 Slip BoreWelde er over the radial mount.
m Install a Welding
g Torch screw of the fee eder conduit fitting.
7
7. Move BoreWelder & radial moun nt to bring the 2 Insert the wirefe
29. eeder end into the feeder
Offset Head directly over the bore e. 1 Attach torch (&
18. & extensions) to BorreWelder
conduit fitting to
o a positive stop. Secure the
Orientation Fitting & secure torch with the 1.5
feeder conduit ffitting with the thum
mb screw.
in. (38 mm) Oriientation Nut.
30. Place the roll of wire on the spool holder so II. OPERATE THE BW3000
that the wire feeds from the bottom of the roll. BOREWELDER Startup/Shutdown
Straighten about 6 in. (152 mm) of wire at the
end of the roll to prepare for feeding. You must use the appropriate safety equipment, Press the WELD button on the control box to start;
including a hand-held welding helmet and safety press it again to stop.
31. If your wirefeeder has the push/pull option,
glasses, when operating the BoreWelder.
place the toggle switch in the normal position. If stubbing occurs on startup, raise the voltage until
32. Disengage the pressure rolls on the wirefeeder the process stabilizes.
Pre-Weld Checklist
by flipping the lever(s) off the pressure roll arm.
Arc Interrupt
33. Thread the wire into the feed mechanism inlet
Weld positive connected to BoreWelder and 
guide. Push the wire past the feed rolls and When your torch approaches an area you don’t
weld power supply.
into the conduit fitting. want to weld, press the ARC INTERRUPT button
34. Engage the feed roll pressure lever(s). Weld negative connected to part and weld  on the control box. Welding stops. Release the
power supply. button to resume welding.
35. Make sure the control box is ON, & press the
WIRE JOG switch. The wire will be pushed Rotation speed set (ROTATION SPEED) 
through the conduit, BoreWelder, & torch. EXAMPLE: 3.5 in. diameter x 10 = 35 SPR Auto Skip
@ 20 IPM.
Attach the Weld Cables & Gas Hose 1. BoreWelder must be centered & parallel to
Wire speed set (WIRE SPEED)  bore.
36. Attach the positive weld cable to the EXAMPLE: 6 sec. of wire jog = 19 in. of wire 2. Rotate torch manually or press ROTATE
BoreWelder quick couple & power supply. in 10 min., for 190 IPM. button. Rotate to the beginning of “interrupt” or
weld area.
37. Attach the negative weld cable to the part to be Step set (STEP SIZE) 
welded. Attach the ground clamp to clean, bare NOTE: If travel speed is 20 in./min., 3. Squeeze outside diameter of the cam discs
metal near the bore being welded. amperage & step value in inches are nearly with your thumb and forefinger, & pull away
38. Attach gas hose to a regulated source of equal. from the spindle, opening a low spot in the cam
shielding gas and a quick connect at discs.
wirefeeder. Voltage set (ARC VOLTAGE)  4. Rotate discs until AUTO SKIP switch just falls
NOTE: Startup value = 18.5 (approximate). into the low area.
39. On the control box, press the PURGE button.
A flow of 35 cfh (l cubic m/h) is good. Shielding gas connected and on (PURGE)  5. Rotate the torch to end of the interrupt area.
NOTE: Shielding gas flow rates should not 6. Hold first disc where you set it in Step 3. Move
Set the Axial & Rotational Start Positions exceed 35 cfh. other disc until AUTO SKIP switch actuates.
40. Jog the torch along its long axis until the Torch at rotation initialize point (step point).  7. Re-check disc settings by rotating spindle
nozzle is positioned properly to start welding at through “interrupt” zone in welding rotation
Twisted wire fed out from BoreWelder.  direction.
the end of hole farthest from BoreWelder. (WIRE JOG)
Typically, the wire is 1/16 to 1/8 in. (1.6 to 3.2
mm) from the end. Quill retracted to correct position to start  Pie Mode/Carriage Return
41. Welding always progresses toward weld. (RETRACT)
Hold down FUNCTION key & press WELD button
BoreWelder. to cycle through Auto Skip, Pie Mode & Carriage
42. Push & hold ROTATION INITIALIZE button Return.
until the torch stops rotating.
CLIM
MAX GL
LOBAL
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ATIONS
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T Special Projjects Rentals
Need somee refresher coursses in setting Climax has beeen solving complicated Withh seven locationns in North Amerrica,
up and opeerating your Clim
max machine on-site machiniing and welding problems two in Europe and two
t in Asia, you are
tool? for our customeers since 1964. nevver far away from
m a Climax portaable
macchine tool.
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uropean Head
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Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

General Safety Practices

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Machine Specific Safety Practices

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Safety Sign and

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Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Introduction to the BW3000

Product Description and Basic Operation

When you are setting up the BoreWelder you must:

When you are welding, you must:

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Operatorrs are respon

Welding Safety Precautions

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Auto Stop and Position Marker

Patented Torch and Extension System

175 Amp Current Limit

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

Table 1: BW3000 BoreWelder

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Control Cables. Theese cables connect

Wirefeedd Conduit. The

Figure 3: Adjustable Base & Mounting

ar, installed on the moun

Copyyright © 2015 Climax Porta

Copyyright © 2015 Climax Porta

Setting Up the BW3000

Figure 4: Attaching BoreWelder Using Adjustable Base

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

The sprin ng washers maintain con

2. To adjust paralllelism, install an extensiion into the Orientation

3. Moove the BoreeWelder forw ward or back until the atta

Copyyright © 2015 Climax Porta

Centerring the BoreWeld

Installiing a Wellding Torrch and Setting

TORCCH WITH STAANDARD

00 0.875–1.75 (22–44) –––

2 4.5–7.5 (114–191) 6.00–9.00 (15

3 6–9 (152–229) 7.5–10.5 (19

The rangge of the torc

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Fine Centering with the Adjustab

Understanding the Boring Bar Interface

Adjusting the Reach

Attaching the Wirefeed Conduit and Loading Wire

2. Open the wirefeeder case.

Copyright © 2015 Climax Portable Machining & Welding Systems, Inc.

4. Attach the wire efeeder end ofo the wirefe

8. Dissengage the pressure ro

2. Attach the negative weld cable

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PRESS THIS PRESS WITH FUNCTION KEY

Function Access the second function of a button

Jog wire at the speed set by the Wire Speed

Rotate the spindle at the speed set by the

Rotate the spindle to the step point (start

Extend Jog the quill/spindle/torch towards the bore Reverse step

Cycle through Auto Skip, Pie, and

Disable Auto Skip