Climax BB7100 User manual

PN: 55769 March 2019 Revision 4
BB7100
BORING MACHINE
OPERATING MANUAL
ORIGINAL INSTRUCTIONS

P/N 55769, Rev. 4 Page A
©2019 CLIMAX or its subsidiaries.
All rights reserved.
Except as expressly provided herein, no part of this manual may be reproduced, copied, transmitted,
disseminated, downloaded, or stored in any storage medium, without the express prior written consent
of CLIMAX. CLIMAX hereby grants permission to download a single copy of this manual and of
any revision hereto onto an electronic storage medium to be viewed and to print one copy of this
manual or any revision hereto, pro- vided that such electronic or printed copy of this manual or
revision must contain the complete text of this copyright notice and provided further that any
unauthorized commercial distribution of this manual or any revision hereto is prohibited.
At CLIMAX, we value your opinion.
For comments or questions about this manual or other CLIMAX documentation, please e-mail
[email protected] .
For comments or questions about CLIMAX products or services, please call CLIMAX or e-mail
[email protected] . For quick and accurate service, please provide your representative with the following:
• Your name
• Shipping address
• Telephone number
• Machine model
• Serial number (if applicable)
• Date of purchase
CLIMAX World Headquarters
2712 East 2nd Street Newberg, Oregon 97132
USA
Telephone (worldwide): [phone]
Toll-free (North America): 1-800-333-8311
Fax: [phone]
H&S Tool World Headquarters
715 Weber Dr.
Wadsworth, OH 44281 USA
Telephone: [phone]
Fax: [phone]
hstool.com
CLIMAX | H&S Tool (UK Headquarters)
Unit 7 Castlehill Industrial Estate Bredbury
Industrial Park Horsfield Way
Stockport SK6 2SU, UK Telephone: +44 (0) 161-
406-1720
CLIMAX | H&S Tool (European Headquarters)
Am Langen
Graben 8 52353
Düren, Germany
Telephone: [phone]
E-mail: [email protected]
CLIMAX | H&S Tool (Asia Pacific Head
-
quarters)
316 Tanglin Road #02-01
Singapore 247978
Telephone: [phone]
Fax: [phone]
CLIMAX | H&S Tool (Middle East
Headquarters)
Warehouse #5, Plot:
369 272 Um Sequim
Road
Al Quoz 4
PO Box 414 084
Dubai, UAE
Telephone: [phone]

Page B BB7100 Operating Manual
CLIMAX WORLDWIDE LOCATIONS

P/N 55769, Rev. 4 Page C
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new
machines are free from defects in materials and workmanship. This warranty is available to the
original purchaser for a period of one year after delivery. If the original purchaser finds any defect
in materials or workmanship within the warranty period, the original purchaser should contact its
factory representative and return the entire machine, shipping prepaid, to the factory. CLIMAX
will, at its option, either repair or replace the defective machine at no charge and will return the
machine with shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all
labor has been performed properly. This warranty is available to the customer purchasing parts or
labor for a period of 90 days after delivery of the part or repaired machine or 180 days on used
machines and components. If the customer purchasing parts or labor finds any defect in materials
or workmanship within the warranty period, the purchaser should contact its factory representative
and return the part or repaired machine, shipping pre- paid, to the factory. CLIMAX will, at its
option, either repair or replace the defective part and/ or correct any defect in the labor performed,
both at no charge, and return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
• Damage after the date of shipment not caused by defects in materials or workmanship
• Damage caused by improper or inadequate machine maintenance
• Damage caused by unauthorized machine modification or repair
• Damage caused by machine abuse
• Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of
merchantability and fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms
control and limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX
cannot guarantee that the information contained in this manual is correct for applications other
than the application described in this manual. Product specifications are subject to change without
notice.

Page D BB7100 Operating Manual
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P/N 55769, Rev. 4 Page i
TABLE OF CONTENTS
GENERAL SAFETY GUIDELINES ................................................................................................ 1 
MACHINE SPECIFIC SAFETY PRACTICES ................................................................................. 2 
SAFETY WARNING SYMBOLS .................................................................................................... 3 
RISK ASSESSMENT AND HAZARD MITIGATION ....................................................................... 4 
RISK ASSESSMENT CHECKLIST ................................................................................................ 5 
INTRODUCTION ........................................................................................................................... 7 
INSPECTING THE MACHINE ....................................................................................................... 8 
SETUP ........................................................................................................................................... 9 
Crane or Hoist........................................................................................................................................ 9
Space Requirements ............................................................................................................................. 9
Boring Bar and Bearing Support Setup................................................................................................ 12
CLAMP COLLARS ....................................................................................................................................... 12
End-mount bearing support setup........................................................................................................ 12
ALIGNING THE BAR AND BEARING SUPPORTS WITH THE CENTER BORE .......................................................... 14
MECHANICAL AXIAL FEED SETUP ................................................................................................................ 16
Mounting the mechanical axial feed to the bar .................................................................................... 16
Setting axial feed direction................................................................................................................... 16
Setting the Axial Feed Rate ................................................................................................................. 17
To set the feed rate:............................................................................................................................. 17
Setting up the Electric Feed................................................................................................................. 17
To mount the electric feed to the bar ................................................................................................... 17
ATTACHING THE MECHANICAL RAPID FEED (OPTIONAL EQUIPMENT) ............................................................ 18
ROTATIONAL DRIVE SETUP ........................................................................................................................ 19
TO SETUP THE ROTATIONAL DRIVE .............................................................................................................. 19
INSTALLING THE FACING AND BORING ARMS TO THE BORING BAR ............................................................... 21
To mount the tool carrier...................................................................................................................... 21
To lock the tool carrier on the bar for other operations........................................................................ 21
To remove the brass nut...................................................................................................................... 22
INSTALL THE SLIDE ARM ONTO THE TOOL CARRIER ..................................................................................... 23
ADJUSTING THE TOOL CARRIER FOR PERPENDICULARITY ........................................................................... 23
FEEDBOX ASSEMBLY ................................................................................................................................. 23
FEEDBOX & TRIP ARM SET-UP ................................................................................................................... 23
Install the Counterweight Arm onto the Tool Carrier............................................................................ 23
MICRO ADJUSTMENT BORING HEAD ........................................................................................................... 24
BORING HEAD SETUP ................................................................................................................................. 25
TO INSTALL THE MICRO ADJUSTMENT BORING HEAD .................................................................................... 28
OPERATION ................................................................................................................................ 29 
PRE-START CHECKS .................................................................................................................................. 29
BEFORE OPERATING THE MACHINE: ............................................................................................................ 29
STARTING THE MACHINE ............................................................................................................................ 29
If boring:............................................................................................................................................... 29
If facing: ............................................................................................................................................... 29
STOPPING THE MACHINE ............................................................................................................................ 30
To stop the machine ............................................................................................................................ 30

Page ii BB7100 Operating Manual
REPETITIVE MACHINING ............................................................................................................................. 30
To set the machine up for repetitive machining....................................................................................30
USING THE REMOTE PENDANTS .................................................................................................................. 31
Feed Pendant.......................................................................................................................................31
HPU PENDANT .......................................................................................................................................... 32
MANUAL OVERRIDE (ELECTRICAL FEED ONLY) ............................................................................................ 32
DISASSEMBLY ............................................................................................................................................ 32
To disassemble the machine................................................................................................................32
ALTERNATIVE DISASSEMBLY ....................................................................................................................... 33
To remove the bearings before removing the bar ................................................................................33
MAINTENANCE ........................................................................................................................... 35
RECOMMENDED LUBRICANTS ..................................................................................................................... 35
BORING BAR AND LEAD SCREW ................................................................................................................... 35
AXIAL FEED ................................................................................................................................................ 35
ROTATIONAL DRIVE .................................................................................................................................... 36
BEARING SUPPORT ..................................................................................................................................... 37
End-mount bearing support assemblies...............................................................................................37
ID-mount bearing support assemblies..................................................................................................37
BORING HEAD ............................................................................................................................................ 37
MECHANICAL FACING HEAD......................................................................................................................... 37
AXIAL TOOL CARRIER ................................................................................................................................. 37
STORAGE ................................................................................................................................... 38
SPARE PARTS ............................................................................................................................ 39
TOOL KIT ..................................................................................................................................... 40
EXPLODED PARTS AND VIEWS ............................................................................................... 41
SCHEMATICS ............................................................................................................................. 75
SPECIFICATIONS ....................................................................................................................... 79
OPERATIONAL DIMENSIONS .................................................................................................... 80
MSDS .......................................................................................................................................... 83

P/N 55769, Rev. 4 Page 1
GENERAL SAFETY GUIDELINES
The primary challenge for most on-site maintenance is that repairs are often done under difficult
conditions.
CLIMAX Portable Machining & Welding Systems leads the way in promoting the safe use of
portable machine tools. Safety is a joint effort. As the operator of this machine, you are expected
to do your part by closely examining the job site and following the operating procedures outlined
in this manual, your own company rules, and local regulations.
WARNING
For maximum safety and performance, read and understand this entire
manual and all other related safety instructions before using this
equipment. Failure to follow the instructions and guidelines in this manual
could cause personal injury, fatalities and property damage.
Qualified Personnel
Before operating this machine, you must receive
training specific to this machine from a qualified
trainer. Do not operate the machine. If you are not
familiar with the proper and safe operation.
Obey Warning Labels
Obey all warning labels. Failure to follow instructions
or heed warnings could result in injury, or even be
fatal. Proper care is your responsibility. Contact
CLIMAX immediately for replacement manuals or
safety decals.
Intended Use
Use this machine according to the instructions in this
operating manual. Do not use this machine for any
purpose other than its intended use as described in
this manual.
Stay Clear of Moving Parts
Keep clear of the machine during operation. Never
lean toward or reach into the machine to remove chips
or to adjust the machine while it is running.
Rotating Machinery
Rotating machinery can seriously injure an operator.
Lock out all power sources before you interact with the
machine.
Keep Your Work Area Clean and Tidy
Keep all cords and hoses away from moving parts
during operation. Do not clutter the area around the
machine.
Secure Loose Clothing and Long Hair
Rotating machinery can cause serious injuries. Do not
wear loose fitting clothing or jewelry. Tie back long
hair or wear a hat.
Hazardous Environments
Do not use the machine near explosive chemicals,
toxic fumes, inappropriate radiation hazards or other
hazardous environments.
Flying Chips
Flying metal chips can cut or burn. Do not remove
chips until after the machine has been locked out, all
power sources are off and the machine has stopped.

Page 2 BB7100 Operating Manual
MACHINE SPECIFIC SAFETY PRACTICES
All aspects of the machine have been designed with safety in mind. Following are safety practices
that you should keep in mind when using the CLIMAX BB7100 Boring Machine.
Personal Protective Equipment (PPE)
Eye and hearing protection must be worn while using
the machine. These safety items do not impose
constraints to the safe operation of the machine.
Operating Conditions
Do not operate the machine if it is not mounted to the
workpiece as described in this manual.
Tooling
The machine is provided with all the tools for the setup
and operation of the machine.
Lifting
Avoid lifting heavy objects by yourself as serious injury
can result. Always follow your plant’s procedures for
lifting heavy objects.
Cutting Fluids
Use only recommended lubricants or similar
equivalent when performing maintenance tasks. See
the “Maintenance” section for more information.
Danger Zone
The operator and other persons can be anywhere in
the vicinity of the machine. The operator must ensure
there are no other persons in danger from the
machine.
Clamp Collars
To prevent the bar from sliding through the support
bearings, or falling, use P/N 42792 – The collars are
made in matching sets and must be used to secure
the bar when the machine is in the vertical orientation.
Torque these collars to 46 ft-lbs. Use the clamp collars
to prevent over tightening of the bearings. Clamp
collars should be positioned ABOVE at least 2 support
bearings when installed in a vertical orientation. Clamp
collars should be shouldered against the bearing when
in use.
Metal Fragment Hazard
The machine dispenses metallic fragments during
normal operation. You should wear eye protection and
gloves at all times when working with the machine.
Hazardous Environments
Do not use the machine in a hazardous environment,
such as near explosive chemicals, toxic fumes, or a
radiation hazard.
Radiation Hazards
There are no systems or components on this machine
that are capable of producing hazardous EMC, UV or
other radiation hazards. The machine does not use
lasers nor does it create hazardous materials such as
gasses or dust.
Adjustments and Maintenance
All adjustments, lubrication and maintenance should
be done with the machine stopped, and disconnected
from power. The shut-off valve should be locked and
tagged out before any maintenance occurs.
Warning Labels
Warning labels are attached to your machine upon
delivery. If any labels are defaced or missing, be sure
to contact CLIMAX immediately for replacements.
Maintenance
Be sure the machine components are free of debris
and properly lubricated prior to use.

P/N 55769, Rev. 4 Page 3
SAFETY WARNING SYMBOLS
The purpose of product safety signs and labels is to increase the level of awareness to possible
dangers.
Safety Alert Symbols indicate DANGER, WARNING or CAUTION. These symbols may be used
in conjunction with other symbols or pictographs. Failure to obey safety warnings can result in
serious injury. Always follow safety precautions to reduce the risk of hazards and serious injury.
DANGER
Indicates a hazardous situation that could be fatal
or cause serious injury.
WARNING
Indicates a potentially hazardous situation that
could be fatal or cause serious injury.
CAUTION
Indicates a potentially hazardous situation that
could result in minor to moderate injury, damage
to the machine or interruption of an important
process.
IMPORTANT
Provides critical information for the completion of
a task. There is no associated hazard to people or
the machine.
TIP
Provides important information regarding the
machine.

Page 4 BB7100 Operating Manual
RISK ASSESSMENT AND HAZARD MITIGATION
Machine Tools are specifically designed to perform precise material-removal
operations.
Stationary Machine Tools include lathes and milling machines and are typically
found in a machine shop. They are mounted in a fixed location during operation
and are considered to be a complete, self-contained machine. Stationary Machine
Tools achieve the rigidity needed to accomplish material-removal operations from
the structure that is an integral part of the machine tool.
In contrast, Portable Machine Tools are designed for on-site machining
applications. They typically attach directly to the workpiece itself, or to an
adjacent structure, and achieve their rigidity from the structure to which it is
attached. The design intent is that the Portable Machine Tool and the structure to
which it is attached become one complete machine during the material-removal
process.
To achieve the intended results and to promote safety, the operator must under-
stand and follow the design intent, set-up, and operation practices that are unique
to Portable Machine Tools.
The operator must perform an overall review and on-site risk assessment of the
intended application. Due to the unique nature of portable machining applications,
identifying one or more hazards that must be addressed is typical.
When performing the on-site risk assessment, it is important to consider the
Portable Machine Tool and the workpiece as a whole.

P/N 55769, Rev. 4 Page 5
RISK ASSESSMENT CHECKLIST
The following checklist is not intended to be an all-inclusive list of things
to watch out for when setting up and operating this Portable Machine Tool.
However, these checklists are typical of the types of risks the assembler
and operator should consider. Use these checklists as part of your risk
assessment:
T ABLE 1-1. R ISK ASSESSMENT CHECKLIST BEFORE SET - UP
Before set-up


I took note of all the warning labels on the machine.


I removed or mitigated all identified risks (such as tripping, cutting, crushing,
entanglement, shearing, or falling objects).


I considered the need for personnel safety guarding and installed any necessary
guards.


I read the machine assembly instructions.


I created a lift plan, including identifying the proper rigging, for each of the setup
lifts required during the setup of the support structure and machine.


I located the fall paths involved in lifting and rigging operations. I have taken pre-
cautions to keep workers away from the identified fall path.


I considered how this machine operates and identified the best placement for the
controls, cabling, and the operator.


I evaluated and mitigated any other potential risks specific to my work area.
T ABLE 1-2. R ISK ASSESSMENT CHECKLIST AFTER SET - UP
After set-up


I checked that the machine is safely installed and the potential fall path is clear. If
the machine is installed at an elevated position, I checked that the machine is
safeguarded against falling.


I identified all possible pinch points, such as those caused by rotating parts, and
informed the affected personnel.


I planned for containment of any chips or swarf produced by the machine.


I followed the required maintenance with the recommended lubricants.


I checked that all affected personnel have the recommended personal protective
equipment, as well as any site-required or regulatory equipment.


I checked that all affected personnel understand and are clear of the danger zone.


I evaluated and mitigated any other potential risks specific to my work area.

Page 6 BB7100 Operating Manual
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P/N 55769, Rev. 4 Page 7
INTRODUCTION
This manual describes how to use your Model BB7100 Portable Boring Machine. Every part
meets CLIMAX’s strict quality standards. For maximum safety and performance, read the
entire Operating Manual before using the portable boring machine.

Page 8 BB7100 Operating Manual
INSPECTING THE MACHINE
Your CLIMAX product was inspected and tested prior to shipment, and packaged for normal
shipment conditions. CLIMAX does not guarantee the condition of your machine upon
delivery. When you receive your CLIMAX product, perform the following receipt checks.
1. Inspect the shipping containers for damage.
2. Check the contents of the shipping containers against the included invoice to ensure
that all components have been shipped.
3. Inspect all components for damage.
IMPORTANT
Contact CLIMAX immediately to report damaged or missing
components.
This is a highly configurable machine with many options and accessories. This manual
covers the use and operation of all of those possible options. The machine configuration
purchased by a customer may not contain all of the options and accessories detailed herein.
If a specific machine application requires additional options or accessories please contact a
CLIMAX sales representative for assistance in obtaining the needed components.

P/N 55769, Rev. 4 Page 9
SETUP
WARNING
When setting up or servicing the machine, disconnect the
power source and lock the machine out. Failure to do so
could result in accidental start-up and seriously injure you
or others.
Crane or Hoist
A hoist, crane, or other lifting device is vital in the setup of the machine. Only use an
apparatus that allows smooth operation with fine adjustment, such as a hydraulic lift or 2-
stage winch. A lifting device that is unstable, erratic, or moves too fast or inconsistently can
crash the machine into the work piece damaging the tool.
DANGER
A machine swinging or falling out of control can cause
serious injury, or even be fatal. Make sure all crane/hoist
operators are trained on the proper use of the machines.
Also make sure the lifting devices are secure and properly
rated for the load.
CAUTION
To prevent damage to the machine, always use the lifting
eyes provided on the machine.
Space Requirements
Before setting up the portable boring machine, determine where you will place each
assembly on the boring bar. Because the rotational drive and tool head assemblies can be
anywhere along the bar, be sure to provide room for them when setting up the machine.

Page 10 BB7100 Operating Manual

P/N 55769, Rev. 4 Page 11

Page 12 BB7100 Operating Manual
Boring Bar and Bearing Support Setup
At least two bearing support assemblies are required to ensure machine stability. The bearing
assemblies may be different styles.
CAUTION
At least two bearing supports are required to ensure
machine stability. The bearing assemblies may be different
styles. Bearing supports placed too far apart allow the bar to
deflect, reducing bore precision.
Clamp Collars
P/N 42792 – The collars are made in matching sets and must be used to secure the bar when
the machine is in the vertical orientation.
This will prevent the bar from sliding through the support bearings or falling.
To prevent over tightening of the bearings, the clamp collars should be placed above at least
two support bearings in a vertical orientation.
DANGER
To prevent the bar from sliding through the
support bearings, or falling, use the 2 clamp
collars provided in the tool kit when using the
boring bar in a vertical orientation. Torque to 46 ft.-
lbs!
End-mount bearing support setup
Even though the end-mount bearing support attaches to the outside of the work piece, it can
be placed anywhere along the boring bar. During setup, the bearings can have as much as 1
degree of angle in the + or – direction.
4. Clean the bore of the work piece with solvent to remove grease, oil, and dirt.
5. Check the bar for nicks or cuts. Dress the bar smooth, if necessary. A bar with nicks
or gouges can damage mating parts beyond repair (including the axial tool carrier and
rotational drive unit).
6. Clean the bar with solvent to remove dirt and chips.
CAUTION
The bar is not hardened. To prevent bar damage, do not
strike the bar against the bearing supports or against the
work piece.