Climax BB5500 User manual

P/N 29327
May2019
Revision 3
BB5500
BORING MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE:
11017900 - 11021000
ORIGINAL INSTRUCTIONS

P/N 29327, Rev. 3 Page 1
TABLE OF CONTENTS
TABLE OF CONTENTS.........................................................................................................................................1
General Safety .......................................................................................................................................................3
Machine Specific Safety ......................................................................................................................................4
Labeling Guidelines................................................................................................................................................5
Risk assessment and hazard mitigation ................................................................................................................6
Risk assessment checklist.....................................................................................................................................7
Warning Labels ......................................................................................................................................................8
CE Mark .................................................................................................................................................................9
Introduction.............................................................................................................................................................10
Receiving Your Machine........................................................................................................................................12
Setup......................................................................................................................................................................13
Operation................................................................................................................................................................37
Disassembly...........................................................................................................................................................39
Maintenance...........................................................................................................................................................40
Storage...................................................................................................................................................................41
Specifications.........................................................................................................................................................42
Exploded Views and Parts.....................................................................................................................................43

Page 2 BB5500 Operating Manual
LIMITED WARRANTY
CLIMAX Portable Machine Tools, Inc. (hereafter referred to as “CLIMAX”) warrants that all new
machines are free from defects in materials and workmanship. This warranty is available to the
original purchaser for a period of one year after delivery. If the original purchaser finds any defect in
materials or workmanship within the warranty period, the original purchaser should contact its factory
representative and return the entire machine, shipping prepaid, to the factory. CLIMAX will, at its
option, either repair or replace the defective machine at no charge and will return the machine with
shipping prepaid.
CLIMAX warrants that all parts are free from defects in materials and workmanship, and that all labor
has been performed properly. This warranty is available to the customer purchasing parts or labor for
a period of 90 days after delivery of the part or repaired machine or 180 days on used machines and
components. If the customer purchasing parts or labor finds any defect in materials or workmanship
within the warranty period, the purchaser should contact its factory representative and return the part
or repaired machine, shipping pre- paid, to the factory. CLIMAX will, at its option, either repair or
replace the defective part and/ or correct any defect in the labor performed, both at no charge, and
return the part or repaired machine shipping prepaid.
These warranties do not apply to the following:
•Damage after the date of shipment not caused by defects in materials or workmanship
•Damage caused by improper or inadequate machine maintenance
•Damage caused by unauthorized machine modification or repair
•Damage caused by machine abuse
•Damage caused by using the machine beyond its rated capacity
All other warranties, express or implied, including without limitation the warranties of merchantability
and fitness for a particular purpose are disclaimed and excluded.
Terms of sale
Be sure to review the terms of sale which appear on the reverse side of your invoice. These terms
control and limit your rights with respect to the goods purchased from CLIMAX.
About this manual
CLIMAX provides the contents of this manual in good faith as a guideline to the operator. CLIMAX
cannot guarantee that the information contained in this manual is correct for applications other than
the application described in this manual. Product specifications are subject to change without notice.

P/N 29327, Rev. 3 Page 3
General Safety
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 scrutinizing the job site and closely
following the operating procedures outlined in this manual, your own company rules, and local regulations. Save all
warnings and instructions for future reference.
WARNING
For maximum safety and performance, read and understand this entire manual and
all other related warnings and safety instructions before using this equipment.
Failure to follow the warnings, instructions and guidelines in this manual could
cause personal injury, fatalities, electric shock, fire and/or property damage.
QUALIFIED PERSONNEL
Before operating this machine, you must receive
training specific to this machine from a qualified
trainer. If you are not familiar with the proper and safe
operation, do not use the machine.
OBEY WARNING LABELS
Obey all warnings and 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 of
damaged or lost manuals or safety decals. 1-800-333-
8311
INTENDED USE
Only use the machine according to the instructions in
this operating manual. Do not use this machine for any
purpose other than the intended use as described in
this manual. When using the tools, machine,
accessories and/or tool bits, you must determine the
proper working conditions and the work to be
performed.
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. Keep
bystanders away while operating this machinery.
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. Keep the work area clean and well lit.
AMBIENT LIGHTING
Do not operate this machine in ambient lighting that is
less than normal intensity.
SECURE LOOSE CLOTHING AND LONG HAIR
Rotating machinery can seriously injure an operator as
well as others close by. Don’t wear loose fitting
clothing or jewelry. Tie back long hair or wear a hat.
HAZARDOUS ENVIRONMENTS
Do not use the machine in a hazardous environment,
such as near explosive chemicals, flammable liquids,
gasses, toxic fumes, or inappropriate radiation
hazards.
HOSES, PENDANT AND ELECTRICAL CABLES
Do not abuse the pendant cable as this can damage
the cable and pedant. Never use the cord for carrying,
pulling or unplugging. Remove any and all kinks before
straightening the cable. Keep cords and hoses away
from heat, oil, sharp edges or moving parts. Plugs
must match the outlet. Never modify the plugs in any
way. Do not use an adapter plug with grounded power
tools. Do not expose the machine to rain or wet
conditions. Always examine hoses and cables for
damage before use. Be cautious and never drop
electrical equipment, this will damage the components.
REPETITIVE MOTION
Individuals can be susceptible to disorders of the
hands and arms when exposed to tasks that involve
highly repetitive motions and/or vibration.
STAY ALERT
Stay alert, watch what you are doing and use common
sense when operating machinery. Do not operate
machinery while you are tired or under the influence of
drugs, alcohol or medication

Page 4 BB5500 Operating Manual
Machine Specific Safety
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 BB7000 Boring Bar Machine.
PERSONAL PROTECTIVE EQUIPMENT
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. Remove all adjustment
tools before starting the machine.
LIFTING
Most of the machine components are heavy and must be
moved or lifted with approved rigging and practices.
Climax accepts no responsibility for the selection of
lifting equipment. Always follow your plant’s procedures
for lifting heavy objects. Do not lift heavy objects by
yourself as serious injury can result.
CUTTING TOOLS AND FLUIDS
There are no cutting or cooling fluids supplied with this
machine. Keep cutting tools sharp and clean.
CONTROLS
The machine controls are designed to withstand the
rigors of normal use and external factors. The on-off
switches are clearly visible and identifiable. If hydraulic
power supply failure occurs, be sure to turn off the
supply before leaving the machine.
DANGER ZONE
The operator and other persons can be anywhere in the
vicinity of the machine. The operator must make sure
there are no other persons in danger from the machine.
METAL FRAGMENT HAZARD
The machine produces metallic fragments during normal
operation. You should wear eye protection at all times
when working with the machine. Only remove fragments
with a brush after the machine has stopped completely.
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 locked out from all
power sources. The shut-off valves should be locked
and tagged out before performing any maintenance. Do
not operate the machine if moving parts are misaligned,
binding or broken. If the machine or parts are damaged,
have the machine repaired before use.
WARNING LABELS
Warning labels are already attached to your machine.
Contact Climax immediately if replacements are
required.
MAINTENANCE
Be sure the machine components are free of debris and
properly lubricated prior to use. Have your machine
serviced by a qualified repair person using only identical
replacement parts
STORED ENERGY
Hydraulic fluids could still be under pressure! Make sure
the HPU is shut off and locked out properly.
MSDS
Material Data Safety Sheets are included in the
maintenance manual.
UNINTENTIONAL STARTING
Prevent unintentional starting. The machine must be
properly locked out and/or shut down before
maintenance.

P/N 29327, Rev. 3 Page 5
Labeling Guidelines
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 6 BB5500 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
attached to it become one complete machine during the material-removal process.
To achieve the intended results and to promote safety, the operator must understand 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 29327, Rev. 3 Page 7
Risk assessment checklist
Use these checklists as part of your on-site risk assessment and include any additional
considerations that may pertain to your specific application.
TABLE 1.RISK ASSESSMENT CHECKLIST BEFORE SET-UP
Before Set-up
I took note of all the warning labels on the machine.
I removed or mitigated all identified risks (such as tripping, cutting, crushing,
entanglement, shearing, or falling objects).
I considered the need for personnel safety guarding and installed any necessary
guards.
I read the Machine Assembly instructions and took inventory of all the items required
but not supplied.
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
precautions to keep workers away from the identified fall path.
I considered how this machine operates and the best placement for the controls,
cabling, and the operator.
I evaluated and mitigated any other potential risks specific to my work area.
TABLE 2.RISK ASSESSMENT CHECKLIST AFTER SET-UP
After Set-up
I checked that the machine is safely installed and the potential fall path is clear. If the
machine is elevated, 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 Maintenance Intervals with the recommended lubricants.
I checked that all affected personnel have the recommended personal protective
equipment, as well as any equipment required by the site or other regulations.
I checked that all affected personnel understand the danger zone and are clear of it.
I evaluated and mitigated any other potential risks specific to my work area.

Page 8 BB5500 Operating Manual
Warning Labels
The following labels are affixed to the machine. If these are damaged or lost, call Climax
immediately for replacements.

P/N 29327, Rev. 3 Page 9
CE Mark
This product is CE marked to indicate compliance with the following European Directive:
•98/37/EC Machinery Directive
•89/392/EEC Health and Safety Requirements
•EN1050 Risk assessment / Hazard Evaluation
•EN292-1 and EN292-2 Safety of Machinery
•EN983 Safety requirements for Pneumatics
•EN982 Safety requirements for Hydraulics
•EN11202 Noise emitted by Machinery and Equipment
•EN563 Temperature of Touchable Surfaces
The Declared Sound Power Level is: LWA= 72.6 dBA
The Declared Operator Sound Pressure Level is: LpA= 64.0 dBA
The Declared Bystander Sound Pressure Level is: LpA= 62.0 dBA
Sound levels are under 85 dBA, hearing protection not required.
The preceding sound information is for the BB5500 machine only. The power supply which is used
with the BB5500 machine will increase the sound levels and may necessitate the use of hearing
protection.

Page 10 BB5500 Operating Manual
Introduction
The Climax Model BB5500 Turbine Coupling Boring Machine is an ID-(Inside Diameter)
machine designed to bore precision coupling bolt holes on turbines or other coupling
applications. The extremely rigid and compact BB5500 enables just one operator to set up the
machine and quickly bore precisely aligned bolt holes the first time. The feed bar removal
feature enables the operator to measure and inspect the bore without the need to re-set the
machine.

P/N 29327, Rev. 3 Page 11
Climax BB5500 Components

Page 12 BB5500 Operating Manual
Receiving Your Machine
The Climax Model BB5500 was run tested and thoroughly inspected before leaving the factory.
When leaving the factory, the machine is packaged well for the demands of normal
transportation. Climax cannot, however, guarantee the condition upon arrival of the machine.
Inspect your machine upon receipt.
1. Inspect the machine for shipping damage.
2. Check the items you received against the items listed on the invoice.
3. Contact Climax immediately should there be damage or for any questions you have about
the machine.
WARNING
A crane, or hoist, is required to remove the machine from the
crate. Before lifting the machine, be sure the crane, or hoist,
has a steady hold. Uncontrolled swinging or falling of the
machine can cause serious injury, death and damage to the
machine.

P/N 29327, Rev. 3 Page 13
Setup Setup of the BB5500 Turbine Coupling Machine consists of the following steps:
1. Remove the machine from the crate.
2. Inspect the machine and perform routine maintain as necessary.
3. Remove the motor: Do not install the motor to the machine until you are ready to begin
machining the work piece. This will ease your setup process.
4. Remove the lower bearing hanger and boring bar.
5. Center the strongback supports..
6. Attach the block feet. The machine needs to be spaced properly from the
coupling/workpiece.
7. Set the machine on the workpiece.
8. Install the RDU.
9. Roughly position the machine onto the workpiece.
10. Install the bearing hanger.
11. Slide the boring bar into the machine.
12. Align the boring bar within the workpiece.
13. Prepare the machine for hydraulic power use.
14. Install the axial feed box.
15. Setup the tooling.
Remove the Machine from the Crate
The machine is equipped with a form fitted container for storage and shipping. With a modular
design, the machine can be broken down into components to ease setup.
Climax recommends using a sling or other suitable lifting device. The machine is fitted with two
lifting eyes which serve as stable lift points.
To remove the machine from the crate
WARNING
Before lifting the machine, be sure the crane, or hoist, has a
steady hold. Uncontrolled swinging or falling of the machine
can cause serious injury, death and damage to the machine.
1. Use the lifting eyes to lift the machine with a crane or hoist out of the crate.
2. Keep the machine in the air to perform necessary setup procedures as indicated in the
following.

Page 14 BB5500 Operating Manual
Inspect the Machine
To maximize the life of the machine, keep all components of the machine in clean, working
order. Make sure parts such as each mounting surface, the lead screw, hydraulic fittings, and
the tool bit itself are free of metal chips, nicks or burrs.
For detailed information about machine maintenance, see “Maintenance.”
Remove the Motor
Do not install the motor to the machine until you are ready to begin machining. The motor
mounted to the machine can make setup of the machine unnecessarily complicated.
To remove the motor
Undo the motor’s mounting bolts and slide it from the rotational drive assembly.
Remove the Lower Bearing Hanger and Boring Bar
Do the following to remove the lower bearing hanger and boring bar.
1. Loosen the clamp assembly.
2. Remove the lower bearing hanger assembly and the boring bar at the same time.

P/N 29327, Rev. 3 Page 15
CAUTION
Use caution when handling the lower bearing hanger
assembly and boring bar. These assemblies are
heavy. Dropping them can cause damage to the
machine and personal injury.
Centering the Strongback Supports
Center the strongback supports before mounting the machine onto the work piece. Centering
the strongback supports to make sure you have the maximum amount of room to properly
adjust the boring bar within the work piece.
Center the strongback supports using the following adjustment points:
Use the jacking bolts to make vertical adjustments
Use the 1/2-20 socket set screws (round nose) to adjust the strongback side to side.
Jacking bolt detail
When making horizontal adjustments, the limiting factor in the machine is the space between
the 1/2-20 x 4-1/2 SHCS screw (part 27550) and the jacking bolts, as shown below.
Horizontal adjustment limit
Socket Head Cap Screw
SHCS

Page 16 BB5500 Operating Manual
Adjust the strongback supports vertically.
Loosen the socket head cap screw locking bolt.
Turn the jacking bolts on both sides of the strongback base support so
that the number of threads above and below the support strongback (P
25591) is equal. Repeat the procedure for the other strongback base
support.
Center the machine vertically.
Adjust the strongback supports horizontally.
Turn the socket set screws out on either side of the support.
The amount of space between the set screw and the
strongback support should be equal on both sides. Repeat the
procedure for the other support.
Center the machine horizontally.

P/N 29327, Rev. 3 Page 17
Prepare the Machine for Work Piece Mounting
Your primary goal when positioning the strongbacks is to support the boring bar itself as rigidly
as possible. Use the following guidelines to maximize bar rigidity.
Positioning the strongback base supports: Position the supports as far apart from each other
as possible. They should remain in full contact with the work piece. The edges of each
standoff should line up with the outer edges of the workpiece.
Positioning the bearings: Position the boring bar bearings as close together as possible.
Always keep enough room for:
•the tool head to fit outside of the work piece without hitting either bearing assembly
•an indicator or other measuring instrument to help you align the bar later on during setup.
IMPORTANT
For optimum results, Climax recommends the following bearing
spacing:
•1-3/8 inch diameter bar up to 11 inches with a bore diameter of 1-1/2 inch
•1-5/8 inch diameter bar up to 13 inches with a bore diameter of 1-3/4 inch
•1-7/8 inch diameter bar up to 15 inches with a bore diameter of 2 inch
•2-1/2 inch diameter bar up to 20 inches with a bore diameter of 2-5/8 inch

Page 18 BB5500 Operating Manual
Spacing the Machine from the Coupling
To set up the machine correctly it must be spaced off of the coupling using the correct shims.
Use the table and graphic below to select the correct shim.
Do the following to select the correct shim.
1. Find the coupling outer diameter in the left-hand column of the table.
2. Moving right, match the coupling diameter with the bolt circle diameter that most closely
matches the bolt circle.
3. The shim will equal the number at the top of the table. The shim you choose will allow up to
1/4 inch of play, which can be compensated for by other machine adjustments.
Spacer Shim Example with 40” coupling outer diameter and 35” bolt circle diameter