Climax LM5200 User manual

P/N 66188
July 2019
Revision 5
LM5200
LINEAR MILLING MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE: 11017900 – 15121870
ORIGINAL INSTRUCTIONS
LM5200 Milling Machine

P/N 66188, Rev. 5 Page 1
Table of Contents
Safety Precautions 2
Warranty Information 10
About this Manual 11
CE Information 12
General Information 14
Rigging and Lifting 15
Operational Dimensions 18
Components 26
Frequently Asked Questions 28
Receiving the Machine 31
Datum Surfaces 32
Bed Assembly 33
Machine Setup 40
Operation 53
Maintenance 57
Disassembly and Storage 59
Specifications 60
Exploded Views and Parts Lists 61
WARNING
For maximum safety and performance, read and understand the entire manual
and all related safety instructions before using this equipment. Failure to follow
the instructions and guidelines in this
manual could cause personal injury,
fatalities or property damage.

Page 2 LM5200 Operating Manual
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
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.
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
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.

P/N 66188, Rev. 5 Page 3
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
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 work piece 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
ensure 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.
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.
NOISE LEVEL
85 dB(A) or higher – Hearing Protection is required.
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.

Page 4 LM5200 Operating Manual
Safety Sign and Symbol Guidelines
The purpose of product safety signs and symbols 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 or death. 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.
INFORMATION
Provides important information regarding the machine.

P/N 66188, Rev. 5 Page 5
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Page 6 LM5200 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 66188, Rev. 5 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 Setup 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 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 (according to the Machine
Setup section) 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 section 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 LM5200 Operating Manual
Labels
Part Number 29154 – Machine Nameplate
Part Number 29152 – Mass Tag displays the
weight of a group of components or the
assembly in Kilos
Part Number 59039 – Designated Lift Point
Part Number 65487 – Mass Tag
Part Number 35772 – Ball Valve Handle
Part Number 27307 – Warning Label
Part Number 61839 – Climax Logo
Part Number 37572 – PE Ground
Part Number 46902 – Warning Hot Surface
Part Number 62888 – Lift Point Only

P/N 66188, Rev. 5 Page 9
Part Number 37576 – Electrical Warning
Part Number 36094 – Speed Controller
Nameplate
Part Number 41949 – Speed Controller
Nameplate CE
Part Number 30081 – 230V
Part Number 32585 – 120V
Part Number 34734 – Warning Label

Page 10 LM5200 Operating Manual
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.

P/N 66188, Rev. 5 Page 11
About this Manual
Climax machines are highly configurable 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 in this manual. If a
specific machine application requires additional options or accessories, please contact Climax
for assistance in obtaining the needed components.
This manual describes the operation and maintenance of your linear and gantry milling
machine. The machine is designed for milling and drilling operations in linear and gantry modes.
All parts meet Climax Portable Machining & Welding Systems’ strict quality standards. For
maximum safety and performance you must read and understand the entire manual before
operating the machine.

Page 12 LM5200 Operating Manual
CE Information
This machine has been tested for European Conformity, and has been designed to strict
engineering standards. Risk assessments and safety have been evaluated and adhered to
during the design and manufacture of this machine.
Risks and hazards associated with the use of this equipment are clearly marked on the machine
or referenced in the operating manual in accordance with International Standards.
If you have any questions or concerns, contact Climax before operating this equipment.
The Declared Sound Power Level is: LWA = 73.9 dB(A)
The Declared Operator Sound Pressure Level is: LpA= 76.5 dB(A)
The Declared Bystander Sound Pressure Level is: LpA= 76.1 dB(A)

P/N 66188, Rev. 5 Page 13

Page 14 LM5200 Operating Manual
General Information
The LM5200 Milling Machine revolutionizes both the capabilities and functionality of portable
mills.
•The machine is extremely rigid, with modular bed design
•Innovative configuration options allow setup for both conventional milling and gantry
milling in one machine
•Powerful, precise machining
Rigid, Modular Design
•Modular bed design allows the machine to be lengthened to machine a variety of work
piece sizes without losing rigidity
•Bed may be shortened to fit into tight work spaces
•Bed connection system provides the ultimate in rigidity, even when bed is extended by 2
or 3 times the original length
Flexible Configuration & Operation
•The innovative new design of these milling machines allow them to be configured for
traditional linear milling, or simply split the rails lengthwise to configure for gantry milling
•Electric feeds can be mounted on the X, Y and Z-axes
•Machining capabilities include milling, drilling and boring
Powerful, Precise Machining
•Features heavy duty spindle design and a choice of hydraulic power units
•Milling can be done in any axis, with a milling head that can rotate 90°. An optional
attachment allows for 360° rotation.
•Fast, aggressive milling in horizontal, vertical, or inverted applications
•Provides reliable, precise milling to meet tight machining tolerances in both conventional
and gantry mill configurations

P/N 66188, Rev. 5 Page 15
Rigging and Lifting
WARNING
Falling or uncontrolled swinging of machinery can cause serious injury or
be fatal to the operator and bystanders. Lift the machine
only by the
properly designated lifting eyes. Do not lift the assembled machine by the
machining arm.
Weights and Dimensions
Machine Weights
Bed (Travel)
48" (36”) 1219mm (914mm)
358 lb
163 kg
72" (60”) 1829mm (1524mm)
506 lb
230 kg
96" (84”) 2438mm (2134mm) 654 lb 298 kg
Ram (Travel)
26" (16”) 660mm (406mm)
176 lb
80 kg
44" (34”) 1118mm (864mm)
269 lb
122 kg
Milling Head
#40 Taper (w/o motor) 62 lb 28 kg
HSK 40A Electric (w/o motor) 51 lb 23 kg
HSK 40A Hydraulic (w/o motor)
45 lb
21 kg
Overall Dimensions
Length
Bed Length + 2.5" (63.5mm)
Width
Ram Length + 3.7" (93.9mm)
Height
w/o Handwheel 18.7" (474.9mm)
w/ Handwheel
22.0" (558.8mm)

Page 16 LM5200 Operating Manual
Lifting Eyes
Ram ONLY Lift Points
Bed Lifting Eye
Example of Vertical Lifting
Lifting Points

P/N 66188, Rev. 5 Page 17
1. To prevent damage to the milling head, carefully remove the milling head with a sling
before lifting the ram.
2. Center the machining arm (ram) over the beds before lifting.
3. Test lift slowly and adjust the center of gravity as necessary for controlled lifting.
4. ONLY lift the entire assembled machine from the bed lifting eyes, DO NOT lift the entire
machine from the machining arm (ram) lift points
5. Use a sling to install the milling head when the complete machine is mounted in position.
WARNING
Parts can shift and loosen during shipment causing components to fall
and drop during rigging causing serious injury or death. Before removing
the tool from the shipping container make sure that all tool fasteners /
components are tight and secure.

Page 18 LM5200 Operating Manual
Operational Dimensions