BB5500

BORING MACHINE
OPERATING MANUAL
SERIAL NUMBER RANGE:
11017900 - 11021000
ORIGINAL INSTRUCTIONS

P/N 29327
May 2019
Revision 3
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

P/N 29327, Rev. 3 Page 1

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 2 BB5500 Operating Manual

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 AMBIENT LIGHTING

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

P/N 29327, Rev. 3 Page 3

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

Page 4 BB5500 Operating Manual

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.

P/N 29327, Rev. 3 Page 5

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.

Page 6 BB5500 Operating Manual

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.

P/N 29327, Rev. 3 Page 7

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

Page 8 BB5500 Operating Manual

CE Mark
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.

P/N 29327, Rev. 3 Page 9

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.

Page 10 BB5500 Operating Manual

 Climax BB5500 Components

P/N 29327, Rev. 3 Page 11

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.

Page 12 BB5500 Operating Manual

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.

P/N 29327, Rev. 3 Page 13

 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.

Page 14 BB5500 Operating Manual

 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.

Socket Head Cap Screw

SHCS

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

P/N 29327, Rev. 3 Page 15

 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.

Page 16 BB5500 Operating Manual

 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

P/N 29327, Rev. 3 Page 17

 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

Page 18 BB5500 Operating Manual

 Coupling
0 shim 0.25 0.5 0.75 1 1.25 1.5 1.75
Diameter

27 18.7 19.2 19.8 20.3 20.8 21.3 21.9 22.4

28 19.8 20.3 20.9 21.4 21.9 22.4 23.0 23.5

29 20.9 21.4 21.9 22.5 23.0 23.5 24.0 24.6

30 22.0 22.5 23.0 23.5 24.1 24.6 25.1 25.6

31 23.1 23.6 24.1 24.6 25.1 25.7 26.2 26.7

32 24.1 24.7 25.2 25.7 26.2 26.7 27.3 27.8

33 25.2 25.7 26.2 26.8 27.3 27.8 28.3 28.8

34 26.3 26.8 27.3 27.8 28.4 28.9 29.4 29.9

35 27.3 27.9 28.4 28.9 29.4 29.9 30.5 31.0

36 28.4 28.9 29.4 30.0 30.5 31.0 31.5 32.0

37 29.5 30.0 30.5 31.0 31.5 32.1 32.6 33.1

38 30.5 31.0 31.6 32.1 32.6 33.1 33.6 34.1

39 31.6 32.1 32.6 33.1 33.6 34.2 34.7 35.2

40 32.6 33.2 33.7 34.2 34.7 35.2 35.7 36.3

41 33.7 34.2 34.7 35.2 35.8 36.3 36.8 37.3

42 34.7 35.3 35.8 36.3 36.8 37.3 37.8 38.4

43 35.8 36.3 36.8 37.3 37.9 38.4 38.9 39.4

44 36.8 37.4 37.9 38.4 38.9 39.4 39.9 40.4

45 37.9 38.4 38.9 39.4 39.9 40.5 41.0 41.5

46 38.9 39.4 40.0 40.5 41.0 41.5 42.0 42.5

47 40.0 40.5 41.0 41.5 42.0 42.5 43.1 43.6

48 41.0 41.5 42.0 42.6 43.1 43.6 44.1 44.6

49 42.0 42.6 43.1 43.6 44.1 44.6 45.1 45.6

50 43.1 43.6 44.1 44.6 45.1 45.7 46.2 46.7

51 44.1 44.6 45.2 45.7 46.2 46.7 47.2 47.7

52 45.2 45.7 46.2 46.7 47.2 47.7 48.2 48.8

P/N 29327, Rev. 3 Page 19

 53 46.2 46.7 47.2 47.7 48.3 48.8 49.3 49.8

54 47.2 47.7 48.3 48.8 49.3 49.8 50.3 50.8

55 48.3 48.8 49.3 49.8 50.3 50.8 51.3 51.9

56 49.3 49.8 50.3 50.8 51.4 51.9 52.4 52.9

57 50.3 50.8 51.4 51.9 52.4 52.9 53.4 53.9

58 51.4 51.9 52.4 52.9 53.4 53.9 54.4 54.9

59 52.4 52.9 53.4 53.9 54.4 55.0 55.5 56.0

60 53.4 53.9 54.4 55.0 55.5 56.0 56.5 57.0

61 54.5 55.0 55.5 56.0 56.5 57.0 57.5 58.0

Spacer Shim Table

Optional special spacer blocks are available.

Special spacer blocks are available for couplings with large OD’s (compared to the bolt circle diameter). These spacers
decrease the bolt circle size in the table by 4”, 8” or 12” inches, depending on how they are stacked. Call your Climax sales
representative for information on this option.

Page 20 BB5500 Operating Manual

 Spacing the Machine off the Coupling

Setting the Machine on the Work Piece

Adjustments to bring the centerlines into precise alignment are made with jacking bolts on the
strongback support after the machine is mounted.
Set the machine on the workpiece.
Before you set the machine onto the work piece make sure the strongback supports and
bearing assembly are positioned to meet the needs of your application.
1. Loosen the chain ends as much as possible.
2. Be sure the block feet are attached to the strongback base supports. For more information,
see “Spacing the Machine from the Coupling”.

P/N 29327, Rev. 3 Page 21

 Do the following to set the machine onto the work piece.

WARNING
Be sure the crane, or hoist, has a steady hold of the
machine before lifting it. Uncontrolled swinging or
falling of the machine can cause serious personal injury
and damage to the machine.

1. Use the lifting eyes to lift the machine with a crane or hoist onto the work piece.
2. Wrap chains around the workpiece.
3. Unscrew the chain clamp nut so that only 2-3 threads of the chain clamp bolt are engaged.
4. While pulling as much slack as possible out of the chain, hook a pin of the chain into the
opposite chain clamp block.
5. Evenly tighten the two chain clamp nuts on each side of the machine.

IMPORTANT
When tightening the chain onto the rocker and large casting
block, make sure the top of the chain assembly does not
contact the base strongback support.

Page 22 BB5500 Operating Manual

 Installing the Bearing Hanger
Make sure the gibs on the upper bearing hanger and RDU are both on the same side.
Failure to keep the gib on the same side prevents the boring bar from aligning and will
cause the bar to bind.

Installing the RDU (Rotational Drive Unit)

Make sure the gib is on the same side of the strongback supports as the gib on the RDU.
Failure to keep the gib on the same side prevents the boring bar from aligning and will
cause the bar to bind.

Once these are positioned and spaced to the correct distance from the bore, tighten the gib
screws to the lock them to the strongback.

Roughly Positioning the Machine onto the Work Piece

Do the following to roughly center the machine to the workpiece

Position the machine so that the middle of the bearing is centered to the shaft of the
workpiece. Look through the work piece at the machine bearing, as shown below, to make
sure the machine is centered.

Aligning the machine to the workpiece

Once the machine is roughly centered as shown above, tighten the chains.

P/N 29327, Rev. 3 Page 23

 Slide the Boring Bar into the Machine
Do the following to slide the boring bar into the machine.
1. Slide the boring bar and lower bearing hanger assembly onto the bearing hanger.
2. Tighten the clamp assembly.

Clamp assembly

3. Clean the bar’s tapered end and the taper on the RDU. Failure to keep the tapers on the bar
and RDU free from dirt, chips, and other debris will cause damage to the boring bar.
4. Draw the bar’s tapered end into the RDU by tightening the draw bolt on the back side of the
RDU. Make sure the drive keys are properly engaged with the drive gear and tighten
securely.
5. At this point, go over the entire machine and make sure all of the bolts and screws are tight.

Page 24 BB5500 Operating Manual

 Aligning the Boring Bar within the Work Piece
To align the machine to the workpiece, use a scale for preliminary alignment and a dial
indicator for a final measurement. Which procedures you follow when aligning the machine
to the work piece depends on the level of precision you need. Use a scale (such as a ruler)
or a dial indicator depending on your precision needs.

Do the following to check concentricity using a dial indicator.

1. Mount a dial indicator to one end of the bore. Using a second dial indicator mounted to
the other end of the bore saves time.

2. Sweep the bore ID.

3. Based on the readings of the dial indicator(s), make fine alignment adjustments as
necessary.

Preparing for Hydraulic Power Use

Do the following to prepare the machine for hydraulic power .
1. Make sure the power unit is OFF.
2. Be sure all fittings are clean.
3. Connect the hydraulic lines between the power unit and the motor.
4. Jog the motor to see which direction the bar is rotating. The bar must rotate clockwise
as seen from the axial feed box end looking toward the rotational drive end of the bar. If
the bar is rotating the wrong direction: Turn off the power unit, and switch the hoses at
the motor.

P/N 29327, Rev. 3 Page 25

 5. Adjust the speed of bar rotation by turning the motor speed control (a knob located on
the operator pendant).

Operator pendant

Page 26 BB5500 Operating Manual

 CAUTION
Connect the motor to the power unit before turning
on the power unit. Failure to do so will damage the
power unit pump and void all warranties.

Installing the Axial Feedbox

There are three types of feed boxes available.
 The single direction mechanical feed.
 The reversible mechanical feed - PN 47287
 The electric feed. Please see your Climax Sales Representative about details for this
option.

Install the Single-Direction Mechanical or Electrical Feed

The axial feed unit can be used with or without the bar rotating in manual mode. To adjust
the feed rate while the bar is rotating, use the feed adjustment knob.
The following procedures apply to both mechanical and electrical feedbox installation.

To install the axial feedbox:

1. Place the axial feed box assembly on the end of the bar.
2. Tighten the socket-head cap screws on the axial feed box collar to hold the feed unit
securely.
3. For the mechanical feedbox only, tie down the axial feed assembly torque rod.

Install the Reversible Mechanical Feed

The axial feed clamps to the bar with a single clamping screw on the main housing of the
feed box.
The tool slide position can be adjusted using the manual feed handle.
When standing at the feed box end of the bar looking towards the RDU, turning the crank
handle clockwise will retract the tool slide towards the feed box.

CAUTION
Always remove the feed handle when the machine is
operating.

P/N 29327, Rev. 3 Page 27

 The feed selector has three positions with detent stops. These stops have approximately
.3” (8mm) of travel between positions.

It may be necessary to slightly turn the feed selector knurled knob when engaging the feed
or if it becomes jammed.

When the feed selector is

pushed IN as shown,
forward feed (tool slide
moving away from the feed
box) is engaged.

When the feed selector

is in the neutral position,
there will be no feed and
the crank handle can be
used to position or
retract the tool slide.

Page 28 BB5500 Operating Manual

 When the feed selector
is in the full retracted
position, the tool slide
will feed towards the
feed box.

WARNING
You, the operator, must monitor the tool slide position. Over-
travel of the tool slide in either direction will result in damage
to the machine.

The feed rate is adjusted from zero to approximately .007” (.178 mm) per revolution by
pressing and holding the “+” or “-“, button while the bar is rotating.

The markings next to the feed adjust

buttons are “+” or “-“, when the bar is
running clockwise, as viewed from the feed
box end.

The markings on the feed adjust buttons are

reversed if the bar is running counter
clockwise, as viewed from the feed box end.

Feed Box Adjust Buttons

P/N 29327, Rev. 3 Page 29

 Each turn of the bar while the button is pushed increments an internal adjustment about
1/100 of the travel range. 10-15 turns of the bar are necessary to change the feed rate
approximately .001” per revolution.

The amount of feed is

shown by the feed
indicator. The length of
the red engraved line on
the feed indicator shows
the relative feed
amount.

Page 30 BB5500 Operating Manual

 Tooling Setup
The Climax Model BB5500 has a traveling tool slide controlled by the leadscrew and axial
feed unit. The tool slide has a rectangular pocket that accepts a variety of tool holders
which are available for different bore diameter ranges and tooling types. The tool holders
included are pictured below.

Cartridge High speed steel bit holder

Figure 1 Tool holders

Figure 2 Tool slide

P/N 29327, Rev. 3 Page 31

 Setting up the tool holder
The 5/16” square bit holder accepts high speed steel, solid carbide or brazed carbide tool
bits. The cartridge holder is designed for the sizes 2 and 3 Microbore cartridges and uses
supplied replaceable carbide inserts.
The cartridge holder is designed for the size 2 and 3 cartridges and uses supplied
replaceable carbide inserts.
Tooling made of high speed steel is recommended for roughing bores. High speed steel
cuts more freely and causes less bar deflection for large depth of cut. Carbide has superior
wear characteristics and is recommended for light finish passes.
Although the tool holder can be installed so the cutting surface faces either the RDU or the
feed end of the bar, always insert the tool holder so it is correctly positioned for clock-wise
bar rotation, as shown below. If needed, simply remove the tool holder and rotate the
locating key 180 degrees.

Gib Adjustment
Turn the center screw counterclockwise to tighten.

IMPORTANT
Always place the tool holder completely in the
pocket of the tool slide and secure with the two
setscrews provided in the tool slide.

IMPORTANT
Excessive clearance in the tool slide can affect final
finish and tolerance of the bore.

Page 32 BB5500 Operating Manual

 Setting up the high speed steel tool
There are two setscrews positioned
diagonally on the top surface of the high
speed steel tool holder. These screws allow
the radial position of the tool bit to be micro
adjusted.
The high speed steel tool holder has two
setscrews that clamp the tool bit in the
broached hole. Do the following procedure to
set up the high speed tool holder.
1. Clamp the tool bit in the holder so that it
is approximately 0.040” (1mm) or less
under the desired cutting radius.
2. Place the tool holder in the tool slide.
3. Lightly tighten the two setscrews in the
tool slide against the tool holder.
4. Place a dial indicator on the tool holder—or the tool slide can be positioned in the bore
from the tool slide for reference.
5. The set screw in the top face of the tool holder closest to the tool bit can then be
adjusted with reference to a dial indicator reading—or until it just touches the existing
coupling bore.
6. Make adjustments until the final depth of cut is set.
7. Tighten the two screws in the end of the tool slide to secure the tool holder and radial
setting. The tool holder should never be extended more than 0.080” (2 mm) out of the
tool slide as damage to the tool slide may result.

P/N 29327, Rev. 3 Page 33

 Assembling the cartridge
1. Remove the lock screw, top adjust spring, and washer from the cartridge.
2. Insert the cartridge on the tool holder.
3. Install the lock screw, top adjust spring, and washer back into the cartridge.
4. Turn the dial nut until the cartridge is at the desired position.
5. Turn the lock screw until there is slight spring tension on the washers. Do not over-
tighten to allow for further adjustability from the dial nut.
6. Install the tool holder on the tool slide.
7. Turn the dial nut to the desired position.

u
p

Page 34 BB5500 Operating Manual

 Setting up the cartridge
The cartridge holder includes a tool for
changing the inserts and an adjusting
wrench for adjusting the radial position
of the tool holder.
The Microbore cartridge uses spring
tension from washers located
underneath the cartridge to hold the
cartridge in place. This cartridge needs
to have some tension but does not
need be tight.
Once in the holder, there is about a
.010” radial travel by manipulating the
dial nut from having enough tension on
the washers, to locking the cartridge. If
this happens, the tool holder needs to be removed from the tool slide.
1. Loosen the lock screw.
2. Feed the cartridge to the desired position with the dial nut to the desired position and
apply enough pressure on the washers with the lock screw.
Do the following for maximum repeatability.
1. Make sure all seating surfaces between the tool holder and the tool slide are clean.
2. Set the tool holder in place, pressing down and to the loading side.
3. Start gently tightening the tool holder locking set screws located on the tool slide; it is
important to start with almost no torque, and switch between screws increasing the
torque. Make sure the set screws always have the same amount of torque so that the
tool repeats position.

P/N 29327, Rev. 3 Page 35

 Choosing the tool holder
Use the following tables to select the appropriate tool holder

TOOL HOLDER TABLE

1-7/8" Bar 2-1/2" Bar

PN Tool Type
Min Max Min Max

2.087 2.707 2.520 3.140

46636
(53.0) (68.8) (64.0) (79.8)
5/16" sq HSS
(PN 46661)
2.660 3.660 2.756 4.056
47189
(67.6) (93.0) (70.0) (103.0)

2.090 2.444
78531 NA NA
No. 2
(53.1) (62.1)
Microbore
(PN 78358)
2.435 2.789 2.515 2.869
Insert 78420
78532
(61.8) (70.8) (63.9) (72.9)

2.650 3.154 2.730 3.234

78342
(67.3) (80.1) (69.3) (82.1)
No. 3
3.145 3.649 3.225 3.729
Microbore
78343
(PN 78359)
(79.9) (92.7) (81.9) (94.7)
Insert 78421
3.635 4.139 3.720 4.224
78344
(92.3) (105.1) (94.5) (107.3)

Page 36 BB5500 Operating Manual

Operation
Pre-start Checks
Before operating the machine, check that:
 All machine parts, including the tool head, tool bit, gib key setscrews, draw bolt, tapered
dovetail way clamp and collar clamps are secure.
 The power is connected and turned on.
 The hydraulic lines are properly connected.
 The bore and tool bit are lubricated with cutting oil, if desired.

CAUTION
Do not leave the crank handle on the feed box
during machining operations!

To operate the machine

1. Press the START button under the HPU heading on the switchbox to turn the machine
on.
2. Set the feed to operate clockwise or counterclockwise (FWD/REV).
3. Turn the BAR RPM to zero by holding the switch at the “-“ position.
4. Set the BAR and FEED RUN/JOG switches to the RUN position.
5. Press START under the BAR heading to start the bar turning.
6. Adjust the RPM to the desired speed.
7. Advance the tool FEED to just before the workpiece.
8. Turn the SPEED dial to the desired speed.
9. Press START under the FEED heading to start the feed.
10. As boring begins, adjust the RPM and SPEED as needed.

To retract the tool carrier

1. Press STOP under the FEED heading to stop the feed.
2. Press STOP under the BAR heading to stop the bar.
3. Use the rapid button, or turn the manual crank handle to retract the tool carrier toward
the axial feed box.
4. Press STOP under the HPU heading to stop the machine.

P/N 29327, Rev. 3 Page 37

 The speed controller consists of an electrical enclosure which houses the DC motor
controller, operator pushbuttons and switches. The control functions are as follows:

1. EMERGENCY STOP—press down to stop the machine, then twist and pull up to reset.
2. HPU—Hydraulic power unit start and stop buttons.
3. BAR—start and stop the bar rotation.
4. RPM—increase or decrease the RMP of the bar.
5. RUN/JOG—in RUN mode, the bar turns continuously. In JOG mode, the bar can be
turned by pressing the BAR start button and will stop when the button is released.
6. FEED—controls the movement of the cutting tool.
7. SPEED—increase or decrease the speed of the tool feed.
8. RAPID—maximum speed of the tool feed as long as the button is pressed.
9. RUN/JOG—in RUN mode, the feed moves automatically. In JOG mode, the feed can
be advanced by pressing the FEED start button and will stop when the button is
released.
10. FWD/REV—changes the direction of the tool feed.

Page 38 BB5500 Operating Manual

Disassembly
Do the following to disassemble the machine.
1. Turn off the hydraulic power unit.
2. Remove the axial feed box assembly.
3. Retract the tool holder.
4. Loosen the bearing cartridge collar.
5. Loosen the rotational drive draw bolt.
6. Loosen the bearing hanger clamp assembly from the tapered dovetail way.
7. Pull the bar assembly and lower bearing hanger assembly from the bore as a
unit.
8. Inspect the bore.
9. If the bore is not to specifications, reinstall the machine and re-machine the
bore.

P/N 29327, Rev. 3 Page 39

Maintenance
Maintenance Items
Follow the list below when maintaining your BB5500 Portable Boring Machine.
 Mounting assembly: Inspect the dovetail ways, clean, lubricate, and carefully
remove any burrs.
 Boring bars: Handle boring bars carefully to prevent damage. Inspect the taper
and carefully remove any burrs. For long-term storage, keep the bar in a vertical
position

CAUTION
Protruding setscrews will damage mating parts. Be sure the
setscrew holding the tool bit in place does not protrude
beyond the outer surface of the bar.

 Axial feed box: Under normal conditions, the axial feed box is maintenance-free.
 Hydraulic power unit: After each 72 hours of operation replace the filter
cartridge, check the heat exchanger for leaks, clean the filler/breather.
 Hydraulic Motor: The hydraulic motor is maintenance-free. Fluid passing through
the motor lubricates the internal moving parts. To make sure long life and
dependable operation, use high-quality, clean hydraulic fluid.
 Hydraulic Filter and Fluid: Periodic replacement of the filter and fluid is required
for proper operation. Initially, change the filter after 72 hours of operation to
remove any impurities in the system. Thereafter, replace every 150-200 hours.
Use only a high-quality filter. Climax recommends a 10-micron, industrial-grade
filter. If the system includes a change-warning gauge, change the filter as often
as indicated. Clean hydraulic fluid will help keep the power unit and motor
running properly.
 Maintain proper fluid level. Do not allow the level to drop below the red line at
the bottom of the level/temperature gauge.
 Maximum recommended oil operating temperature is 150° F (66° C).

Page 40 BB5500 Operating Manual

Storage
Proper storage protects the machine from damage and corrosion.
1. Before storing, clean the machine with solvent to remove grease, metal chips, and
moisture.
2. Spray with a light oil for short-term storage or use diesel for long-term storage to
prevent corrosion.
3. Place the boring bar with all tools and accessories in the case provided.
4. Include desiccant or wrap with metal protection to protect from moisture.

P/N 29327, Rev. 3 Page 41

Specifications
All specifications are dependent on experienced operators, proper machine setup, and correct
bearing spacing.

Bearing Spacing: Cutting should take place no further from a bearing than 4 times the bar
diameter. Distance between bearings should not exceed 8 times the bar diameter.

1-3/8” boring bar: Maximum recommended bearing spacing to achieve specs 11”
1-7/8” boring bar: Maximum recommended bearing spacing to achieve specs 15”
2-1/2” boring bar: Maximum recommended bearing spacing to achieve specs 20”

Specification Detail
Surface finish 125 Ra (micro-inch) can be achieved when using a
carbide insert or a suitably hand ground tool bit with
appropriate nose radius and correct feed and speed
Cylindricity 0.001 inch (0.025 mm) per 12 inches, at or below
recommended bearing spacing
Axial feed rate 0 - 0.007 inch (0 – 0.178 mm) per revolution
Gear / Drive ratio 1.13:1
Torque produced 2.2 cubic inch HPU: 22 ft. lbs.
3.6 cubic inch HPU: 40 ft. lbs.
5.9 cubic inch HPU: 65 ft. lbs.

Perpendicularity and alignment are dependant on operator setup.

Page 42 BB5500 Operating Manual

Exploded Views and Parts
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 & Welding Systems to perform service on
the machine.

P/N 29327, Rev. 3 Page 43

 27294 HANGER BEARING ASSEMBLY LOW ER 1-7/8 DIA BAR
BALLOON NO PART DESCRIPTION
1 26483 RING SNAP 3.543 ID (90 mm)
2 26446 BEARING CARTRIDGE 1-7/8 ID 3.543 OD
3 26447 HANGER BEARING LOWER
4 25625 CLAMP ASSEMBLY BEARING HANGER
5 10160 SCREW 1/4-20 X 3/4 SHCS

29043 HANGER BEARING ASSEMBLY LOW ER 2-1/2 DIA BAR STRAIGHT

BALLOON No PART DESCRIPTION
1 29045 RING SNAP 5 ID
2 29042 BEARING CARTRIDGE 2-1/2 ID X 4.9213 OD (STRAIGHT)
3 29044 HANGER BEARING LOWER 2-1/2 DIA STRAIGHT
4 25625 CLAMP ASSEMBLY BEARING HANGER
5 10160 SCREW 1/4-20 X 3/4 SHCS

Figure 3 - Hanger Bearing Lower

1-7/8 Dia Bar 27294
2-1/2” Dia Bar 29043

Page 44 BB5500 Operating Manual

 27295 HANGER BEARING ASSEMBLY LOW ER 2-1/2 DIA BAR SPHERICAL
BALLOON NO PART DESCRIPTION
1 25502 BEARING CARTRIDGE 2-1/2 ID X 4.9213 OD SPHERICAL
2 25624 HANGER BEARING LOWER 2-1/2 DIA SPHERICAL
3 25625 CLAMP ASSEMBLY BEARING HANGER
4 10160 SCREW 1/4-20 X 3/4 SHCS

Figure 4 - 27295 Hanger Bearing Lower 2-1/2 Dia Bar Spherical

P/N 29327, Rev. 3 Page 45

Page 46 BB5500 Operating Manual
 27285 BAR BORING ASSEMBLY 2-1/2 DIA X 36 LONG
BALLOON NO PART DESCRIPTION
1 25461 BAR BORING 2-1/2 DIA X 36 IN. LG.
2 25631 KEY BORING BAR
3 12418 SCREW 1/4-20 X 5/8 SHCS
4 11165 WASHER THRUST .625 ID X 1.125 OD X .060
5 10538 BEARING THRUST .625 ID X 1.125 OD X .0781
6 25532 LEADSCREW
7 25467 CAP END

P/N 29327, Rev. 3 Page 47

 Figure 5 - 27285 & 28765 Bar Boring 2-1/2 Dia

Page 48 BB5500 Operating Manual

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