SECTION ONE
INTRODUCTION
TABLE OF CONTENTS
TITLE PAGE
INTRODUCTION........................................................................................................................................ 1-1
INFORMATION ABOUT THIS MANUAL..................................................................................................1-1
MACHINE DESCRIPTION......................................................................................................................... 1-1
MACHINE CONFIGURATION................................................................................................................... 1-2
MACHINE SPECIFICATIONS ................................................................................................................... 1-3
HORSEPOWER CHARTS......................................................................................................................... 1-8
COORDINATE SYSTEMS......................................................................................................................... 1-9
AXIS POSITION MEASUREMENT SYSTEM ........................................................................................... 1-9
BEFORE STARTING ANY DISASSEMBLY...........................................................................................1-10
MECHANICAL & HYDRAULIC DOCUMENTATION..............................................................................1-10
HOW TO ORDER PARTS .......................................................................................................................1-11
INTRODUCTION
This is a composite manual for Giddings & Lewis 480 Series Horizontal Boring Machines.
The purpose of this manual is for instruction and maintenance purposes and it covers the mechanical and
hydraulic systems for the machines described in this section of the manual. Material covered includes
installation, machine alignments, mechanical units, coolant, hydraulic, lubrication and pneumatic systems.
Procedures for repair (of certain parts of the machines) and troubleshooting are outlined in this manual
with the interest of keeping machine downtime to a minimum.
INFORMATION ABOUT THIS MANUAL
This manual is divided up into different sections. The General Contents, indicating what can be found in
the various sections, is found near the very front of the manual. The first page(s) of each section is the
Table of Contents for that particular section. The pages immediately behind the Table of Contents are
then numbered consecutively: 1-1, 1-2, etc.
PRINT BOOKS AND VENDOR DOCUMENTATION
The drawings, sketches, and photographs included in this manual are for reference only. Each machine
is shipped with a specific set of machine drawings in large size format. These drawings or "prints" are
referred to as Print Books. The large prints are assembled in numerical order with the print number being
shown in the lower right hand title box. The Print Books are what should be used when performing
maintenance procedures. This manual covers maintenance procedures with a brief overview but refers
to the Print Books for complete and detailed instructions and procedures. The Print Books should be
studied before beginning any maintenance procedures. Maintenance procedures should be conducted
by qualified maintenance personnel only.
This manual also refers to vendor documentation. Some components of the machine are assembled by
suppliers of Giddings & Lewis. These components come with their own documentation and should be
referred to when conducting maintenance procedures on those components.
MACHINE DESCRIPTION
The Horizontal Boring Machines are computerized numerically controlled production centers suited for
producing work pieces contained in a program envelope. The basic configuration of the machine is a
table-type machine. The table-type machine has a stationary column and "X" axis motion is provided by
a movable machine table (figure 1-1). The plain table (PT) machine is a four-axis machine that has four
linear axes of travel. The rotary table (RT) and machining center (MC) machines are five-axis machines
that have four linear axes of travel and one rotary axis. The machine axes are as follows:
Rotary table movement = "B" axis
Saddle movement in and out towards the column = "W" axis
Table movement back and forth (perpendicular with the spindle) = "X" axis
Headstock movement up and down = "Y" axis
Spindle movement in and out of the headstock = "Z" axis ("Z" and "W" are collinear, however
separately controlled)
1-1
MACHINE CONFIGURATION
Note: Machine/component specifications can vary depending on individual customer and/or
machining requirements.
Y+ Axis Designation
& Direction
X+
B+
Z/W+
C+
A+
Z/W-
X-
Y Axis
Y-
Z Axis
X Axis
W Axis
PT 1500 / PT 1800
PLAIN TABLE
Figure 1-1
1-2
MACHINE SPECIFICATIONS
PT SPECIFICATIONS
CAPACITIES
PT 1500 PT 1800
X-axis travel 118.1 (3000) 141.7 (3600)
165.4 (4200)
Y-axis travel 82.6 (2100) 82.6 (2100)
Optional 98.4 (2600) 98.4 (2600)
122.0 (3100) 122.0 (3100)
141.7 (3600)
Y-axis travel below table top 0 0
W-axis travel (saddle) 59.0 (1500) 59.0 (1500)
78.7 (2000) 78.7 (2000)
98.4 (2500) 98.4 (2500)
137.8 (3500) 137.8 (3500)
PLAIN TABLE
Table Size 59 x 118.1 (1500 x 3000) 70.9 x 141.7 (1800 x 3600)
70.9 x 165.4 (1800 x 4200)
Allowable Load 55,100 lbs. (25,000 kg) 88,200 lbs. (40,000 kg)
SPINDLE
Spindle Diameter Spindle Travel Power Spindle Speed
S6-40
5.1 (130) 2 Speed 31.5 (800) 60 HP (45 kw) Low 10 - 1000
High 1000 – 4000
5.1 (130) 4 Speed 39.4 (1000) 60 HP (45 kw) Range 1 10 – 185
Range 2 174 – 463
6.1 (155) 4 Speed 49.2 (1250) 74 HP (55 kw) Range 3 446 – 1190
Range 4 1116 – 3500
FEEDS / TRAVERSE
X, Y, Z, W 985 ipm (25,000 mm/min)
B 6 RPM
TOOLCHANGER
Tool Magazine Capacity (optional) 60 – 90 - 120
Tool Diameter (adjacent pocket full) 4.9 (125)
(adjacent pocket empty) 9.8 (250)
Tool Length 29.5 (750)
Tool Weight 110 lb. (50 kg)
1-3
Y Axis
Z Axis
B
Axis
X Axis
W Axis
RT1250 / RT1600
Rotary Table
Figure 1-2
1-4
RT SPECIFICATIONS
CAPACITIES
RT 1250 RT 1600
X-axis travel 98.4 (2500) 98.4 (2500)
141.7 (3600) 141.7 (3600)
Y-axis travel 82.6 (2100) 82.6 (2100)
98.4 (2600) 98.4 (2600)
122.0 (3100) 122.0 (3100)
141.7 (3600)
Y-axis travel below table top 3.937 (100) 5.315 (135)
W-axis travel (saddle) 59.0 (1500) 59.0 (1500)
78.7 (2000) 78.7 (2000)
98.4 (2500) 98.4 (2500)
137.8 (3500) 137.8 (3500)
NC ROTARY TABLE
Table Size 49.2 x 63 (1250 x 1600) 63 x 78.7 (1600 x 2000)
63 x 70.9 (1600 x 1800) 63 x 98.4 (1600 x 2500)
Allowable Load 33100 lbs. (15000 kg) 55100 lbs. (25000 kg)
Number of Positions 360,000
Index Rate 6 rpm
SPINDLE
Spindle Diameter Spindle Travel Power Spindle Speed
S6-40
5.1 (130) 2 Speed 31.5 (800) 60 HP (45 kw) Low 10 - 1000
High 1000 – 4000
5.1 (130) 4 Speed 39.4 (1000) 60 HP (45 kw) Range 1 10 – 185
Range 2 174 – 463
6.1 (155) 4 Speed 49.2 (1250) 74 HP (55 kw) Range 3 446 – 1190
Range 4 1116 – 3500
FEEDS / TRAVERSE
X, Y, Z, W 985 ipm (25,000 mm/min)
B 6 RPM
TOOLCHANGER
Tool Magazine Capacity (optional) 60 – 90 - 120
Tool Diameter (adjacent pocket full) 4.9 (125)
(adjacent pocket empty) 9.8 (250)
Tool Length 29.5 (750)
Tool Weight 110 lb. (50 kg)
1-5
Y Axis
Z Axis
X Axis
W Axis
MC1250 / MC1600
MACHINING CENTER
FIGURE 1-3
1-6
MC SPECIFICATIONS
CAPACITIES
MC 1250 MC 1600
X-axis travel 98.4 (2500) 98.4 (2500)
141.7 (3600) 141.7 (3600)
Y-axis travel 82.6 (2100) 82.6 (2100)
Optional 98.4 (2600) 98.4 (2600)
122.0 (3100) 122.0 (3100)
141.7 (3600)
Y-axis travel below table top 3.937 (100) 5.315 (135)
W-axis travel (saddle) 59.0 (1500) 59.0 (1500)
78.7 (2000) 78.7 (2000)
98.4 (2500) 98.4 (2500)
137.8 (3500) 137.8 (3500)
NC ROTARY TABLE
Pallet Size 49.2 x 49.2 (1250 x 1250) 63 x 63 (1600 x 1600)
49.2 x 63 (1250 x 1600) 63 x 78.7 (1600 x 2000)
63 x 70.1 (1250 x 1800) 63 x 98.4 (1600 x 2500)
Allowable Load (ON PALLET) 15430 lbs. (7000 kg) 33000 lbs. (15000 kg)
(ON MACHINE) 33100 lbs (15000 kg) 55100 lbs. (25000 kg)
Number of Positions 360,000
Index Rate 6 rpm
SPINDLE
Spindle Diameter Spindle Travel Power Spindle Speed
S6-40
5.1 (130) 2 Speed 31.5 (800) 60 HP (45 kw) Low 10 - 1000
High 1000 – 4000
5.1 (130) 4 Speed 39.4 (1000) 60 HP (45 kw) Range 1 10 – 185
Range 2 174 – 463
6.1 (155) 4 Speed 49.2 (1250) 74 HP (55 kw) Range 3 446 – 1190
Range 4 1116 – 3500
FEEDS / TRAVERSE
X, Y, Z, W 985 ipm (25,000 mm/min)
B 6 RPM
TOOLCHANGER
Tool Magazine Capacity (optional) 60 – 90 - 120
Tool Diameter (adjacent pocket full) 4.9 (125)
(adjacent pocket empty) 9.8 (250)
Tool Length 29.5 (750)
Tool Weight 110 lb. (50 kg)
1-7
HORSEPOWER CHARTS
FOUR-SPEED HEADSTOCK WITH 74 HORSEPOWER
FOUR-SPEED HEADSTOCK WITH 60 HORSEPOWER
1-8
TWO-SPEED HEADSTOCK WITH 60 HORSEPOWER
COORDINATE SYSTEMS
The standard XYZ right hand coordinate system is used on milling machines. Figure 1-1 shows the
standard XYZ right hand coordinate system. Machine motions agree with what is shown only if the cutter
moves in a particular axis. If the cutter doesn't move in a particular axis, the machine motion will be
opposite what is shown. The cutter motion relative to the workpiece is always as shown. Your machine
might not have all the axes shown or the entire system may be rotated. In any case, the relationship
between the axes you have always remains as shown.
AXIS POSITION MEASUREMENT SYSTEM
Axis position measurement on the machine is done using Heidenhain ® linear encoders (figure 1-4). The
linear encoders eliminate axis drive errors due to backlash, stick slip, windup and distortion. The
encoders are mounted adjacent to the axes guide ways, independent of drive members. Because there
is no contact between the sensing head (fastened to the moving member) and scales (fastened near the
guide way), precision accuracy is maintained during the life of the machine. See section five, COLUMN,
BED, SADDLE, AND ENCODERS for detailed information on linear encoders.
1-9
Scanning Unit
(Fastened to Moving
Slid )
Aluminum Housing
(Fastened to Stationary Part)
Figure 1-4 Heidenhain Linear Encoders
Heidenhain ® = Heidenhain Corporation
BEFORE STARTING ANY DISASSEMBLY
Authorized personnel should perform the disassembly of any machine components. Improper
disassembly/reassembly could cause severe damage to vital machine components. Experienced
maintenance personnel can do many procedures. However, there are many procedures that may require
the expertise of an experienced and properly trained Giddings & Lewis service technician. Be certain of
the proper procedures before starting disassembly.
As with all disassembly tasks, the machine should be turned off with the power disconnected and all
safety measures in place. Also, a thorough investigation of the problem and its remedy should be
completed. Some questions to ask yourself may be:
What is the problem and what could be causing it? Always rule out the simple things first!
What will allow the easiest and quickest access to the repair area?
What is the proper disassembly procedure and sequence?
What tools and equipment will I need to complete the task?
What will be the procedure and sequence for reassembly?
What should be checked to verify that the machine has been returned to its OEM specifications?
Studying the manuals and machine prints will help you answer these questions. Be sure to thoroughly
review your specific machine prints for detailed information on torque settings, areas that require glue or
sealant, proper spacer settings, preloads, etc.
MECHANICAL & HYDRAULIC DOCUMENTATION
The Mechanical & Hydraulic documentation required for your specific machine tool consists of multiple
copies of the following (2) types of documentation. This material is sent with the machine at the time of
shipment:
1. The 480 Series Horizontal Boring Machine Mechanical Service Manuals which contain the
written material, photos and sketches showing what is required when doing machine repairs and
making machine adjustments.
2. The Engineering Print Books contain the specific mechanical & hydraulic drawings used to build
your machine tool. Drawings are in numerical order, as listed inside the front cover.
1-10
HOW TO ORDER PARTS
The primary purpose of this manual is for instruction and maintenance purposes, but it can be used (in a
limited capacity) for ordering parts. We recommended using the engineering print books shipped with
your machine when ordering parts. They contain assembly and layout drawings that are specific for your
machine. The engineering print books should have the latest changes that were made (if any) before
being sent. Also, for all features on the machine the engineering print books will include the needed
drawings.
Repair Parts Orders are processed immediately and shipped without delay.
1. To assure this prompt service the following information must be furnished when ordering:
A. The serial number of the machine (located on the back of the column or on the toolchanger.)
B. The part number, part name, and quantity required.
2. To locate and identify the required part:
A. Refer to this manual and/or the Engineering Print Book that was shipped with your machine.
Drawing numbers and titles are located on the lower right hand corner of the drawings.
B. Locate the part required on the drawing; this will give you the part number.
C. When in doubt about part identification, give machine serial number, (and model number if
you have it), describe the major part and unit in which the required part is located.
3. If additional manuals are required, they can be identified by the part number located on the front
cover and then ordered. If additional Engineer Print sets are required, they can be identified by
using your machine specific Machine Serial Number and then ordered.
If the above suggestions are followed, our Parts Department will be able to give your order immediate
attention and make prompt delivery.
1-11
