SECTION TWO

INSTALLATION

TABLE OF CONTENTS

TITLE PAGE
SHIPMENT AND UNLOADING................................................................................................................. 2-1

FOUNDATION ........................................................................................................................................... 2-4

INSTALLATION......................................................................................................................................... 2-6

MACHINE BED.......................................................................................................................................... 2-6

LEVELING ................................................................................................................................................. 2-7

INSTALLING THE COLUMN .................................................................................................................... 2-8

PREPARING TO INSTALL THE HEADSTOCK ON THE COLUMN......................................................2-13

TWO SPEED HEADSTOCK.......................................................................................................2-14
FOUR SPEED HEADSTOCK.....................................................................................................2-16

INSTALLATION OF THE HEADSTOCK TO THE COLUMN .................................................................2-17

HEADSTOCK GIBS.................................................................................................................................2-18
GIB ADJUSTMENT PROCEDURE ............................................................................................2-19

INSTALLING THE TABLE AND SADDLE AS AN ASSEMBLY ............................................................2-20

INSTALLING THE PLAIN TABLE AS A SEPARATE UNIT (IF REQUIRED)........................................2-24

INSTALLING THE ROTARY TABLE AND BASE AS A SEPARATE UNIT (IF REQUIRED) ...............2-26

INSTALLING THE TOOL CHANGER .....................................................................................................2-30

INSTALLING THE CONTROL ................................................................................................................2-30

HYDRAULICS AND PNEUMATICS........................................................................................................2-32

INSTALL OPTIONS.................................................................................................................................2-34
SHIPMENT AND UNLOADING
Your Giddings & Lewis machine tool has been completely assembled and inspected at the factory. The
size prevents shipment of the machine fully assembled, and for this reason, it has been carefully
dismantled. For domestic shipment, the major machine units are placed on skids. Small parts are packed
separately. All machined surfaces are coated with a slushing compound and the entire machine is
protected with waterproof paper and a plastic cover.
When removing the machine units from the trucks, or when lifting during assembly, heavy pads or wood
blocks should be placed at all points where lifting cables or chains could contact finished surfaces. Extra
care is required to protect scraped surfaces and machine components. Make sure no cables or chains
exert strain on any projecting parts. The "bill of lading" sent with the machine would provide detailed
information on the weights of your specific machine. The following are the weights of the major
components (for reference only). Always refer to the "bill of lading" for specific weights. Also major
component weights can be found on the line and foundation prints.
Auxiliary Runways (each) ...............................1350 lbs. 612 kg
Bed...................................................................18000 lbs. 8160 kg
Chip Conveyor..................................................1000 lbs. 453 kg
Column ............................................................21000 lbs. 9520 kg
Control Cabinet ................................................2200 lbs. 997 kg
Headstock - 2speed .........................................7600 lbs. 3445 kg
- 4speed..........................................8550 lbs. 3855 kg
Hydraulic Unit..................................................1,200 lbs. 544 kg
Miscellaneous Sheet Metal & Parts...............6,000 lbs. 2720 kg
Saddle & Table ...............................................32000 lbs. 14506kg
Tool Changer (60-tool capacity) .....................7050 lbs. 3196kg
Way Covers......................................................2,500 lbs. 1133 kg
Carefully check all parts of the machine against the packing list, as they are unpacked. All small parts
should be placed in parts racks or cabinets to guard against their loss or being misplaced. A careful
check of all packing material and bags should be made before disposal of this material.
Note: Carriers may refuse any damage claims if unpacking is continued to completion. When
damage is evident, it is necessary to discontinue further unpacking until authorized by the
carrier. Immediately report any damages or shortages to the carrier and to the Giddings &
Lewis dealer representative from whom the machine was purchased.
************************************************************************************
CAUTION
BEFORE INSTALLATION, VERIFY ELECTRICAL POWER
CONFIGURATION MATCHES MACHINE SPECIFICATIONS. I.E.
SOME SHOPS MAY USE ELECTRICAL CONFIGURATION THAT USES
230 DELTA INSTEAD OF THE 230 Y, WHICH IS WHAT IS USED WHEN
THE MACHINE IS BUILT. FAILURE TO CHECK THIS MAY RESULT IN
SEVERE DAMAGE TO THE SYSTEM.
************************************************************************************

2-1
 Frame Works For Suspending Foundation Hardware Until Concrete Is Poured

Hold-down Cannisters Held

Steel Reinforcing Rods
In Place With Metal & Wood Frame Works

Photo #450-08-

Top Photo Shows Foundation Before Concrete Is Poured

Note: This shows a foundation for a machine that had multiple

auxiliary runways on each side of machine.

Machine Column
Base Location

Photos for reference

only Machine Bed Location
Always Refer To Certified Auxiliary Saddle Support
Line & Foundation Drawings Runway Location
When Building A Foundation
Photo #450-08-

Bottom Photo Shows Foundation Complete Ready To Receive The Machine

Figure 2-1
Machine Foundation

2-2
 Figure 2-2
Machine Foundation Hardware

Note: Use wood framing or other sturdy material to secure hold-down bolts and cans in place
while pouring concrete to ensure accurate location.
Insert wood plug into the top of can before pouring concrete. Remove after pouring.
This should stop concrete from going into can and restricting bolt movement.
The leveling plates supplied by Giddings and Lewis must be set over the hold-down bolts
before the machine is set on the foundation.
Maximum torque on the M24 hold-down bolts = 100 to 125 ft lbs. (136 to 170 Nm)

2-3
 Figure 2-3
Tool Changer Foundation Hardware

FOUNDATION
The foundation for your machine tool should be prepared in accordance with factory approved
specifications. Certified line and foundation drawings are supplied in advance. These prints contain all
the information required to construct a proper foundation. Additional copies are available upon request.
A smooth flat surface on the concrete is essential to allow the leveling plates to lie flat.
Note: The hold down assembly must not be above the concrete surface. If this condition
occurs, the pipes must be ground flat with the concrete surface.
The machine described in this manual is provided with a one piece bed and column base of heavy box
type, internally ribbed construction. Regardless of the rigidity obtained from this type of construction, the
foundation should be solid and free from vibration. DO NOT place any anti-friction devices of either
spring or rubber pad construction under the machine.
The foundation should be solidly constructed reinforced concrete per the foundation plan. The minimum
recommended depth is shown on the foundation plan. The actual depth required will vary based on the
load bearing capacity of the local soil. The depth of the foundation should be determined by test borings
and soil samples. Figure 2-1 shows what a foundation looks like before and after the concrete is poured.

2-4
The line and foundation drawings shown in this manual are for reference purposes only, always refer to
the specific certified drawings for the particular machine being worked on when building a foundation. On
the line and foundation drawings in this manual, there are locations marked to identify the foundation
hardware leveling screw locations (DWG. MD.2000.9816, sheets 5 of 5). Also see Figures 2-2 and 2-3.
A considerable amount of time in final alignment of the machine can be saved if proper attention was paid
to foundation detail.
Note: All hold down bolts must be free floating; do not weld or grout in place.
Note: Place all leveling plates over the hold down bolts. Measure all hold down bolts for their
proper length above the floor level as shown on the line and foundation print. This will
assure that no bolts will be to short because of some cans being lower in the foundation
than others. Measure the centerline distance between all hold down bolts to ensure that
none will interfere with bolt position in the bed or auxiliary runway.

019-49058-65 DRIVE UNIT D-34 (NOT SHOWN)

FURNISHED BY GIDDINGS & LEWIS

Capsule Anchor-Unisorb

Dwg. No. 011-03743-04

2-5
INSTALLATION
Prior to installation of the machine components, they must first be prepared by removing the slushing
compound from each unit during assembly and thoroughly cleaning any machined surfaces. Use a
nonflammable solvent to remove the slushing compound. The solvent should be of a type that has no
adverse effect on rubber or finished surfaces. After cleaning, finished surfaces will still need to be
protected. The use of light oil or spray rust preventive is recommended.
Note: Do not use scrapers, knives, abrasive wheels, or any such devices to remove slushing
compound and/or shipping/packing material. These types of tools could scratch or gouge
machined surfaces and cause damage.

Figure 2-4
Lifting the Machine Bed
Ensure that the crane, chains, eyebolts and other lifting devices are rated to handle the load you are
lifting.
Note: Care should be taken during the assembly of the machine to avoid any possible problems.
If something is unclear, check the prints or contact the Giddings & Lewis Service
Department.

MACHINE BED
To install the machine bed, proceed as follows: Hook up the bed as shown in Figure 2-4, raise the
assembly above the floor level. The bottom of the assembly should now be cleaned of all slushing
compound and foreign material. Be sure that foreign material is removed from the leveling screws and
their threaded holes in the bed. The leveling screws should be coated with an anti-seize lubricant before
the bed is lowered onto the foundation. The hold down bolts should be treated in the same manner. All
leveling screws should be extended .250" below bottom of the bed. This will allow the machine to set on
the leveling pads with equal contact on all points. Make sure the foundation and leveling plates are free
from dirt and foreign material.

2-6
After all the above requirements have been met the bed should be ready for installation over the
foundation hold down bolts. Lower it over the hold down bolts. Bolts should be guided into the base
using wooden sticks. NEVER USE YOUR HANDS TO GUIDE THE BOLTS INTO THE BED! After the
bed is resting on the leveling plates, it should be completely leveled by using the proper leveling
procedure explained in this section. After leveling is complete, all the hold down bolts should be
tightened. Refer to the line & foundation drawing for torque specifications.

LEVELING
The equipment used for leveling should consist of the following:
A. Two electronic levels or two precision spirit levels (make sure they have been properly
calibrated).
B. One scraped or granite parallel that is long enough to span the trucks on the bed ways. This will
permit setting the leveling equipment up so that levels can be placed at right angels to one
another (Fig. 2-6).
C. Possibly two ground parallel blocks. These will be required to get the parallel bar above other
components that may be lower when setting up leveling equipment on various parts of the
machine.
See Figure 2-5 for general placement of level, but verify their placement by checking the machines
alignment sheets.

Note: Final or finish leveling will be the first check when doing the alignments and will be done
with the machine under power and the hydraulics warmed up to operating temperature.

The parallel bar, ground blocks and the bed ways must be free from dirt, nicks, and burrs. Place the
parallel across the way surfaces above the leveling screws at right angles to the bed length. If the
parallel extends beyond the width of the ways it should be positioned so the extended amount is the
same on both sides. After the parallel is in place on the ways then place a level in the center of it. The
second level should be placed on the bed ways between the leveling screws in line with the bed length.
The surfaces near the ways should be marked with a pencil so that the parallel and the levels can be set
at the same relative position on the bed ways. Level adjustments should be made with the leveling
screws on either side of the machine bed assembly.
Bed should be raised or lowered gradually by using leveling screws nearest the level and the next several
sets of leveling screws. Never try to accomplish all the necessary adjustments on one leveling screw, as
this will tend to leave that particular section extremely high or low compared with the rest of the bed.
The parallel should then be moved to a position over the next pair of leveling screws and the level placed
on it in the same location. The other level should be moved farther down the bed way between the next
pair of leveling screws and appropriate adjustments made in each direction. This procedure should be
repeated along the entire length of bed. It will be necessary to repeat the leveling procedure two or three
times or more to correct errors that were created in the continuous leveling procedure. When the bed is
perfectly level, the locking nuts on all leveling screws should be tightened. Do not over tighten the
locking nuts as this could affect the level condition of the bed.
Be sure that the bed is perfectly level and that the hold down bolts are all tightened before installing the
rest of the machine units. This will simplify final machine alignments.
A list of alignment equipment that could be used during the installation is in Section 3 of this manual.
Note: The auxiliary runways should be handled in the same manner as the machine bed. A
dimension of 87mm ±.3 (3.425”) must be maintained between top cast iron surface of
auxiliary runways and way seat of bed way per the print. A dimension of 178.3mm (7.02”)
should be maintained between the top surface of the auxiliary runways and the top

2-7
 surface of the trucks or (7.250” with truck spacers M.1301.8881) under parallel. This is
done to allow for proper travel of saddle support adjustment during machine leveling.
Levels must be placed on the machined cast iron surface on the auxiliary runways.
Note: Never use the adjustment screws in the saddle supports as the major leveling adjustment
of the table and saddle. This is to be done with the leveling screws on the bed and the
auxiliary runways.

Place level here and

fasten in place

Place parallel on
trucks as shown
Set runway
to 7.02”
height for
rough
leveling or
7.250” with
truck
spacers
under
parallel

Figure 2-5
Precision Levels Shown on Bed

INSTALLING THE COLUMN

Some of the items you will need to install the column will be as follows:
A. Crane and lifting chains rated to handle the weight of column.
B. Lifting bar (rated to handle column weight), a couple of feet longer than the width of the column.
C. Hardwood blocking.
D. Bumping bar or timber for shifting large components.
E. Stone or mill file for removing nicks and burrs.
F. One torque wrench (rated so cap screws can be torqued to 245 Nm (180 ft. lbs.).

2-8
Clean and check the column ways. They should be free of paint, slushing compound, nicks and burrs.
After cleaning, lightly oil the ways with Mobil DTE 26 (ISO VG 68).
Rig up the column as shown in Figures 2-6, 2-7, 2-8. The lift must be as straight and level as possible.
Move the column to an area near the machine base if possible. Completely clean the column, which
includes the inside. To clean the inside it is advisable to set it on hardwood blocks on the floor.
Hook up and carefully roll the column to a vertical position as shown in Fig. 2-9. Be sure you are rolling
the unit on hardwood or a non-marring surface. Again the lift must be as straight and level as possible.
Then work through the top with an air hose and blow out any debris that may have collected on the
inside. Once clean then lift the column and inspect the bottom for nicks and burrs. If any nicks or burrs
appear, they must be removed with a stone or file. Completely clean the column base and remove any
nicks and burrs that are found. Locate and clean the column shims then place shims in position on top of
column base. The shims are marked and must be placed with their matching mark on the column base.
When satisfied that the column is straight and level, position it over the column base (Fig. 2-10). Line up
the column using extended studs screwed into the base at a couple locations. When the column is
approximately one inch above the column base, inspect the mating surfaces for dirt or lose material that
may have fallen from the inside of the column. This material must be removed before mating the two
parts; if it is not removed it will affect column alignment.
With the column just touching the base, check the shims with a .001" feeler gauge (Fig. 2-11). Before the
column is weight is completely on the shims, install the column cap screws (Fig. 2-11). When satisfied
that the shims are flush, slowly release the weight from the crane and recheck with a .001" feeler gauge.
With most of the weight on the column base, hand tighten the column bolts until they just touch the
column. At this point it may be necessary to use a heavy timber or bumping bar to make sure the column
is tight against the alignment keys and shims. With all of the weight resting on the column base but with
the rigging still in place, tighten all of the alignment key bolts and then tighten all of the column cap
screws (Fig. 2-11). Check the mating surfaces of the column, shims and base with a .001" feeler gauge,
the joint must be feeler tight (feeler must not slide between the two).
Note: The following pictures may not be of a 480-style column but the principles are the same.
Pictures in this manual may not match your machine.

Use chains around steel

bars to lift

Support hoses and

cables

Figure 2-6
Set Up for Lifting Column
Ensure the items used to lift the component are of sufficient strength to maintain the load.

2-9
 Note: Wood blocks must spread chains enough to clear
ways & other components during the lift

2 blocks on the 3 blocks on the

left side right side

Y axis gearbox with

motor below

Figure 2-7
Set Up for Lifting Column

Figure 2-8
Lifting Column

2-10
Roll column up on
to steel horse with
hardwood top Hardwood
blocks on
floor

Figure 2-9
Lifting Column to the Upright Position

Shims must be installed

before lowering column on
to base

Shims are match marked.

Position shims in proper
location.

Figure 2-10
Column Shims

2-11
Clean bottom of column of any burrs Put shims down on base before setting down

Figure 2-11
Column in Upright Position
Column jack
screws used to get
the shims out.

Column shims

Column alignment blocks. Do not

use to push excessively.

Figure 2-12
Column in Place on Base - Rear View Showing Shims, Jack Screws, and Bolts

2-12
Just before the column touches the base, install the column cap screws and place shims in position on
top of column base. The shims are marked and must be placed with their matching mark on the column
base (Fig. 2-10). With the column just touching the base, check the shims with a .001" feeler gauge.

Figure 2-13
Column in Place on Column Base

PREPARING TO INSTALL THE HEADSTOCK ON THE COLUMN

The 2-speed headstock weight is roughly 7600 pounds or 3445 kg.
The 4-speed headstock weight is roughly 8500 pounds or 3855 kg.
Remove the headstock from its shipping skid and clean thoroughly. Remove all slushing compound and
packing material.
The headstock is normally shipped with the headstock retainers fastened in place. They will have to be
removed and cleaned. Get a set of headstock retainer brackets if possible. (See Appendix) These
brackets will hold the heavy headstock retainers on the headstock while it is being installed onto the
column. The slots in the brackets allow the retainers to be slid out of position so that the headstock can
be placed against the ways. Then the retainers are slid into their normal position and fastened in place.
Once the retainer screws are tightened, then the retainer brackets (on top of headstock) can be removed.
If the aforementioned brackets are not used then the retainers will have to be positioned at the backside
of the ways using an eyebolt and a rope from the top of the column.
Get a (part number M.2000.7571) headstock lifting bracket if possible. (MD.2000.8933)(4 speed head
only)

2-13
Locate the headstock gibs; (along with the gib heads that hold them in place) clean gibs and the gib
heads thoroughly. They may be packaged separately in one of the shipping containers. The gibs, plates
and gib heads are matched at assembly and marked. Do not mix them up.
Clean and check the column ways. They should be free of paint, slushing compound, nicks and burrs.
After cleaning, lightly oil the ways with Mobil DTE 26 (ISO VG 68). Use same oil on the gibs when
installing them.
If nicks and burrs are found on the bearing surfaces use a small mill file to clean them up. These must be
removed prior to assembly of the headstock to the column.

TWO SPEED HEADSTOCK

Install three M16 x 2 eyebolts 35mm long, (swivel type if possible, G&L number M.1301.9745) on
headstock as shown in the following photos.
If you have procured retainer brackets, bolt them on using M6 x 1 15mm long bolts and install eye bolts
M10 x 1.5 25mm long in retainers. Also install a come along or other lifting devices to the headstock for
balance or slight rolling. After install lifting devices of sufficient capacity, lift headstock up approximately
two feet off floor.
Gather the roller pack gibs and be sure they are etched for proper location. Install the face roller pack
assemblies to the headstock if not already in place. Set aside the remaining gib roller back assemblies
for later use.
Remove the cover over the spindle drive motor to ballscrew coupling.
Install a level on the headstock parallel to the spindle travel.
Move the spindle in and or out using the bolt in the coupling keeping the headstock level. (This may be
around 14 inches of spindle extension). Level crosswise also, if needed add a come along to roll
headstock.
Remove all lines that interfere with the headstock retainer brackets and install brackets on head and
retainers. Loosen all bolts in the headstock retainers and slide them over to allow clearance for the ways.

Do not use these eye

bolts for lifting head

Front retainer Rear retainer

Front retainer bracket Rear retainer bracket in

position. Note: retainer place, Note: retainer
not yet slid to side for not slid to side for
hanging. hanging

2-14
Lifting 2 Speed Head using Eye Bolts 2 Speed Head Back View – retainers aside

2 Speed Head using Eye Bolts Top View 2 Speed Head Hung on Column

Spindle axis drive cover removed to set spindle

extension
By using an M10 Allen wrench on the back of the
spindle ballscrew the spindle can be extended from
the front of the headstock.

Use to drive the

spindle forward
and backward as
needed for
balance

2-15
Make a note of the spindle extension dimension after being leveled. If the headstock ever needs to be
removed, extending the spindle to that extension can attain the “headstock level condition” quickly and
easily.

FOUR SPEED HEADSTOCK

Install a (part number M.2000.7571) headstock lifting bracket if possible, see drawing (MD.2000.8933).
Bolt on other lifting devices to the headstock and install the proper eyebolt M36 x 4, swivel type if
possible. Install lifting devices of sufficient capacity and lift headstock up approximately two feet off floor.
Gather the roller pack gibs and be sure they are etched for proper location. Install the face roller pack
assemblies to the headstock if not already in place. Set aside the remaining gib roller back assemblies
for later use.
Remove the cover over the spindle drive motor to ballscrew coupling.
Install a level on the headstock parallel to the spindle travel.
Move the spindle in and or out using the bolt in the coupling keeping the headstock level. (This may be
around 17 inches of spindle extension). Level crosswise also, if needed add a come-along to roll
headstock for level.
Remove all lines that interfere with the headstock retainer brackets and install brackets on head and
retainers. Loosen all bolts in the headstock retainers and slide them over to allow clearance for the ways.

Retainers slid aside

Level in place

Face roller
packs

Headstock
hanging on lifting
fixture with the
retainer brackets
installed Roller
packs as seen
from the back

Figure 2-14
Preparing a Four Speed Headstock before moving to Column - Rear View

2-16
 Note ballnut
position

Clear cover for

inspection during
cycling

Note spindle
extension

Figure 2-15
4 Speed Headstock being installed on Column

INSTALLATION OF THE HEADSTOCK TO THE COLUMN

Be sure the ball screw nut is approximately 1 meter (3feet) above the lower bearing block. The machine
should arrive in this position.
Level the headstock as well as possible before lifting into position.
Lift the headstock until the ball screw nut mounting surface is about 6 inches below the bottom of the ball
screw nut. Slowly move headstock toward the column. Be careful especially careful when near the ways
surfaces. Move the headstock toward the column until the face roller packs contact the face of the
column ways. Steady the headstock in this position and move retainers into position behind ways. Install
M20 bolts by hand. After all retainer bolts are in tighten to 650nm (400ft lbs.).
Install the previously removed gib roller packs as marked in the proper locations 12 total. It may be
necessary to rock the headstock slightly to get the packs in. They may have to be tapped slightly with
rubber hammer. After all the packs are installed torque these packs to 25 inch pounds (2.8 Nm). Raise
and lower the headstock with the crane a few inches. Recheck the roller pack torque and adjust to 25 in
lbs.
************************************************************************************
CAUTION
DO NOT ALLOW THE HEADSTOCK TO MOVE UP AND "BUMP" THE
BALLNUT. DAMAGE TO BALLSCREW & BALLNUT INTERNAL
PARTS MAY OCCUR.
************************************************************************************
To aid in alignment of the holes in the ballnut and tapped holes in the headstock, two (6" long) studs can
be placed through the ballnut and screwed into the headstock to be used as guides. Raise headstock

2-17
until almost meeting the ballnut and install bolts by hand. When the headstock is seated against the
ballnut remove the two (2) studs and fasten the ballnut to the headstock with the proper socket head cap
screws. Then torque the bolts to 136 Nm (100ft lbs.).

Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if
needed by positioning near a bearing block and loosen then re-torque the bolts.

Assemble the reader head of the scale package to the rear of the headstock.
Block the headstock up using a bottle jack and hardwood.
Loosely assemble way wipers to the headstock they will be removed after the machine is turned on for
final gib adjustment. Then and attach the oil lines to the lube points that were removed earlier.

HEADSTOCK GIBS
The purpose of machine gibs is to keep the "moving axes" snug against the way surfaces they move
back and forth on. The gib is a tapered metal wedge used to keep the axes bearing surface in constant
contact with the axes way surfaces. If a gib were to become loose or out of adjustment, the axes would
have a tendency to cock every time it changed direction. This would cause problems with machine
accuracy and if it were allowed to become severe, could cause damage to the machine. Therefore it is
important that gib adjustments be checked every 90 days for the first year after installation and every 180
days thereafter.
These horizontal machining centers use roller packs on the gibs. The gibs are marked and must be
installed in its matched location in the machine component. This will insure a proper fit and allow the gibs
to perform as intended.
Top View of Headstock

2 Back Side 2 Guide Way 2 Guide Plates & Rollers 2 Back Gibs
Gibs Gibs

4 Guide Plates and

Rollers

The roller packs are located at an upper and a lower position on each contact surface

Figure 2-16
Locations of Headstock Gibs & Guide Plates

2-18
GIB ADJUSTMENT PROCEDURE
G&L gibs have a .31 in/ft taper (26 mm/m) or roughly a 40 to 1 ratio. Gibs on these machines must be
adjusted using an inch lb. torque wrench. The following procedure should be used to adjust “Y” axes
gibs. Make certain to read and completely understand entire procedure before beginning.
Note: Gib adjustments must be checked every 180 days. The machine must be in operating
condition with the hydraulics on.
If the machine is equipped with retractable way covers, they should be cleaned, unfastened, and pulled
backed so the axes ways are exposed. The “Y” axis has rubber way wipers that partially cover the gib
heads. These wipers will have to be unfastened and pulled back on the ways to expose the gib heads.
Pull the wipers to the end of the ways to allow the axes to travel back and forth. This is necessary for the
proper setting of the gibs during the adjustment procedure.
Individual gibs on each axes must be loose, with the adjusting set screws and the gib retaining screws
backed off. All threads must be free from dirt and not binding. This will prevent screws from bottoming
out on dirt and chips in the hole. It will also prevent inaccurate torque readings due to screw threads
binding on dirt.
Make sure gib retaining screws move freely into the threaded gib holes. CAP SCREWS SHOULD NOT
TOUCH SIDES OF HOLES IN GIB RETAINER BRACKETS. Do not loosen the gib head. It has been
centered and secured to allow gib retaining screws freedom to move. If the gib head is removed or
loosened for any reason, use care in re-tightening the head screws so as not to cause any binding of the
gib retaining screws.
A. The gibs on each individual slide must be loose, with the adjusting set screws (pushes gibs in) and
the gib retaining screws (pulls gibs out) backed off. All threads must be free from dirt and not
binding; the retaining screws must not touch the sides of the gib heads.
************************************************************************************
CAUTION:
NEVER MOVE ANY MACHINE AXES WITH GIB AND/OR THE GIB
HEAD RETAINING SCREWS LOOSE! MACHINE MISALIGNMENT
AND POSSIBLE DAMAGE MAY OCCUR. ALWAYS CHECK THE
LENGTH OF A GIB RETAINING SCREW. THEY MUST HAVE ENOUGH
THREAD TO ADEQUATELY RETAIN THE GIB, ROUGHLY 1½ - 2
TIMES THE DIAMETER OF THE SCREW TO DEPTH OF THREAD
ENGAGEMENT.
************************************************************************************
B. Turn the gibs adjusting set screws CW to 25 inch lbs. (2.8 Nm) of torque. Turn the gibs retaining
screws CW to 100 inch lbs. (11.3 Nm). Move the slide at a slow feed rate (about 10 IPM) in both
the "+" and "-" directions for about 1 inch. This tends to position the slide over against the guide
edge of the way.
C. Retract or loosen the gib.
1. Turn the gib adjustment set screw CCW.
2. Turn the gib retaining screws CW. This will pull the gib back toward the gib head and loosen
the gib.
3. Turn the gib retaining screws CCW.
D. Apply the following torque to adjusting set screws on the following gibs:
1. Tighten all head gib retaining screws to 100 inch lbs. (11.3 Nm).

2-19
E. Move the axis at a slow feed rate (about 20 IPM) back and forth about twenty (20) times. At
random, move the axis its full travel at traverse rates. This will tend to seat the gibs.
F. Loosen the gibs retaining screws and check the torque reading on the gib adjusting set screws.
Check to make sure that the gibs are still torqued to values specified in step D.
G. If re-adjustment was required in Step G, repeat steps C, D, and E until no re-adjustment is required.
H. Tighten all gib retaining screws to100 inch lbs. (11.3 Nm) torque.
I. Clean and/or replace all molded way wipers. Do NOT over tighten wiper screws.

INSTALLING THE TABLE AND SADDLE AS AN ASSEMBLY

Level the bed & auxiliary runways before installing table & saddle.
Clean bed ways, roller packs, shims, the ballnut mounting surfaces and check for nicks or burrs if found
they must be removed. After checking bed ways, oil them with Mobil DTE 26 (ISO VG 68) just before
installing the saddle. The saddle support runways must be cleaned, checked and oiled in the same
manner as the bed ways.
On most machines the table and saddle will be shipped as one unit. However, on some machines due to
their size and/or customer lifting capacity, the table and saddle will be shipped as separate units.
Assuming the saddle and table are assembled together, lift the unit together as shown in Figures 2- 17 &
18 & 19. The unit must be level.
The table and saddle must be cleaned of all slushing compound and shipping material. Use a non-
flammable solvent to remove the slushing compound from each unit as needed during assembly.
Note: Do not use scrapers, knives, abrasive wheels, or any such devices to remove slushing
compound and/or shipping/packing material. These types of tools could scratch or gouge
machined surfaces and cause damage.
If solvent is used, it should be of a type that has no adverse effect on rubber or painted surfaces. After
cleaning, finished surfaces will still need to be protected. The use of light oil or spray rust preventive is
recommended.

Make sure shipping Note: The

bracket is secure chains on the
front are 3
links higher
than the back
for level

Figure 2-17
Lifting Table and Saddle

2-20
Table drive motor

Be sure this shipping bracket is

secure until the table and saddle
are set on way roller backs on bed

Figure 2-18
Table to Saddle Shipping Bracket

Long drop to 3 high for level

swivel M36
eyebolts

Figure 2-19
Lifting Table and Saddle

2-21
If saddle wedges and shims were shipped removed from the saddle, they must be located, thoroughly
cleaned, and checked for nicks or burrs. Also the roller packs mounting area need to be cleaned and
deburred.
The saddle supports are normally shipped assembled to the saddle. These must be cleaned and the
roller chains oiled with Mobil DTE 26 (ISO VG 68).
Install the two side shims on the saddle on the guide way, one for each roller pack, one on the front, one
on the opposite side of the saddle (Fig. 2-20). Each side shim is marked with a number. This number
must match with the same number marked on the saddle. Make sure you double check the number
marked on the side shim, the top shim and the saddle location.

Wedge clamp

Guide Non guide

way way
Side shim
used for
alignment Photo of side shim and
roller packs shows this
area

Guide way roller pack area of saddle Bed with saddle just set down, no bolts in place

Wedge that holds Side shim for

roller pack alignment
against side
shim. Do not
bottom out

Top shim
and roller
pack area

Figure 2- 20
Area for Roller Pack and Top Shim – Shown Upside Down
Note: Each guide way roller pack has a similar shim and wedge on opposite sides of the saddle.

2-22
After the side shims are installed, move the unit over the bed ways. Line up the saddle pockets (roller
pack mounting areas) with the bed ways. When you are satisfied the units line up, gently lower the unit
over the ways. ). Be careful that the ballnut mounting pocket clears the ballscrew while lowering the
saddle. Just before the unit touches the bed way roller packs and top shims, push the table and saddle
unit up against the side shim edge.
When the saddle is down on the roller packs (trucks) and top shims, verify that the alignment shims both
top and side are snug.
Note: At this point use .001" feeler gage to verify saddle is feeler tight to bed roller pack top and
side shims on all four corners and that saddle supports are not holding it up off the bed
roller packs.
Install the wedge that pushes the roller pack securely against the side shim. Be sure when you install the
wedge that it does not bottom out on the saddle. If it does it will not hold the roller pack securely against
the side shim. Remove the wedge and remove enough material so that it will not bottom out on the
saddle.
************************************************************************************
CAUTION:
DO NOT ALLOW THE MOUNTING SURFACE TO MOVE UP AGAINST
AND "BUMP" THE BALLNUT. DAMAGE TO BALLSCREW &
BALLNUT INTERNAL PARTS MAY OCCUR.
************************************************************************************
Align the ballnut to the cavity in the saddle. To aid in alignment of the holes in the ballnut and tapped
holes in the mounting surface, two (6" long) studs can be placed through the ballnut and screwed into the
mounting surface to be used as guides. Move the unit until the mounting surface almost meets the
ballnut and install bolts by hand. When the unit is seated against the ballnut remove the two (2) studs
and fasten the ballnut to the mounting surface with the proper socket head cap screws. Then torque the
bolts to 136 Nm (100ft lbs.).
Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if
needed by positioning near a bearing block and loosen then re-torque the bolts.
With the saddle in position on the bed and roller blocks, the crane can be released.
Remove the saddle shipping bracket and insert plugs in the holes. Store the bracket for possible use
later.
Connect the ballnut lubrication and all other lubrication lines, saddle supports, etc.
Connect the reader head for the encoder to the mounting bracket.
Connect all electrical wires and hydraulic hoses from the utility carriers to the manifolds or junction boxes.
This will vary with the type of equipment shipped with the machine. Always use the machine specific
electrical and hydraulic schematics that were shipped with your machine.
Note 1: Bleeding the damper hoses to the bearing blocks all axes. Be prepared to catch
some oil. Also have rags available. Bleed the damper hoses to the bearing blocks by opening
the bleeder screw on the screw side of the bearing block with the hydraulics running until all the
air is out of the system. If an axis is jittery air in the damper may be part of the problem. It may
have air in the system or a block restrictor at the input. If bleeding does not improve the system
then a blocked restrictor can be removed and cleaned using a .007 dia. wire that is supplied with
(M.2000.8027), reference layout MD.2000.0906.
Note 2: If the line has been disconnected and drained. This would allow a large amount of air
to enter the system. It may be necessary to install a union and plug on the line feeding the
bearing block. After installing the fittings on the bearing block end of the hose start the hydraulics
running, be prepared to catch some oil. Also have rags available, then crack open the plug until

2-23
 all the air is out of the system. Shut down the hydraulics, then reinstall the hose and bleed the
bearing pack using the bleeder screw.

INSTALLING THE PLAIN TABLE AS A SEPARATE UNIT (IF REQUIRED)

Level the bed & auxiliary runways before installing table & saddle.
Clean ways, roller packs, shims, ballnut mounting surfaces and check for nicks or burrs, if found they
must be removed. After checking ways, oil them with Mobil DTE 26 (ISO VG 68) just before installing the
table.
The unit must be lifted as level as possible. Be sure your lifting equipment can safely handle the lift.
The table must be cleaned of all slushing compound and shipping material. Use a non-flammable solvent
to remove the slushing compound from each unit as needed during assembly.
Note: Do not use scrapers, knives, abrasive wheels, or any such devices to remove slushing
compound and/or shipping/packing material. These types of tools could scratch or gouge
machined surfaces and cause damage.
If solvent is used, it should be of a type that has no adverse effect on rubber or painted surfaces. After
cleaning, finished surfaces will still need to be protected. The use of light oil or spray rust preventive is
recommended.

Holes for lifting on either end

Headstock side of table

1 1

Roller packs (trucks) on guide way.

Same number on opposite way. Only the
two trucks on ends are used for aligning
the table with shims to turn the table axis
(marked 1)

Figure 2-21
Plain (PT) Table and Lower Trucks

If table wedges and shims were shipped removed from the table, they must be located, thoroughly
cleaned, and checked for nicks or burrs. Also the roller packs mounting area need to be cleaned and
deburred.
Install the side shims on the table on the guide way, one for each roller pack (Fig. 2-20). Each side shim
is marked with a number. This number must match with the same number marked on the table. Make
sure you double check the number marked on the side shim, the top shim and the table location.

2-24
After the side shims are installed, move the unit over the ways. Line up the table pockets (roller pack
mounting areas) with the ways. When you are satisfied the units line up, gently lower the unit over the
ways.). Be careful that the ballnut mounting pocket clears the ballscrew while lowering the table. Just
before the unit touches the way roller packs and top shims push the table unit up against the side shim
edge.
When the table is down on the roller packs (trucks) and top shims, verify that the alignment shims both
top and side are snug. These alignment shims will only be on the guide edge on two corners of the table.
Note: At this point use .001" feeler gage to verify table is feeler tight to roller pack top and side
shims on all roller pack positions.
Install the wedge that pushes the roller pack securely against the side shim. Be sure when you install the
wedge that it does not bottom out on the table. If it does, it will not hold the roller pack securely against
the side shim. Remove the wedge and remove enough material so that it will not bottom out on the
mounting component.
************************************************************************************
CAUTION:
DO NOT ALLOW THE MOUNTING SURFACE TO MOVE UP AGAINST
AND "BUMP" THE BALLNUT. DAMAGE TO BALLSCREW &
BALLNUT INTERNAL PARTS MAY OCCUR.
************************************************************************************
Align the ballnut to the cavity in the table. To aid in alignment of the holes in the ballnut and tapped holes
in the mounting surface, two (6" long) studs can be placed through the ballnut and screwed into the
mounting surface to be used as guides. Move the unit until the mounting surface almost meets the
ballnut and install bolts by hand. When the unit is seated against the ballnut, remove the two (2) studs
and fasten the ballnut to the mounting surface with the proper socket head cap screws. Then torque the
bolts to 136 Nm (100ft lbs.).
Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if
needed by positioning near a bearing block and loosen then re-torque the bolts.
With the table in position on the roller blocks, the crane can be released.
Connect the ballnut lubrication and all other lubrication lines.
Connect the reader head for the encoder to the mounting bracket.
Connect all electrical wires and hydraulic hoses from the utility carriers to the manifolds or junction boxes.
This will vary with the type of equipment shipped with the machine. Always use the machine specific
electrical and hydraulic schematics that were shipped with your machine.

Note 1: Bleeding the damper hoses to the bearing blocks all axes. Be prepared to catch
some oil. Also have rags available. Bleed the damper hoses to the bearing blocks by opening the
bleeder screw on the screw side of the bearing block with the hydraulics running until all the air is
out of the system. If an axis is jittery air in the damper may be part of the problem. It may have air
in the system or a block restrictor at the input. If bleeding does not improve the system then a
blocked restrictor can be removed and cleaned using a .007 dia. wire that is supplied with
(M.2000.8027) Reference Layout MD.2000.0906.
Note 2: If the line has been disconnected and drained. This would allow a large amount of air
to enter the system. It may be necessary to install a union and plug on the line feeding the
bearing block. After installing the fittings on the bearing block end of the hose, start the
hydraulics running; be prepared to catch some oil. With rags available, crack open the plug until
all the air is out of the system. Shut down the hydraulics, then reinstall the hose and bleed the
bearing pack using the bleeder screw.

2-25
INSTALLING THE ROTARY TABLE AND BASE AS A SEPARATE UNIT (IF
REQUIRED)
Level bed, auxiliary runways, and saddle before Installing Rotary Table (RT).
Clean ways, roller packs, shims, ballnut mounting surfaces and check for nicks or burrs if found they must
be removed. After checking ways, oil them with Mobil DTE 26 (ISO VG 68) just before installing the RT
table.
The unit must be lifted as level as possible. Be sure your lifting equipment can safely handle the lift.
The RT table must be cleaned of all slushing compound and shipping material. Use a non-flammable
solvent to remove the slushing compound from each unit as needed during assembly.
Note: Do not use scrapers, knives, abrasive wheels, or any such devices to remove slushing
compound and/or shipping/packing material. These types of tools could scratch or gouge
machined surfaces and cause damage.
If solvent is used, it should be of a type that has no adverse effect on rubber or painted surfaces. After
cleaning, finished surfaces will still need to be protected. The use of light oil or spray rust preventive is
recommended.
If RT table roller pack spacer, adjuster block and shims were shipped removed from the table; they must
be located, thoroughly cleaned, and checked for nicks or burrs. Also the roller packs mounting area need
to be cleaned and deburred.
Install the roller pack spacer and adjuster block on the RT table onto the guide way of the guide way side,
one for each roller pack (Fig. 2-23). Each roller pack spacer and adjuster block is marked with a number.
This number must match with the same number marked on the RT table base. Make sure you double
check the number marked on the roller pack spacer, adjuster block, the top shim and the RT table
location.
After the roller pack spacer and adjuster block are installed, move the unit over the ways. Line up the
table pockets (roller pack mounting areas) with the ways. When you are satisfied the units line up, gently
lower the unit over the ways. Be careful that the ballnut mounting pocket clears the ballscrew while
lowering the table. Just before the unit touches the way roller packs and top shims, install the bolts into
the roller packs using them for alignment of the roller pack, the roller pack spacer and the RT table base.
Then push the RT table base up against the roller pack spacer and adjuster block using a 5mm shim
between the adjuster block and the side of the roller pack. (The 5mm is a reference dimension from
layout MD.2000.6671).
When the RT table is down on the roller packs (trucks), roller pack spacers, and top shims, verify that the
roller pack spacer, top shim and adjuster block are snug.
With the table in position on the roller blocks, the crane can be released.

Note: At this point use .001" feeler gage to verify table is feeler tight to roller pack top and sides
on all roller pack positions.

Move the RT base until the mounting surface almost meets the ball screw nut. Remove the 5mm shims
from between the roller packs and the adjuster plate. Adjust the alignment of the table to the ballnut,
ballscrew and way by using the adjusting block on the guide way side of the RT table. Adjust the roller
pack spacer sideways using the adjuster block screws until the threaded holes in the RT base are
centered on the holes in the ball screw nut. Install bolts in the ballnut one turn from snug. Adjust the
blocks on either end of the RT table until the ball screw nut to its mounting surface is square, using a
feeler gage to check the gap. Then move the RT base until it makes contact with the mounting surface.
Be sure the surfaces are feeler tight. Then snug up the ball screw nut bolts and the roller block bolts.

2-26
 ************************************************************************************
CAUTION:
DO NOT ALLOW THE MOUNTING SURFACE OF THE RT TABLE TO
MOVE UP AGAINST AND "BUMP" THE BALLNUT. DAMAGE TO
BALLSCREW & BALLNUT INTERNAL PARTS MAY OCCUR.
************************************************************************************

When the RT base is seated against the ballnut, then securely fasten the ballnut to the mounting surface
with the proper socket head cap screws. Torque the bolts to 136 Nm (100ft lbs.).
Note: Later be sure to check ball screw alignment to way surfaces and adjust ballnut position if
needed by positioning near a bearing block and loosen then re-torque the bolts, if
necessary.
Note: Once the adjuster plate lock bolts and set screws have been adjusted and the bolts to the
ballnut and the roller block bolts have been torque to specification do not readjust. This
adjustment is not intended to align the B axis table edge to the rest of the machine. It is
for initial alignment of the RT base to the ballnut and ways.
Connect the ballnut lubrication and all other lubrication lines.
Connect the reader head for the encoder to the mounting bracket.
Connect all electrical wires and hydraulic hoses from the utility carriers to the manifolds or junction boxes.
This will vary with the type of equipment shipped with the machine. Always use the machine specific
electrical and hydraulic schematics that were shipped with your machine.

Note 1: Bleeding the damper hoses to the bearing blocks all axes. Be prepared to catch some oil
and have rags available. Bleed the damper hoses to the bearing blocks by opening the bleeder
screw on the screw side of the bearing block with the hydraulics running until all the air is out of
the system. If an axis is jittery, air in the damper may be part of the problem. It may have air in
the system or a block restrictor at the input. If bleeding does not improve the system then a
blocked restrictor can be removed and cleaned using a .007 dia. wire that is supplied with
(M.2000.8027) Reference Layout MD.2000.0906.
Note 2: If the line has been disconnected and drained. This would allow a large amount of air to
enter the system. It may be necessary to install a union and plug on the line feeding the
bearing block. After installing the fittings on the bearing block end of the hose start the
hydraulics running, be prepared to catch some oil. Also have rags available, then crack open
the plug until all the air is out of the system. Shut down the hydraulics, then reinstall the hose
and bleed the bearing pack using the bleeder screw.

2-27
 Make the lift
as level as
possible.
Using a
machine
level at the
center of the
table will
help

Block the
table so
that chains
do not
mare the
surface

Figure 2-22
Rotary Table Lift

Adjuster block
Roller pack spacer

5 mm spacer used here for

reference at assembly during
alignment. Then remove
spacer and install set screws
through the plate

Figure 2-23
Rotary Table Roller Pack (Truck)

2-28
 Retaining Bolts for
Adjuster Block to RT

Pulling
Adjustment Bolts

Pushing Adjustment
Set Screws

Figure 2-24
Adjuster Block

When unit is in place

attach power track
lines and services
Set the table down
on the roller blocks
and top shims on
the four corners of
the table. Install
bolts and torque to
195 Nm (145 ft
lbs.)

Figure 2-25
Rotary Table down on Roller Packs

2-29
 Tool changer
attachment area

Rear of hydraulic
service unit
Column

“X”-Axis
gearbox &
drive motor
Rotary Table Base

Saddle lube
distributors Saddle

Power track
connections Roller pack, Saddle
shims & way support

Balls screw Linear

and mounting encoder
surface

W-Axis drive
motor W-Axis drive Saddle
gearbox Support
Runway

Figure 2-26
Table Assembled to Saddle

INSTALLING THE TOOL CHANGER

Refer to the Tool Changer Section for information covering the installation.

INSTALLING THE CONTROL

The control base can now be placed in position according to the line and foundation drawings. Figure 2-
27 shows the control base and wiring coming in below the control before it is set in place.
The photo also shows some of the other components behind the control.

Note: Care should be taken during the assembly of the machine to avoid any possible problems.
If something is unclear, check the prints or contact the Giddings & Lewis Service
Department. Read and understand the electrical and hydraulic startup procedures before
attempting to bring the machine on line.

2-30
 Four
Loop electrics Speed
and hydraulics Headstock
to headstock Oil Chiller
Unit
Tool Changer hoses

Wire way to bed

Hoses
Main
Hydraulic Unit

The wiring shown before setting

the control in place
Set control on
this surface

Figure 2-27
Base of Control

The control enclosure then can be set in place on top of the base structure. Be sure to lift the enclosure
only at the specified lifting points or damage could occur to the unit

2-31
 Operator's Control Station
shipped with the control

Figure 2-28
Control Enclosure Hook Up

All ductwork and cabling should be connected at this time following the electrical diagrams supplied with
your machine. Also refer to the Electrical Service Manual for detailed information about the machine's
electrical components, their function, and the proper installation and maintenance. All of the cables and
wires were tagged at the factory and should be connected to their proper terminal or plug.
The enclosure then can be finish wired. Be sure to tighten all of your connections and to verify all
connections that may have been done by someone else. Doing a tug and pull check is advised to help
verify tight connections.

HYDRAULICS AND PNEUMATICS

In order for the machine to function, a factory supply of dry and lubricated air must be connected to the
machine. The number of pneumatic circuits is dependent on the number or various options that can be
ordered with these machines.
The hydraulic power supply unit can now be installed according to the line and foundation drawings. At
the time of this writing the standard hydraulic unit used on these Giddings & Lewis Horizontal Boring
Machines (HBM's) is the Rexroth Hydraulic unit. This unit is equipped with a heat exchanger that is
designed to keep the oil temperature below 120° F. Thereby maintaining machine accuracy and
increasing component life by dissipating heat.

2-32
 Figure 2-29
Hydraulic Unit

The hoses and lines supplied for the machine were plugged and/or capped for shipment and tagged for
reassembly. When reassembling these hoses or lines, it is important that they are installed in their proper
location by matching the identification tags. Before connecting any hoses, make certain there are no
plugs or caps left in the connections. Keep all the hoses clean, especially the connection points. It is
very important that the hoses are not contaminated during the reassembly of the machine. This could
cause internal damage to machine components. Refer to the section eight of this manual for the
hydraulic unit set up information.

Marking on
connections
and
manifold

It is not recommended that the oil reservoirs (hydraulic, lube, etc.) be filled with their appropriate oils at
this time. This should be done just before the initial start up of the machine along with a complete grease
and lubrication of the machine. Refer to the section ten for information on grease and lube points,
reservoir location, types of oils and grease to be used and the frequency of lubrication.

2-33
Assemble miscellaneous covers, guarding and shielding. This may include way covers, shielding on or
around the table or even an enclosure around the entire work area.

Also add a hook up to these

eye bolts for safety. Do not
lift only by these eyebolts

Upper brackets of
Headstock Shield, Lift with
a strap looped around
each one individually and
centered above them at
this location
Lower brackets
of Headstock
Shield

Figure 2-30
Headstock Shield

INSTALL OPTIONS
Optional Equipment must be placed in accordance with the line and foundation drawings. The wiring must
completed as shown on the electrical prints supplied with the machine also.
Many machines have optional equipment such as:
Four Speed Headstock Oil Chiller
Indexers and Steady rests
Separate Coolant Systems
Pallet Systems
Enclosures
Mist Collection Systems
Fixtures and Clamping
Right Angle Milling Attachments
Spindle Supports
Various Cutting Attachments
Miscellaneous Other Options.
The following photos show machines as they are being assemble and are included as a reference only.
There can be various changes to any specific machines components and therefore the reason for use as
a reference only.

2-34
 Various way Access covers
covers bed,
saddle and
headstock

Figure 2-31
Assembled RT Machine (no enclosure)

Service panel
on rear of
headstock

Oil Chiller
typical location
behind tool Tool changer (Optional)
changer and guarding on Coolant Tank
headstock temporary and Filter
wooden support

Figure 2-32
Rear Side View of Machine during Assembly

2-35
 Front enclosure doors
also are interlocked
during machine
Enclosure side door operation. Can be
interlocked during opened using entrance
operation switches if allowed

Figure 2-33
Enclosure Being Assembled to Machine

2-36