Giddings & Lewis Sect10 Maintenance

SECTION TEN
MAINTENANCE
TABLE OF CONTENTS
TITLE PAGE
PREVENTATIVE MAINTENANCE SCHEDULE .....................................................................................10-1
VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE ......................................................10-1
AUTONOMOUS MAINTENANCE CHECK POINTS...............................................................................10-2

PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER ......10-2
RT 1250/1600 WITH 2-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER ......10-4
MC 1250/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER .....10-6
EMERGENCY STOP BUTTON LOCATIONS.........................................................................................10-8
ENERGY CONTROL POINTS FOR MAINTENANCE ............................................................................10-8

PREVENTATIVE MAINTENANCE SCHEDULE
The following preventative maintenance checks are suggestions based on a “typical” machine usage.
These checks should be tailored to your own shop conditions. Each machine needs to have a shop
preventative maintenance schedule with detailed and descriptive maintenance logs. Once setup, follow
the requirements of the schedule.
Do not allow excessive accumulation of chips and cast iron dust to build up around way covers, moving
members, and other machine components. The entire machine and machine area should be cleaned
every eight hour shift. Cleaning the machine using high pressure air is not recommended. Brushing the
machine or use of shop vacuum cleaners is safer for the operator and the machine.
Note: Many components of this machine were supplied by other manufactures. Their manuals
were supplied with the machine documentation. Review these manuals for their specific
instructions, adjustments, maintenance procedures, and maintenance schedules.
VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE

The legend below describes the symbols and color schemes used in the autonomous maintenance check
point descriptions and visual management maps. A visual management noteplate, specifically compiled
for your machine, is attached to the electrical control panel. A number of these maps and descriptions
are included in this manual.
Do not, Under Any Circumstances,

delay repair of machine components
even if they can be run under
adverse conditions.
This practice will lead to further
problems and even longer machine
downtime
Figure 10-1
Visual Uptime Management Noteplate Legend
10-1
NOTE: THE FOLLOWING DIAGRAMS AND INFORMATION ARE FOR REFERENCE ONLY! REFER
TO THE ACTUAL MAINTENANCE SCHEDULE AND EMERGENCY LOCKOUT PLACARDS
ATTACHED TO YOUR MACHINE.
AUTONOMOUS MAINTENANCE CHECK POINTS

A number of machine diagrams and periodic maintenance checks are included in this manual. As
previously stated, these are for reference only. The various machine types, equipped with typical options,
are shown. A description of the maintenance check, the recommended checking frequency and special
instructions are mapped to the machine shown. The maintenance checks vary dependent upon the
following: If rotary table present (RT & MC machines), type of headstock (two or four speed), type of
coolant system which can include filter mounted on main hydraulic unit, whether pallet changer present
(MC machine), and whether tool changer present.
PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
Figure 10-2
Visual Management Map (MD.2001.2895 Ver. 0)
10-2
PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
Figure 10-3
Maintenance Check Points
(Use with Figure 10-2)
10-3
RT 1250/1600 WITH 2-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
Figure 10-4
10-4
RT 1500/1600 WITH 2-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
Figure 10-5
10-5
MC 1250/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
Figure 10-6
10-6
MC 1500/1600 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER
DESCRIPTION FREQUENCY SPECIAL INSTRUCTIONS

3
DRIVE BOX RESERVOIR LEVEL FILL RESERVOIR AS REQUIRED WITH MOBIL SHC 634.
MONTHS
3
DRIVE BOX RESERVOIR LEVEL FILL RESERVOIR AS REQUIRED WITH MOBIL SHC 634.
MONTHS
ROTARY TABLE HYDROSTATIC
DAILY FILL RESERVOIR AS REQUIRED WITH MOBIL SHC 634.
RESERVOIR LEVEL
HEADSTOCK HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70-76 BAR.
SPINDLE BEARING PRE-LOAD PRESSURE DAILY VERIFY OPERATING PRESSURE IS 3.5-8.3 BAR
HEADSTOCK LUBRICATION PRESSURE DAILY VERIFY OPERATING PRESSURE IS 5-7 BAR
HEADSTOCK NEEDLE BEARING 3 GREASE REAR BALLSCREW NEEDLE BEARING THROUGH FITTING
LUBRICATION MONTHS ON SIDE OF REAR HOUSING. MOBIL TEMP SHC 32 GREASE, 0.5CC.
HYDRAULIC OIL RESERVOIR DAILY FILL RESERVOIR AS REQUIRED WITH MOBIL DTE 26.
MAIN HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70 BAR.
SECONDARY HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70-76 BAR.
LUBRICATION PRESSURE DAILY VERIFY OPERATING PRESSURE IS 26-28 BAR.
MAIN HYDRAULIC PRESSURE FILTER DAILY REPLACE ELEMENT AS REQUIRED (VIA ELECTRICAL INDICATION).
LUBRICATION PRESSURE FILTER DAILY REPLACE ELEMENT AS REQUIRED (VIA ELECTRICAL INDICATION).
SYSTEM AIR PRESSURE DAILY VERIFY OPERATING PRESSURE IS 5.5-7 BAR
LINEAR SCALE AIR PRESSURE DAILY VERIFY OPERATING PRESSURE IS 0.6-1 BAR
HEADSTOCK LUBRICATION AIR

DAILY VERIFY OPERATING PRESSURE IS 5.5 BAR
PRESSURE
SYSTEM AIR PRESSURE FILTER DAILY REPLACE ELEMENT AS REQUIRED.
SYSTEM AIR COALESCING FILTER DAILY REPLACE ELEMENT AS REQUIRED.
COOLANT SUPPLY FILTER DAILY REPLACE ELEMENT AS REQUIRED (VIA ELECTRICAL INDICATION).
CHILLER OIL RESERVOIR LEVEL DAILY FILL RESERVOIR AS REQUIRED WITH MOBIL DTE 24
PRESSURE NOT TO EXCEED 10.3 BAR. USED TO SET UP PRESSURE AT

LUBRICATION PRESSURE DAILY
CHECK POINT 9.
LUBRICATION OIL FILTER DAILY REPLACE ELEMENT AS REQUIRED (VIA ELECTRICAL INDICATION).
FILL RESERVOIR AS REQUIRED WITH SHELL OMALA EP 220 (ISO

GEARBOX RESERVOIR LEVEL MONTHLY
VG220)
PALLET SHUTTLE CHAIN MONTHLY OIL CHAIN LIGHTLY WITH MOBIL DTE 26
LINEAR GUIDES FOR CHANGER SLIDE

YEARLY REGREASE YEARLY WITH MOBILUX EP2
AND SHUTTLE BRIDGE
CLEAN EXCHANGE MECHANISM RAIL AND MAKE SURE RAIL AND CHAIN ARE FREE FROM CHIPS. CLEAN AS
MONTHLY
CHAIN REQUIRED.
TOOL MATRIX CHAIN MONTHLY OIL CHAIN LIGHTLY WITH MOBIL DTE 26.
GREASE ROLLERS, CAMS, PLUNGERS, WHEELS AND GRIPPERS

TOOL CHANGER GREASE POINTS MONTHLY
WITH MOBIL TEMP SHC 32 AS REQUIRED.
Figure 10-7
10-7
EMERGENCY STOP BUTTON LOCATIONS
A noteplate has been included with the machine that shows the locations of the three emergency stop
button locations. The emergency stop buttons are located as follows:
1. Pendant operator’s station
2. Handheld station(s)
3. Tool changer control box (side of tool magazine)
The emergency stop buttons are indicated by a red button with yellow ring.
ENERGY CONTROL POINTS FOR MAINTENANCE

When maintenance is required, make sure that any stored energy in the form of pneumatic, electrical, and
gravity has been controlled. The lockout location, control action to perform, and verification process for
each type of stored energy is listed in table below.
ENERGY LOCKOUT CONTROL VERIFICATION

SOURCE LOCATION ACTION PROCESS
Electrical Lockout Main electrical panel Place disconnect handle in off Attempt to restart the system.
Primary Disconnect position. Attach multiple The system must not start.
device, lock & tag. Visually verify.
Open disconnect and locking device
Installed.
Pneumatic Lockout Machine air inlet on Slowly close lockout valve to Verify the valve Is closed
Primary Air Supply main hydraulic unit gradually shut off air and lockout device is properly
pressure. Attach multiple attached.
device, lock & tag.
Control Gravity Headstock Bottom out, block, pin or Make sure vertical axis components
chain vertical axis are completely secured and not
components. capable of movement.
10-8

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SECTION TEN

VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE ......................................................10-1

AUTONOMOUS MAINTENANCE CHECK POINTS...............................................................................10-2

EMERGENCY STOP BUTTON LOCATIONS.........................................................................................10-8

ENERGY CONTROL POINTS FOR MAINTENANCE ............................................................................10-8

VISUAL UPTIME MANAGEMENT SYMBOL AND COLOR GUIDE

Do not, Under Any Circumstances,

AUTONOMOUS MAINTENANCE CHECK POINTS

PT 1500/1800 WITH 4-SPEED HEADSTOCK, TOOL CHANGER, & COOLANT FILTER

DESCRIPTION FREQUENCY SPECIAL INSTRUCTIONS

HEADSTOCK HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70-76 BAR.

HEADSTOCK LUBRICATION PRESSURE DAILY VERIFY OPERATING PRESSURE IS 5-7 BAR

MAIN HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70 BAR.

SECONDARY HYDRAULIC PRESSURE DAILY VERIFY OPERATING PRESSURE IS 70-76 BAR.

LUBRICATION PRESSURE DAILY VERIFY OPERATING PRESSURE IS 26-28 BAR.

SYSTEM AIR PRESSURE DAILY VERIFY OPERATING PRESSURE IS 5.5-7 BAR

HEADSTOCK LUBRICATION AIR

SYSTEM AIR PRESSURE FILTER DAILY REPLACE ELEMENT AS REQUIRED.

SYSTEM AIR COALESCING FILTER DAILY REPLACE ELEMENT AS REQUIRED.

PRESSURE NOT TO EXCEED 10.3 BAR. USED TO SET UP PRESSURE AT

FILL RESERVOIR AS REQUIRED WITH SHELL OMALA EP 220 (ISO

LINEAR GUIDES FOR CHANGER SLIDE

GREASE ROLLERS, CAMS, PLUNGERS, WHEELS AND GRIPPERS

ENERGY CONTROL POINTS FOR MAINTENANCE

ENERGY LOCKOUT CONTROL VERIFICATION

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