SECTION FOUR

HEADSTOCK

TABLE OF CONTENTS

TITLE PAGE
HEADSTOCK INTRODUCTION................................................................................................................4-1
Two Speed Headstock Features................................................................................................4-1
Four Speed Headstock Features ...............................................................................................4-3
Common Headstock Features ...................................................................................................4-5

TOOL CLAMPING SYSTEM ...................................................................................................................4-14

Mounting Tool for the Gripper Assembly ...............................................................................4-15
To Remove the Gripper Assembly from the Drawbar ...........................................................4-15
To Install the Gripper Assembly into the Spindle..................................................................4-16
Important Facts to Remember when Working with the Tool Clamping System.................4-16
Tool Clamping System Trouble Shooting Guide ...................................................................4-17

ADJUSTMENT PROCEDURE FOR THE TOOL CLAMPED/UNCLAMPED PROXIMITY SWITCHES 4-18

Tool Clamped – Normally Open Switch ..................................................................................4-18
Tool Unclamped – Normally Open Switch..............................................................................4-19
Final Check ................................................................................................................................4-19

TWO SPEED TRANSMISSION ...............................................................................................................4-20

Shifter Solenoid Replacement .................................................................................................4-21
Sliding Sleeve Setting...............................................................................................................4-21
Two Speed Gearbox Lubrication.............................................................................................4-22

REMOVING THE TWO SPEED HEADSTOCK SPINDLE CARTRIDGE ...............................................4-22

FOUR SPEED TRANSMISSION .............................................................................................................4-25

Hydra-Rib Bearing.....................................................................................................................4-27

REMOVING THE FOUR SPEED HEADSTOCK SPINDLE ....................................................................4-28

REMOVING THE FOUR SPEED HEADSTOCK SPINDLE SLEEVE .....................................................4-30

HEADSTOCK INTRODUCTION
This manual covers headstocks that are equipped with either two speed or four speed transmissions.
The headstock utilizes an independent variable speed electric motor that drives only the spindle. Infinitely
variable spindle speeds allow cutting tools to be run at optimum for increased tool life and improved work
finish. The headstock contains a live spindle, (meaning that the spindle is capable of travel in and out of
the headstock). The spindle is a programmable axis, (that may be designated as the “W” or “Z” axis), with
complete control functions providing movement for drilling and tapping operations. At the time of this
writing, the headstocks on 480 serial number machines had the following specifications:

Two Speed Four Speed

Spindle Diameter 130 MM (5.1”) 130 MM (5.1”) 155 MM (6.1”)

Spindle Travel 800 MM (31.5”) 1000 MM (39.4”) 1250 MM (49.2”)
Spindle Taper #50 ANSI B5.50 #50 ANSI B5.50 #50 ANSI B5.50
Constant
10 - 260 10 – 69
Range 1 Torque
Constant HP 10 - 999 10 - 185
Constant
10 - 1060 10 – 173
Range 2 Torque
Spindle Constant HP 1000 - 4000 174 - 463
Speed
(RPM) Constant
10 – 445
Range 3 Torque N/A
Constant HP 446 - 1190
Constant
10 - 1015
Range 4 Torque N/A
Constant HP 1116 - 3500
Spindle S1-100 40 HP (30 KW) 40 HP (30 KW) 43 HP (32 KW)
Power
S6-40 60 HP (45 KW) 60 HP (45 KW) 74 HP (55 KW)

TWO SPEED HEADSTOCK FEATURES

The two speed headstock is equipped with a ZF-DUOPLAN® two speed gearbox that transfers the power
from an electric drive motor to the spindle. The gearbox drives an output gear through an idler gear to a
bull gear, which is keyed and secured with a locknut onto the spindle sleeve. This precision spindle
sleeve is mounted in a set of four ball bearings inside the spindle cartridge. Two in the front of the spindle
cartridge and two in the back near the bull gear. The spindle cartridge is assembled to the cast iron
headstock housing, providing the spindle sleeve support. In the spindle sleeve are two drive keys which
are fixed in the sleeve by cap screws. They protrude into the key ways located down the sides of the
spindle. This allows the spindle to move in and out of the headstock while the drive keys maintain contact
with the spindle. ZF-DUOPLAN® = Trademark of ZF Industrial Drives
The gearbox is lubricated with oil from the main hydraulic reservoir. A scavenger pump returns the oil
back to the hydraulic unit. Lubrication to the rest of the headstock gears and bearings is supplied by the
Vogel Lube System which also lubricates the linear ways and ballscrews. The oil for the Vogel Lube
System is also supplied from the main hydraulic reservoir.

4-1
 Two Speed Gearbox
Spindle (Drive) Rotation Motor

Spindle

Headstock
Spindle Positioning Motor
Rear Housing

Figure 4-1
Two Speed Headstock Assembly

Output Gear

Spindle
Cartridge
Thrust Bracket
Idler Gear

Spindle Sleeve

Spindle Drive Keys

Bull Gear
Spindle Sleeve Bearings
Spindle Bearings Rear

Figure 4-2
Two Speed Headstock Cross Section

4-2
FOUR SPEED HEADSTOCK FEATURES
The four speed headstock consists of a series of precision bearings and hardened and ground helical
gears, located inside the headstock casting (gear housing). See figure 4-3. Two internal-tooth clutches
use electro-hydraulic shifting to provide the four speed ranges. The transmission input shaft is connected
to the electric spindle drive motor output shaft using a motor coupling. A bull gear which is keyed,
threaded and locked onto a spindle sleeve receives the power from the output gear. The front support for
the spindle sleeve is cast into the gear housing, (unlike the two speed headstock, which has a separate
spindle cartridge that provides the support and mounts to the headstock front housing).
The spindle sleeve is mounted in two bearings. In the front of the spindle sleeve is a roller bearing. In
the rear of the spindle sleeve is a Hydra-Rib bearing. The Hydra-Rib bearing allows for variable spindle
bearing preload pressure. The bearing preload pressure is controlled by a hydraulic line plumbed directly
to the bearing via a proportional pressure reducing valve which is servo controlled. As the spindle RPM’s
increase or decrease, the controls will decrease or increase bearing preload respectively. The Hydra-Rib
bearing is used to insure spindle accuracy and bearing life.
The gear lines are lubricated by a set of six top mounted spray nozzles that receive oil from the head lube
line. The front bearings in the four gear lines, and the front and rear spindle sleeve bearings receive lube
from the head lube line. The head lube line oil is supplied by a separate chiller unit with a scavenger
pump returning the oil to the chiller. The hydraulic pressure required for the shifter hydraulic cylinders
and for the Hydra-Rib bearing, as well as, the lubrication oil supplied to the Vogel Lube System for the
ways and ballscrews is supplied from the main hydraulic reservoir.

Motor Coupling
“E” Gear Line

“D” Gear Line

Shifter Hyd. Cylinders

“C” Gear Line

“B” Gear Line Clutch Gears

Bull Gear on Spindle Sleeve Spindle Drive Key & Hydra-Rib Bearing
Cover Location

Figure 4-3
Four Speed Transmission
(Shown without Shifter Rods/Forks)

4-3
 Spindle Positioning Motor

Services Bracket

Spindle (Drive) Rotation Motor

Rear Housing

Gear Housing

Scavenger Pump & Motor

Figure 4-4
Four Speed Headstock Assembly

Motor Coupling
Clutch Gears

Thrust Bracket
(Shown Extended & Retracted)

Spindle
Sleeve

Bull Gear Hydrostatic Bearing

Figure 4-5
Four Speed Headstock Cross Section

4-4
COMMON HEADSTOCK FEATURES
The spindle is a precision ground nitrided forging made to hold ANSI B5.50, No. 50 taper, “V” flange tools.
The spindle rotates the tool (or attachment) which can perform a variety of cutting operations. The tool is
held in the spindle by a power drawbar. The power operated collet type tool retention and ejection
system is controlled by the hydraulically actuated drawbar. Collet fingers (which are available in various
types to accept different tool holder retention knobs) slide forward from the guide bushing to expand and
except or release a tool holder during a tool change cycle. Tool pull-in force ranges from 23,000 to
25,000 N (5171 to 5620 lb-force). Tool changing can be accomplished via a program command which
will do an automatic tool change to an optional tool matrix. Manual tool changes can be performed using
the two-position selector switch located on the hand held pendant.
The spindle is extended or retracted by means of an electric servo motor. The motor transfers rotation to
the ballscrew using motor dependent sprockets and a belt. The ballscrew, whose ballnut is in support on
the thrust housing, rotates inside the rear housing (ram guide). The thrust housing holds the rear spindle
bearings and moves linearly, guided by preloaded roller bearings which ride on linear ways. As the motor
rotates the ballscrew, the thrust bracket runs the spindle back and forth via the linear ways. The spindle
is thus supported over its full range of travel.
The headstock is mounted to an upright column. Front and rear way clamps are assembled to the main
gear housing to create box sections. Inside these two box sections, a total of twelve roller bearing packs,
eight for column front way and four for column rear way, are used to keep the bearing surfaces in
constant contact with the column way surfaces. The roller packs are located at an upper and a lower
position on each column way contact surface. In each pair of opposing roller packs, one pack is mounted
with a tapered gib and one is mounted with a flat plate. The tapered gib allows for adjustment.
The following Figures 4-6 through 4-12, show the main components of two speed headstocks.
Figures 4-13 through 4-19 show the main components of four speed headstocks.

Part Probe
(Optional)
Drive Motor
Cover

Spindle
Cartridge
Spindle Cap

Spindle Sleeve

Spindle

Figure 4-6
Two Speed Headstock Front Housing

4-5
 Mounting Surface
Front Housing to
Rear Housing

Figure 4.7
Two Speed Headstock Housing (Rear View)
Mounting Surface
Rear Housing to Front Housing

Figure 4-8
Two Speed Headstock Rear Housing

4-6
 Spindle Sleeve

Spindle Cartridge
Spindle Key Cover

Spindle Sleeve

Spindle Bull Gear

Spindle Cap

Front Bearing
Thermister Bearing Lube Line
Connector Fitting Tapped Holes

Spindle Key Cover Rotary Union

(Part of Drawbar)

Bull Gear
Locknut
Thrust Cartridge

Figure 4-9
Two Speed Headstock Spindle Cartridge Assembly

4-7
 Adjustable Bearing Packs
Two Shown and One in
Square Not Shown

Fixed Position Bearing

Packs in Circled Areas
Not Shown
Retainer Plate Retainer Plates

Clamp Bar
Clamp Bar Front
Rear

Gearbox
Lube Return
Hose

Fixed Position Adjustable

Bearing Pack Bearing Pack
Figure 4-10
Two Speed Headstock Column Attachment Surface

View from Front Looking Rear Utility Carrier

Spindle
Linear Way and
Runner Block

Drawbar
Clamp/Unclamp
Proximity Switches Spindle Orientation
Thrust Housing (Bero) Switch
Figure 4-11
Two Speed Headstock, Rear Housing Bottom View

4-8
Service Panel Connections Made at Service Panel Connections Made at
Headstock Assembly Machine Final Assembly
Metering Unit

Gearbox
Scavenger Pump

Part Probe
Connector

Spindle Orientation Connector

Connections from
Utility Carrier

Figure 4-12
Two Speed Headstock Service Panel (Bosch-Rexroth Components Shown)

4-9
 Part Probe Gear Shaft
(Optional) Covers

Spindle Cover

Gear Shaft
Spindle Covers

Spindle Sleeve

Figure 4-13
Four Speed Headstock Gear Housing

Mounting Surface for Gear

Housing to Rear Housing

Figure 4-14
Four Speed Headstock Gear Housing (Side and Rear View)

4-10
 Front of Rear Housing

Mounting Surface for Rear

Housing to Gear Housing

Linear Ways and

Runner Blocks

Figure 4-15
Four Speed Headstock Rear Housing

Fixed Position Fixed Position

Bearing Pack Bearing Packs

Adjustable Adjustable
Bearing Pack Bearing Packs

Rear Way Front Way

Clamp Bar Clamp Bar

Fixed Position
Bearing Pack Adjustable
Bearing Pack
Figure 4-16
Four Speed Headstock Column Attachment Surface

4-11
 Locknut

Drawbar Cylinder and Rotary Union

Sensor Target Spacer
Spindle
Hydra-Rib
Bearing

Gripper
Fingers

Spindle Drive
Key and Cover

Sleeve Retainer

Spindle Sleeve

Figure 4-17
Four Speed Headstock Spindle and Spindle Sleeve

4-12
 Thrust Cartridge
Covers – Left & Right

Drawbar Clamped Drawbar Unclamped

Proximity Switch Proximity Switch

Spindle Orientation
Rear Spindle Bearing (Bero) Switch
Thermocouple 4-18
Four Speed Headstock Rear Housing
(Bottom View)

Service Panel Connections Made at Service Panel Connections Made at

Headstock Assembly Machine Final Assembly

Profibus

Part Probe
Connector

Worklight Spindle Orientation

Connector Scavenger Pump Hose Connector
Figure 4-19
Four Speed Headstock Service Panel (Bosch-Rexroth Components Shown)

4-13
TOOL CLAMPING SYSTEM
The 480 series machines are equipped with a tool clamping system manufactured to Giddings & Lewis
specifications by OTT-JACOB Spanntechnik. The system consists of an inside spindle drawbar and
clamping springs, with an intensifying mechanism and piston, built into a cylinder outside of the spindle
shaft. The nominal size of the tool interface is per SK-50 standards, which determines the gripper
configuration, as well as, the spindle inside contour. Gripper assemblies are available in a number of
styles that specifically accommodates steep taper tool standard DIN, ANSI and MAS retention knobs.
The system has central medium (coolant/air) transfer. Position indication (clamp/unclamp) is
accomplished with a signal ring, located on the piston cylinder. A dual-passage rotary union supplies the
hydraulic fluid for unclamping of the power drawbar and central coolant supply or cleaning of the tool
interface with air. The rotary union is integrated behind the cylinder. The drawbar length varies
according to the length of the spindle. There is one length for the two speed headstock and a longer
length for the four speed headstock. On four speed headstocks, the same tool clamping system is used
for either a 130mm or 155mm spindle diameter.
The tool clamping system mechanism works in the following manner, (Figure 4-20). The tool is pulled into
the spindle taper by means of the gripper assembly, attached to the drawbar by a clamp adapter, and a
Belleville spring set. Within the working range a nearly constant pull force is maintained. Safety is
accomplished by a patented wedge ring mechanism The clamping force on tool, due to force of
intensifying mechanism, is 340% greater than force of Belleville springs acting alone.
Note: If the hydraulic system would shut down, the tool will stay securely clamped.
Unclamping the tool is accomplished by means of hydraulic pressure working on a piston, which pushes a
clamp sleeve forward with push rods, and compresses the Belleville spring set while it also unlocks the
wedge-lock mechanism. The forward movement of drawbar moves gripper assembly into a wider
opening inside spindle and a helical spring around top part of gripper assembly opens the gripping fingers
and releases the tool. The front of the gripper assembly contacts with the retention knob to eject the tool
from spindle taper.

M45X1.5 External Thread Dual-passage Rotary Union

(Drawbar Assy to Spindle)

Belleville Spring Set

Piston Cylinder &

Spring Intensifier Signal Ring

Drawbar From MD.2000.0510 version 2

Clamp Adapter
Gripper Assembly Drawbar Bushing and S-rings
(ANSI B.5.50 Shown) (added to drawbar assembly)
Figure 4-20
Tool Clamping System Components

4-14
MOUNTING TOOL FOR THE GRIPPER ASSEMBLY
The gripper assembly consists of the gripper holder, socket head set screw, helical spring and four
grippers (fingers) (Figure 4-21). A mounting tool is available to remove/install the gripper assembly. The
mounting tool has Giddings & Lewis part # M.1301.5763 (OTT-JACOB #: 95.101.337.9.2). If the tool is
not available, a large slotted screwdriver and 6mm Allen wrench can be substituted. The slot machined in
the front of the gripper holder is 2.38mm (.094”) wide by 25.4mm (1.0”) long. Be sure to use the proper
size screwdriver.

TO REMOVE THE GRIPPER ASSEMBLY FROM THE DRAWBAR

1. Remove tool from spindle and leave the drawbar in the unclamped position. Check the
current setup dimension by measuring from the front of the spindle to the front of the gripper
holder. See table for proper setup dimension based on gripper type.
(Most machines are equipped with the ANSI B 5.50 – 78 tool standard).

SK 50 Interface
Tool Standard ANSI B 5.50 - 78 DIN 69871/69872 MAS 403 – 1982 MAS 403 – 1982
BT/PT 2 (30°) BT/PT 1 (45°)
ISO 7388/1/2 Typ B ISO 7388/1/2 Typ A
Setup Dimension 126.5mm 134.6mm 145.75mm 145.75mm
± 0.1mm (.004”) (4.98”) (5.30”) (5.74”) (5.74”)
2. Insert 6mm Allen wrench into center of gripper holder, and loosen the set screw by turning it
CCW (viewed from front of spindle) about two turns. Once the set screw is loose, insert the
mounting tool into the two holes in the front of the gripper holder. If mounting tool is not available
use screwdriver. Remove the gripper assembly by turning it CCW until it separates from the
clamp adapter. Pull the gripper assembly out the front of the spindle. If there is difficulty
removing the gripper assembly, the gripper holder is tapped to receive an 8mm pin puller for easy
removal from the spindle.

Setup
Dimension Grippers Helical Spring
Clamp Adapter

Socket Head
Mounting Tool Gripper holder Set Screw
(M.1301.5763)

Figure 4-21
Gripper Assembly and Adjustment Tool

4-15
TO INSTALL THE GRIPPER ASSEMBLY INTO THE SPINDLE
1. Place grease on outside of gripper assembly. Insert gripper assembly into front bore of spindle.
2. Insert a 4mm diameter tube/rod through gripper assembly into the bore of the clamp adapter. If
there is sag in the drawbar shaft/clamp adapter, the rod will lift the shaft and aid in aligning
external thread in clamp adapter with internal thread in gripper assembly. Rotate the gripper
assembly CW, (as viewed from front of spindle), to start thread.
3. Once thread started, remove rod and insert mounting tool (or screwdriver) into front of gripper
holder. Rotate CW to tighten.
4. Measure from front of spindle to front of gripper holder, adjusting gripper holder position to match
setup dimension listed in table above. After dimension is set, use the mounting tool to prevent
gripper holder from turning while the 6mm tee handle Allen wrench is used to lock it in place with
socket head set screw.

IMPORTANT FACTS TO REMEMBER WHEN WORKING WITH THE TOOL CLAMPING SYSTEM
1. Run the spindle only when a tool is clamped in the taper with the drawbar. Failure to do this will
cause the back hydraulic seal to wear prematurely.
2. The Belleville spring-pack is rated for check and/or replacement at 1-2 million cycles.
3. The gripper fingers are matched sets and should not be mixed.
4. The clamp force (pull-in-force) for ANSI & DIN gripper assemblies is 25000 N (5620 lb-force).
5. The clamp force (pull-in-force) for MAS gripper assemblies is 23000 N (5171 lb-force).
6. Hydraulic and coolant lines must be flexible and must not load the rotary union. The hydraulic
pressure has to be within the recommended range.
7. The hydraulic pressure should not drop more than one bar (15 PSI) after being applied for 30
minutes.
8. The series number of the rotary union is engraved into the outer diameter of the unit and this
number as well as the serial number should be recorded.

4-16
TOOL CLAMPING SYSTEM TROUBLE SHOOTING GUIDE
TROUBLE POSSIBLE CAUSE
Tool will not pull in. Setup dimension is not properly
set or is out of adjustment.
Counter screw got loose.
Wrong gripper fingers were
installed.
Wrong inside contour of
spindle.
Belleville spring broken, dirt in
intensifying unit.
Tool cannot be pulled in, tool
position wrong.
Retention knob too big or not
threaded in all the way on top of
the tool
Tool will not release Dirt in hydraulic oil.
Piston seals are defective.
Rotary union leaks.
Insufficient oil pressure.
Tool was left in spindle for
extended period of time.
Tool pulls out during Gripper fingers broken.
working cycle
Retention knob not concentric.
Helical coil spring around
gripper fingers broken.
Retention knob too long or
short.
4-17
REMEDY
Recheck setup dimension, readjust if
necessary.
Tighten counter screw.
Install correct gripper fingers.
Check inside contour of spindle.
Disassemble, clean and check
Check toolchanger.
Install the correct size retention knob.
Tighten knob.
Clean oil filters and flush oil lines.
Replace piston and seals.
Install new rotary union. Use flexible
high pressure oil lines so as to not to put
excessive load on the rotary union
bearings.
Check hydraulic system for proper
setting.
Increase oil pressure momentarily to help
release tool.
Install new gripper fingers.
Check tool holder retention knob.
Remove gripper assembly from spindle,
disassemble and replace coil spring.
Replace or correct retention knob.
ADJUSTMENT PROCEDURE FOR THE TOOL CLAMPED/UNCLAMPED PROXIMITY
SWITCHES
The proximity switches for sensing drawbar position are in either a two speed or four speed switch
bracket, located in the rear of the thrust housing/bracket. Each switch is mounted into an eccentric switch
mount with a jam nut and the switch mount is locked in position by a clamp (Figure 4-22). To replace a
switch, loosen the clamp and rotate the flat on the clamp to allow for removal of the switch mount from the
switch bracket. Remove jam nut and turn switch to remove from switch mount. After turning in new
switch and jam nut, follow adjustment procedure listed below.

Clamp Switch Bracket

Jam Nut
Switch Mount

Figure 4-22
Drawbar Clamp/ Unclamp Proximity Switches
(Four Speed Headstock Switch Bracket Shown)

Before performing the switch adjustment procedure, be sure that the draw finger assembly has been
adjusted to the proper set-up (gage) dimension required for retention knob style in use.

TOOL CLAMPED – NORMALLY OPEN SWITCH

Use a tool holder that has been qualified to meet the gage dimension and retention knob dimensions of
ANSI 5.50 V-Flange #50 taper spindle. Insert tool holder in spindle and clamp drawbar. With proximity
switch in switch mount, turn switch so that
end is within (0.5 to 1.0 mm) of sensing
area, outside diameter of flange, shown in Drawbar Unclamped Position
(Figure 4-23). Remove switch mount and
tighten jam nut. Reinsert switch mount,
lightly tighten clamp, and reconnect the
cable to the proximity switch. Rotate switch
mount so that switch is not activated.
Slowly turn the switch mount in opposite
direction until the switch actuates. Switch Drawbar Clamped Position
should be on rear half of flange. Tighten
Proximity
clamp without moving switch mount. Figure 4-23
Switch Sensing
Area Drawbar Rear End

4-18
TOOL UNCLAMPED – NORMALLY OPEN SWITCH
Place the drawbar switch in the unclamped position. Pressure on main hydraulic gauge should be 152 to
186 bar (2200 to 2700 psi.). Pressure on secondary system gauge should be 76 bar (1100 psi.). With
proximity switch in switch mount, turn switch so that end is within (0.5 to 1.0 mm) of sensing area, outside
diameter of flange, shown in (Figure 4-23). Remove switch mount and tighten jam nut. Reinsert switch
mount, lightly tighten clamp, and reconnect the cable to the proximity switch. While maintaining pressure,
rotate the switch mount so that the switch is not activated. Slowly turn the switch mount in opposite
direction until the switch actuates. Switch should be on front half of flange. Tighten clamp without
moving switch mount.

FINAL CHECK
After both switches are adjusted, cycle the drawbar to each position and verify that the switches actuate
properly. Refer to the logic table for the drawbar switches for detailed information.

4-19
TWO SPEED TRANSMISSION
The transmission or “gearbox” as it is often referred to, used for the two speed headstock is purchased
complete from ZF Industries, Inc. Gearbox is type 2K300 with bearing on shifter fork, modified main
housing with back spotfaced mounting holes and includes an adapter plate for Siemens 1PH7163 motor.
The specifications for this gearbox include the following:
• Motor balancing type is full key, where the motor shaft is balanced with a fitted key, the hub
without.
• Gearbox interface is closed with hub, hub bearing and radial shaft seal.
• Gear box type is for motor frame of h =160 mm (Figure 4-24) and gear ratio of i = 4.00
• Output bearings are angular-contact ball bearings.
• Gearbox output type is with output flange of outside diameter = 130 mm.
• Installation position type is B5 (turned around longitudinal axis).
• Motor shaft diameter, d = 55mm (Figure 4-24).
• Torsional backlash on gearbox output is type “reduced backlash”, max. 20 arcmin.
The ZF transmission is a two-speed single planetary gearbox with a shift mechanism. It was
developed to meet strict machine tool needs with respect to high running smoothness and low-noise
operation. In contrast to conventional gearboxes with spur gear trains, this planetary gearbox has the
distinct advantage of allowing an extremely compact and space-saving design since the power is split
between 4 or 5 planet gears. In addition, the four simultaneously-meshing planet gears with helical
gearing also assure low-noise operation at high rpm. See the operating instruction manual included in
CD for additional information.

Motor Frame Type

Shifter Solenoid Adapter Plate

Spindle Motor

Output Flange

Spindle Gearbox Lube In

Headstock Gearbox
Housing
Figure 4-24
Two Speed Gearbox

4-20
SHIFTER SOLENOID REPLACEMENT
In the event of faults in the shifting solenoid, start by checking the electrical connections. If there is a fault
in the solenoid itself, the solenoid will have to be replaced. The shift unit itself is maintenance free and
does not contain any adjustable components. Moving the shift unit along the gearbox adjusts the shift
forks. Re-adjust the shift fork position after renewing the shifter unit.
To remove the shifter solenoid: Solenoid
Adapter Plate
1. Remove the electrical connections.
2. Remove the four socket head cap
screws on adapter plate.
3. Lift and remove the solenoid with
adapter plate. Selector Shaft

To install the shifter solenoid:

1. The sliding sleeve must be at the stop
position for first gear.
Shift Fork
2. Insert the selector shaft into the sliding
sleeve and place the shift unit in the
correct position on the gearbox
housing.
Ensure the pin in the sliding sleeve engages in
the recess in the selector shaft. To do this: Sliding Sleeve X
1. Move the shift unit (1st gear shift Figure 25
position) in the oval holes for the ZF Gearbox Shifter Mechanism
mounting bolts towards the gearbox
output (do not force) until it reaches the
stop.
2. Move shift unit away from gearbox output approximately 0.5 ± 0.01 mm and secure the shift unit
in this position.
3. Check the setting and adjust as necessary. See Sliding Sleeve Setting below.
4. Hook up electrical connections
5. Check the unit by performing a test shift.

SLIDING SLEEVE SETTING

This check can only be performed with the gearbox removed from the motor.
1. Engage 2nd gear (1:1).
2. Measure the distance between the housing mating surface and the sliding sleeve on each of the
segments (Figure 4-25 dimension “X”). The lower measured value must be equivalent to the
desired value. Reference dimension for gearbox type 2K300: 49.7 mm to 50.5 mm.
3. If the reference dimension is not as specified, check the shift unit as explained above and adjust
in necessary.

4-21
TWO SPEED GEARBOX LUBRICATION
The ZF gearbox is designed to be lubricated in a variety of ways, but in this application recirculating oil is
used. The incoming oil is routed through a hydraulic motor/pump set, before it is piped to the gearbox.
The incoming oil turns the motor which runs the pump to remove the oil from the gearbox. A proximity
switch is used to monitor the rotation of the motor/pump to be sure that it is working (Figure 4-26). The
lube return connection used is designated as CONNECTION H (M42X1.5 threads) and the input
connection is designated as CONNECTION I (M22X1.5 threads) on the ZF gearbox drawing,
MD.1000.0344 version 1.

Lube Return
Lube Return
(Opposite Side from Lube Input)

Lube Input
Hydraulic
Motor/Pump Set

Proximity Switch

Figure 4-26
Two Speed Gearbox Lubrication

REMOVING THE TWO SPEED HEADSTOCK SPINDLE CARTRIDGE

The two speed headstock spindle cartridge is a complete assembly whose major components consists of
the cartridge, spindle sleeve, spindle and thrust cartridge (Figure 4-9). Within the spindle is the tool
clamping system. There are a number of precision fit spacers in both the cartridge and thrust cartridge
that provide the proper bearing preload. The spindle sleeve, which includes front and rear spindle
bushings, is balanced as an in process assembly along with keys, bull gear and the inner front bearing
spacer (part of a matched set inner and outer spacer). Disassembly of the spindle cartridge in the
field is not recommended.
If there is a need to remove the spindle cartridge, be sure to carefully review your machine specific prints
before disassembling any components. Improper disassembly or handling can cause damage to the
machine components. The following procedure is for removing the spindle cartridge, including the tool
clamping system (gripper assembly, drawbar, piston cylinder, and rotary union) as a complete unit.
1. Remove ram guide guard and bottom headstock guard.
2. Disconnect hydraulic and coolant hoses from drawbar rotary union.
3. Disconnect three cables: for clamp and unclamp proximity switches, and for spindle orientation
(bero) switch (Figure 4-11).
4. Disconnect both of the thrust cartridge lube lines (Figures 4-9 and 4-27).

4-22
 Thrust Cartridge Lube Lines

Fully
Threaded
Holes

Figure 4-27 Figure 4-28

Bottom View of Thrust Bracket Rear View of Thrust Bracket
5. Remove (clamp/unclamp) switch bracket by taking out six M6X16 socket head screws. The three
switches can be left in the bracket, be careful not to hit the end of switches during bracket
removal.
6. Remove twelve M10X35 socket head screws to release thrust cartridge from thrust bracket.
7. Two of the six tapped holes used to fasten the switch bracket to the thrust bracket are full thread.
The fully tapped holes are shown in (Figure 4-28). Use two M6 full thread screws minimum
55mm long, inserted into these tapped holes to push the thrust cartridge out of pilot bore in the
thrust bracket.
8. Reposition spindle so that front of cartridge is approximately 150mm (6”) from end of spindle
sleeve (Figure 4-29). This will balance the spindle cartridge for easier lifting.

150mm

Figure 4-29
Position of Spindle in Preparation of Spindle Cartridge Removal
(Shown Removed from Headstock)

9. Remove the six M10X16 button head screws from one of the spindle drive key covers. Leave the
drive key in the keyway. Place a M10 lockwasher between the key and the spindle key cover and
replace the screws to drive the key into the spindle keyway, locking the spindle in position.
10. Remove cover on bottom of headstock (front housing). This will provide access to thermister
cable and four spindle sleeve bearing lube line connections.
11. Disconnect the cable for front bearing thermister (RTD). Remove the four spindle sleeve bearing
lube lines. Must unscrew the Vogel socket unions (requires M8 wrench) which connect the lube
lines to the rear cartridge flange (Figure 4-9).

4-23
12. Remove twelve M12X70 socket head screws on the front flange of the spindle cartridge.
13. The spindle cartridge needs to be supported with a nylon strap attached to a crane before
proceeding with the next steps.
14. Insert two M12X50 flat point setscrews
into tapped holes in cartridge flange
(Figure 4-30). After setscrews make M12 Tapped
contact with housing, turn in equally to Holes Here &
push spindle cartridge out of the 180°. Used to
headstock housing. After 20mm, the Push Spindle
spindle cartridge will be off the pilot OD Cartridge Out
and fall onto the clearance OD. of Headstock
Housing.
15. Move the spindle cartridge forward
100mm out of the headstock housing
bore. You will need to reposition the
nylon sling behind the cartridge flange to
achieve the proper balancing point. Figure 4-30
View of Front of Spindle Cartridge
16. After the sling is repositioned, move the
spindle cartridge out of the headstock
cavity. Make sure not to bump the exposed spindle surface or the drawbar rotary union.
17. Place the spindle cartridge in large wooden vee blocks, on the front and rear ends of the cartridge
(Figure 4-9). Make sure to protect the spindle’s precision ground outer diameter from any
possible damage.

4-24
FOUR SPEED TRANSMISSION
The four speed transmission, located within the gear housing, transfers the power from the electric drive
motor to the spindle. This is accomplished through a series of shafts, supported by precision bearings,
spacers for locating the gears on the shaft and providing the required preloads on the bearings, and the
hardened and ground helical gears. The four gear ranges are shifted by two hydraulic cylinders that
actuate one of two shifting forks (Figure 4-31). Two proximity switches are mounted on each cylinder to
monitor cylinder position and provide feedback to whether shift forks are fully engaged. The gear train for
each of the four ranges is shown (Figure 4-32). The transmission drives a final drive bull gear that is
keyed to the spindle sleeve and locked into position with a threaded locknut. The spindle sleeve is
mounted in two bearings. One bearing located in the extended spindle support on the front of the gear
housing and the other in the midsection of the gear housing. The bearing in the midsection is a Timken
Hydra-Rib bearing. See the following section for a description of this bearing.

Gear Shaft Motor Coupling

Front Bearing
Lube Line

Shift Shaft
Shift Fork Coupling

Shift Cylinders
(Shown without Proximity
Switches)

Hydra-Rib
Hydraulic Line

Thermister
Access Cover
Spindle Sleeve Chilled Oil
Bearing Lube Spray into Gear
Line Housing Cavity

Shift Cylinders Proximity Switches

Figure 4-31
Four Speed Transmission with Covers Removed

4-25
 SPINDLE SPEED RANGE 1 SPINDLE SPEED RANGE 2

MOTOR INPUT SHAFT

OUTPUT TO SPINDLE SLEEVE

SPINDLE SPEED RANGE 3 SPINDLE SPEED RANGE 4

Figure 4-32
Four Speed Headstock Gear Trains

4-26
HYDRA-RIB BEARING
In the four speed headstock a special bearing is used that automatically adjusts bearing preload to
prevent overheating and maintain spindle accuracy and bearing life. Hydraulic pressure controls bearing
preload in the Timken Hydra-Rib bearing. This bearing allows changes of preload in the spindle system
to obtain an optimum preload setting. Once this optimum setting is obtained, the preload remains
constant and is not affected by changes in speed and load which will produce temperature and thermal
growth variations. Should cutting requirements change, a new optimum preload is obtained by making
adjustments to the hydraulic pressure supplied to the bearing. The pressure is modulated by a
proportional pressure reducing valve which is electronically servo controlled. A pressure transducer is
used to help maintain precise control. If this bearing is ever in need of replacement, please contact the
Giddings & Lewis Machine Tools service department.

Figure 4-33
Timken Hydra-Rib Bearing

The Hydra-Rib bearing is mounted in the mid section of the gear housing and opposed by a single row
tapered roller bearing in the extended spindle support. The conventional tapered roller bearing has a
fixed rib on the inner race or “cone” in contact with the large end of the rollers. In the Hydra-Rib bearing,
the rib is adjacent to the outer race and is movable. See (Figure 4-33) for the proper Hydra-Rib bearing
nomenclature. A pressure supply line is connected to the inlet pressure port to pressurize the rib
chamber, which is formed by the seal retainer and seal. Oil pressure in the chamber transfers a force to
the rib and from the rib to the rollers, thus preloading the spindle bearings.
In the working mode, a gap exists between the rib and the cup shoulder. As thermal conditions in the
bearing vary, tending to increase or decrease the bearing preload, the floating rib will back off or advance
to maintain a constant preload force at all times. The pressure is changed during the operating cycle to
handle a change in spindle load or speed, thus increasing or decreasing the bearing preload as required.
At the time of this writing, Hydra-Rib bearing pressure is set at 8.3 bar (120 psi) for spindle speeds from
0-1200 rpm. The pressure decreases linearly to 3.4 bar (50 psi) from 1200 to 2000 rpm. A constant 3.4
bar (50 psi) is held from 2000 to 3500 rpm. Always check your specific machine engineering prints for
exact pressures.

4-27
REMOVING THE FOUR SPEED HEADSTOCK SPINDLE
The spindle and spindle sleeve are part of a matched set of components identified as Sleeve Spindle
Process Assembly (P.A.). There is a set of bushings inside the spindle sleeve that are machined to
correspond to the exact measured outside diameter of the spindle. For this reason, spindles are not
interchangeable with spindle sleeves.
If there is a need to remove the spindle, be sure to carefully review your machine specific prints before
disassembling any components. Improper disassembly or handling can cause damage to the machine
components. This procedure is for removing the spindle, including the tool clamping system (gripper
assembly, drawbar, piston cylinder, and rotary union).
1. Position the spindle at the “0” position or completely retracted into the headstock.
2. Remove the lower front and rear guard covers and pulley cover.
3. Disconnect hydraulic and coolant hoses from rotary union.
4. Remove the two spindle keys. Note location of the keys, they will need to be installed in the
same location on reassembly (Figure 4-34).
5. Remove the two adapter keys, which hold in the brass wiper-scraper. Note location of the keys,
they will need to be installed in the same location on reassembly (Figure 4-34).

Spindle Key

M5X0.8
Threaded Holes

Wiper-Scraper
Keyway Wiper & Spring
Adapter Key Figure 4-34
Removal of Keys and Wipers

6. There are (2) M5X0.8 tapped holes in the brass wiper. Thread two screws in these tapped holes
long enough to pull the wiper-scraper from the spindle (Figure 4-34). Pull equally on the screws
to prevent the wiper-scraper from jamming on the spindle.
7. Remove the two spring loaded keyway wipers (Figure 4-34).
8. Loosen the two M5X20 flat head cap
screws on the front retainer of the rubber
spindle wiper (Figure 4-35). Once these
screws are loose, move the spindle
forward so that the spindle wiper
assembly can be removed. Use M12
Allen wrench in socket head screw
located in rear of ballscrew shaft to rotate
ballscrew and move spindle forward.
Make sure to mark the spindle wiper
assembly, so that the tabs will be inserted Figure 4-35
into the same spindle keyway when
reassembled.
Spindle Wiper & Retainer Assembly

4-28
9. Remove the splash guard and front cover from the gear housing. Note: the front cover has a
bead of Permatex #2 sealant, (G&L part # M.1014.5750), applied at cover assembly. Before
reassembly this material must be removed and a new bead applied. The front cover is being
removed in order to access the spindle sleeve.
10. In the spindle sleeve are two drive key cover plates (Figures 4-3 & 4-17). Remove the four corner
M10X16 button head screws from the spindle key cover. Remove one of the two center screws
and thread in a slide hammer. Pull out the spindle key cover and spindle key as one unit. Keep
this unit together and make sure to note location and position. They must be reinserted into the
spindle sleeve is the same location and position upon reassembly.
11. Remove M6X8 nylok setscrew,
located between the two mixing
blocks, under thrust bracket
(Figure 4-36). .Note: nylok
setscrew is not reusable. Loosen
M6X10 dog point setscrew which
is beneath setscrew. This dog
point is used to orient spindle
bearing spacer to receive lube
from mixer blocks.
12. Remove twelve M10X25 socket Setscrew and Dog
heads screws that hold on the Point Location
right and left thrust cartridge
covers (Figure 4-37). Note Figure 4-36
orientation of slots in covers for Spindle Bearing Spacer Lock Screw Location
reassembly. Once covers are
removed, remove two piece fitting
spacer.

13. Move the spindle so that it is at

least 150mm (6”) from face of
spindle sleeve. Use the
M10X1.5 threads (used for
spindle keys) to attach a metal
bar across the front of the
spindle. Place blocks between
bar and spindle sleeve. Use Note Orientation of
M12 Allen wrench in rear of Drain Slots in Covers
ballscrew shaft to rotate Right and Left Thrust
ballscrew and move thrust Cartridge Covers
bracket aft, thereby, pulling Figure 4-37
spindle bearings from thrust Thrust Cartridge Covers
bracket bore.
14. Remove previous front of
spindle setup. Install two eyebolts in M10X1.5 threads for the spindle keys. Place a steel bar
through the eyebolts and, by pulling on the bar; start to slide the spindle out of the spindle sleeve.
15. Continue to slide the spindle out of the spindle sleeve. The spindle should be supported with a
flat nylon sling, attached to a crane. Slide the spindle out of the spindle sleeve using the sling for
support and balance. Do not bump or pry the spindle side to side during withdrawal. Otherwise,
damage could occur to the front and rear spindle sleeve, precision ground bushings. Inspect
these sleeve bushings after spindle removal.
16. Place the spindle in wooden vee blocks, using rust preventive paper between the spindle and
wood. Make sure to protect the spindle’s ground outer diameter from any possible damage.

4-29
REMOVING THE FOUR SPEED HEADSTOCK SPINDLE SLEEVE
In order to remove the spindle sleeve you must first remove the spindle as described in previous section.
The spindle and spindle sleeve are part of a matched set of components identified as Sleeve Spindle
Process Assembly (P.A.). There is a set of bushings inside the spindle sleeve that are machined to
correspond to the exact measured outside diameter of the spindle. For this reason, spindle sleeves are
not interchangeable with spindles. The spindle sleeve (with the matched set of bushings); the bull gear,
split spacer, key, setscrews & locknut; both sets of spindle drive keys & covers; the adapter keys & rear
retainer with spacers, and all the fasteners associated with these components are balanced as a
complete process assembly. If any of these components are removed, there exact location and
orientation must be recorded, so that at reassembly they are replaced as balanced. In addition, the
Hydra-Rib bearing is precisely pre-loaded during the headstock assembly process. For the above
reasons, disassembly of the spindle sleeve in the field is not recommended.
If there is a need to remove the spindle sleeve, be sure to carefully review your machine specific prints
before disassembling any components. Improper disassembly or handling can cause damage to the
machine components. The following procedure is for removing the spindle sleeve.
1. The splash guard and front cover should already have been removed from the gear housing
during spindle removal. Remove the rear cover from the gear housing. Note: the front and rear
covers have a bead of Permatex #2 sealant, (G&L part # M.1014.5750), applied at cover
assembly. Before reassembly this material must be removed and a new bead applied.
2. Remove twelve M8X45 socket head screws from the spindle cover (Figure 4-13). Remove the
spindle cover. There is a small O-ring near the bottom of the spindle cover and a large O-ring
that fits on the spindle cover OD.
3. Remove the spindle sleeve bearing lube lines (Figure 4-31).
4. Remove cover by
taking out two M6X10 Spacer Ring
button head screws (One of Two Pieces Shown)
Cover
(Figure 4-38).
5. Support under side of
sealing ring.
Remove eight M8X45 Spacer
socket head screws
from flange of sealing
ring. Take out both Sealing Ring
pieces of spacer ring
and the one piece Figure 4-38
spacer (Figure 4-38). Sealing Ring & Cover
Slide sealing ring aft,
to back of gear housing. Remove sealing ring from gear housing cavity.

4-30
 Spindle Sleeve Retainer
Seal Retainer

Figure 4-39
Rear Bearing
Seal Retainer & Spindle Sleeve Retainer Inner Race

6. Remove seal retainer from back of spindle sleeve retainer by taking out six M8X35 nylok socket
head screws. Remove the retainer and two piece spacer, (from the end of spindle sleeve), by
taking out the remaining four M8X35 nylok socket head screws (Figure 4-39).

Split Spacers
beneath Gear Hub

Figure 4-40
Bull Gear & Locknut

7. Remove wire from outside of bull gear locknut. Remove 3/8”-16X1/4” locking setscrews in three
locations on locknut. In location marked dog point, back out dog pt setscrew at least 6mm. In
other two locations, back out 3/8”-16X1/2” setscrews (Figure 4-40). Turn off the locknut.
8. Pull the key out of the bull gear.
9. You must now separate the rear bearing inner race (Figure 4-39) from the OD of the spindle
sleeve. Either push on the rear face of the spindle sleeve using a centrally located portable
cylinder or use eyebolts in the M20X2.5 threads located on front face of spindle sleeve to pull on
the spindle sleeve. After enough force is applied the inner race will “pop” loose. Remove inner
race from spindle sleeve.
10. Remove the spindle sleeve from the gear housing. As you move the sleeve forward you will
expose the split spacers beneath the bull gear. Remove these spacers before continuing to
move spindle sleeve from gear housing.
11. When the end of the spindle sleeve is near the locknut, slide locknut off of spindle sleeve.
12. When the end of the spindle sleeve is near the bull gear, slide bull gear off of spindle sleeve.
13. Place the spindle sleeve in wooden vee blocks, using rust preventive paper between the spindle
sleeve and wood.

4-31