Related Manuals for BONFIGLIOLI 300 Series
Summary of Contents for BONFIGLIOLI 300 Series
- Page 1 300 - 300M Series Installation, Operation and Maintenance Manual PRODUCTS & SOLUTIONS INCLUDED...
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Page 3: Table Of Contents
ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS ANNEX 2 - LUBRICANT CHARGE QUANTITY ANNEX 3 - MOUNTING POSITIONS AND PLUG POSITIONS Revisions The catalogue revision list is given on page 52. The most recent versions of the catalogue are available at www.bonfiglioli.com. 1 / 52... -
Page 4: General Information
GENERAL INFORMATION PURPOSE OF THE MANUAL This Manufacturer’s manual provides information regarding the safe transport, handling, installa- tion, maintenance, repair, disassembly and dismantling of the gear unit. All information for users and designers is given in the Sales Catalogue. As well as adher- ing to established engineering practices, the information given in this manual must be read carefully and rigorously applied. -
Page 5: Product Identification
PRODUCT IDENTIFICATION The information identifying the product is shown on its nameplate. Gearmotors are equipped with two nameplates; one on the gear unit which bears the gear unit data, and one on the motor (elec- tric or hydraulic), bearing the motor data. The drawing below illustrates the layout of the data. -
Page 6: Glossary And Terminology
GLOSSARY AND TERMINOLOGY Some of the frequently occurring terms used in this manual are described below to unequivocally define their meaning. Routine maintenance The set of operations required to preserve the functionality and efficiency of the gear unit. These operations are usually scheduled by the Manufacturer, who defines the qualifications and tasks involved. -
Page 7: Consignment Conditions
It is capable of satisfying a range of specific requirements in the mechanical, chemical, agricultural and food industries, etc. BONFIGLIOLI RIDUTTORI supplies a range of accessories and optionals to make their products as versatile as possible. For further technical information and descriptions, refer to the corre- sponding Sales Catalogue. -
Page 8: Conformity
• Temperature class: T4 for 2G and 135°C for 2D. OPERATING LIMITS AND CONDITIONS Modification of the motor execution or mounting position is only permitted if previously authorised by BONFIGLIOLI RIDUTTORI’s Technical Service. Failure to obtain said authorisation renders the ATEX certification null and void. Ambient conditions •... -
Page 9: Allowed Temperature Limits
ALLOWED TEMPERATURE LIMITS Value (*) Symbols Description / Condition Synthetic Mineral Ambient temperature -30°C -10°C Minimum operating ambient temperature au min Maximum operating ambient temperature +50°C +40°C au Max -40°C -10°C Minimum storage ambient temperature as min Maximum storage ambient temperature +50°C +50°C as Max... -
Page 10: Safety Information
SAFETY INFORMATION SAFETY STANDARDS • Carefully read the instructions given in this manual and those posted directly on the gear unit, especially those regarding safety. • Persons charged with working on the gear unit at any time in its service life must be trained spe- cifically for the purpose with special abilities and experience in the area as well as being equipped with the appropriate tools and individual safety equipment (as per Legislative Decree 626/94). -
Page 11: Handling And Transport
On receipt of the gear unit, make sure the delivery corresponds to the purchase order and that it is not damaged or faulty in any way. Report any nonconformity to your BONFIGLIOLI RIDUTTORI reseller. Dispose of packaging materials as stipulated by applicable legislation. -
Page 12: Moving The Packages
4.2.1 Moving the packages • Prepare a suitable, delimited area with a level floor or surface for unloading the packages. • Prepare the equipment required to handle the package. The lifting and handling equipment (e.g. crane or lift truck) must be of adequate capacity for the weight and size of the load, taking into account its attachment points and centre of gravity. - Page 13 Identify the attachment points for lifting the gear unit. Refer to the diagrams given below. Horizontal positions 300 L ... 316 L , 310M L ... 316M L 317 L ... 325 L , 317M L , 318M L Screw clamp (use with Maximum permissible tilt during Ring harness harness)
- Page 14 300 R ... 316 R , 310M R ... 316M R 317 R ... 321 R , 317M R , 318M R Screw clamp (use with Maximum permissible Ring harness harness) tilt during handling: 15° Rope and hooks Snap hook (use with rope) Eyebolt (already fi tted on gear Open harrness with units 317-321 , 317M , 318M)
- Page 15 300 R ... 316 R , 310M R ... 316M R 317 R ... 321 R , 317M R , 318M R Screw clamp (use with Ring harness harness) Rope and hooks Snap hook (use with rope) Maximum permissible tilt during Eyebolt (already fi tted on gear Open harrness with handling: 15°...
- Page 16 3V 00 ... 3V 16 , 3V 10M ... 3V 16M 3V 17 ... 3V 21 , 3V 17M , 3V 18M Screw clamp (use with Maximum permissible Ring harness harness) tilt during handling: 15° Rope and hooks Snap hook (use with rope) Eyebolt (already fi tted on gear Open harrness with units 317-321 , 317M , 318M)
- Page 17 3A 00 ... 3A 07 Screw clamp (use with Maximum permissible Ring harness harness) tilt during handling: 15° Rope and hooks Snap hook (use with rope) Open harrness with Eyebolt eyelets 15 / 52...
- Page 18 Vertical positions 300 L ... 325 L , 310M L ... 318M L 300 R ... 321 R , 310M R ... 318M R 3V 00 ... 3V 21 , 3V 10M ... 3V 18M 3A 00 ... 3A 07 Screw clamp (use with Maximum permissible Ring harness...
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Page 19: Storage
• Prepare the gear unit for lifting by attaching straps, hooks and screw clamps etc. to its attach- ment points. Alternatively, use a pallet to move the load. If using a crane, first lift the gear unit vertically out of its packaging. •... -
Page 20: Installation
7. Fit suitable guards to protect against the gear unit’s external moving parts. 8. If the work environment is corrosive for the gear unit or any of its parts, follow the special precautions required for aggressive environments. In this case, contact the BONFIGLIOLI RIDUT- TORI sales service. - Page 21 For machining the spigot on the driven machine, refer to the diagrams below: 300...307 gear units - male output shaft motor execution 300...307 309...321 , 310M...318M gear units - male output shaft motor execution These gear units are fitted with two spigots. When machining the coupling flanges, one spigot may be sufficient if the output shaft is not subject to overhung loads or loads are less than 60% of the permissible load.
- Page 22 318 / 318M • Remove the two axial mounting half-rings (1) from the gear unit • Make the customer shaft (2) as indicated in the technical catalogue (see www.bonfiglioli.com for up-to-date version) • Properly lubricate both the shaft and its housing, then connect the shaft to the gear unit •...
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Page 23: Foot Mounting
5.1.2 Foot mounting Foot-mounted motor execution Gear units of this type must be mounted on a suitably rigid base, machined flat with a planarity error margin of no more than 0.2 mm / 100 mm. See diagram below: 300...321 310M...318M Foot-mounted gear unit mounting bolts 300 301 303 304 305 306 307 309 319 321... - Page 24 Clean and degrease both the internal coupling surface of the gear unit shaft and the external cou- pling surface of the machine’s driven shaft. Mount the shrink disk to the gear unit’s shaft after lightly lubricating its entire outer surface. Mounting sequence for shrink discs with gear units sizes 300-313 , 310M-313M •...
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Page 25: Installing Accessories On Solid Input And Output Shafts
Locate the closed oil plug used during shipping and replace it with the vent plug supplied in the shipment. 5.1.4 Installing accessories on solid input and output shafts Do not use hammers or other tools that might damage the gear unit’s shafts or bearings when mounting external parts. - Page 26 Mounting pulleys Clean all parts before installing them. When installing belt drive pulleys, the shafts must be paral- lel with their pulleys aligned. Do not over tension the drive belt as this can damage the bearings. Shaft end: threads 300...315 316 , 316M 317 , 317M 310M...315M...
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Page 27: Installing The Electric Motor
MZ-HZ Always use the stop end plate supplied with the gear unit. 5.2 INSTALLING THE ELECTRIC MOTOR Further to all the precautions indicated above, when installing a standard IEC 72-1 electric motor, the following precautions must also be observed: • Do not force the coupling and do not use inappropriate tools during assembly. Take care not to damage the flat/cylindrical coupling surfaces. -
Page 28: Installing The Hydraulic Motor
5.3 INSTALLING THE HYDRAULIC MOTOR Connecting the hydraulic motor Remove the protective plug. Hydraulic motor mountings are available in two versions: a) Version with O-ring oil gasket between motor flange and gear unit. In this case, mount the gasket to ensure an oil tight seal between the motor and gear unit, taking care to fit it correctly in its seat without damaging it. -
Page 29: Connecting The Hydraulic Brake
5.4 CONNECTING THE HYDRAULIC BRAKE On gear units designed for coupling to hydraulic motors and fitted with a brake, connect the brake control fitting to the hydraulic circuit at the time of assembly. Start-up The minimum pressure to release the brake (see chart) must be less than 320 bar. Technical data Brake 4... - Page 30 Installing the gearmotor If a gearmotor is supplied fully assembled, follow the precautions and instructions given above when mounting to the machine. For the electrical and hydraulic connection, refer instead to the two sample diagrams below. These are generic only since each specific installation has its own special requirements, which must be evaluated on a per case basis by the Manufacturer.
- Page 31 a) Connecting to the hydraulic circuit The motor can be installed on both a closed and open loop circuit. In the case of an open circuit installation, the solenoid valve or control valve may be of either the closed centre or open type. The circuit line corresponding to the hydraulic motor delivery port must always be equipped with a pressure relief valve calibrated to a pressure no greater than the motor’s pmax.
- Page 32 b) Connecting drain port T These motors have a 1/8” G drain hole in the centre of the cover. The motor is supplied with the port closed by a metal plug (see figure below). Two non-return valves are incorporated in the motor casing to maintain internal pressure at the same level as the low pressure line A or B if the drain port is not connected to the tank.
- Page 33 c) Brake control For gearmotors equipped with brakes, there are two motor versions available, i.e. the B02P or P010 executions. In the B02P version, the motor has an in-built, direct brake control system. In the P010 version, an auxiliary branching is required to control the brake. See the following diagram.
- Page 34 Drive with hydraulic motor All motors must be charged with hydraulic fluid before being operated and during installation. Position the drain hole so that it is positioned uppermost for charging with fluid. Make sure the hoses are routed in such a way as to prevent the motor casing from emptying and hence, prevent air pockets from forming which may affect pump suction during operation.
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Page 35: Lubrication
5.5 LUBRICATION Before starting up the gear unit, it must be charged with lubricant to the level corresponding to its specified mounting position. The lubricant and its relative viscosity should be selected from the following chart, in accordance with the type of duty and ambient temperature. If the gear unit is supplied ready charged with lubri- cant, replace the closed shipping plug with the vent plug included in the shipment before installing it. - Page 36 Mobile machines (A 3) SAE standard .. API GL5 grade -20°C / +30°C +10°C / +45°C SAE 80W/90 SAE 85W/140 Shell Spirax HD Spirax HD Mobil Mobilube HD Mobilube HD AGIP Rotra MP Rotra MP Aral Getriebeol HYP Getriebeol HYP Hypogear EP Hypogear EP Castrol...
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Page 37: Testing The Gear Unit
6.0 TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer. Before start-up, make sure that: • this partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the “Machinery Directive”... -
Page 38: Maintenance
8.0 MAINTENANCE Maintenance and replacement work must be carried out by expert maintenance technicians trained in the observance of applicable laws on health and safety at work and the special ambient problems attendant on the installation. Before doing any work on the unit, the operator must first switch off power to the gear unit and ensure that it is out of service, as well as taking all necessary precautions against it being accidentally switched on again or its parts moving without warning (due to suspend- ed loads or similar external factors). -
Page 39: Routine Maintenance
8.1 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule. Good maintenance ensures the unit’s maximum performance, extended service life and continued compliance with safety regulations. (A 4) Frequency Component Type of check Action Check that the external Stop the machine and... -
Page 40: Oil Changes
Depending on the temperature reached by the lubricant, it should be replaced at the intervals indicated in the table below. (A 5) Interval replacement [h] Average oil opera- ting temperature synthetic oil mineral oil [C°] EP(*) < 65 8000 25000 25000 65 <... -
Page 41: Checking Operational Efficiency
Handle them with care using suitable individual safety equipment. Do not dump them into the environment and dispose of in accordance with applicable legislation. 8.3 CHECKING OPERATIONAL EFFICIENCY • Remove any dust from the gear unit and motor casings. • Check that the noise generated at continuous load does not vary. Excessive vibration or noise can indicate wear of the gear train or failure of a bearing. -
Page 42: Replacing Parts
9.0 REPLACING PARTS • Immediately replace parts and components if they are not able to guarantee safe and reliable operation. • Never improvise repairs. • The use of non-original spare parts not only renders the warranty null and void but can jeopard- ise the gear unit’s operation. -
Page 43: Decommissioning The Gear Unit
9.2 DECOMMISSIONING THE GEAR UNIT The unit must only be taken out of service by operators trained in the observance of applicable laws on health and safety at work. Do not dump non-biodegradable products, lubricants and non-ferrous materials (rubber, PVC, resins, etc.) into the environment. -
Page 44: Annex 1 - Checking The Oil Level On Atex-Specified Gear Units
ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS Gear units are normally fi tted with oil level check plugs. To check the oil level, fi rst identify the level plug. - Horizontal position: Remove the plug and insert a bar of the right size in the hole and of the shape shown in the fi gure. -
Page 45: Annex 2 - Lubricant Charge Quantity
ANNEX 2 - LUBRICANT CHARGE QUANTITY 3_L Series Mounting position Mounting position 310M 311M 313M 314M 315M 316M 317M 318M Contact Bonfi glioli Riduttori Technical Service N.B. Oil quantities are indicative. Check actual level after fi lling through the appropriate plug. 43 / 52... - Page 46 3_R Series Mounting position Mounting position 310M 311M 313M 314M 315M 316M 317M 318M N.B. Oil quantities are indicative. Check actual level after filling through the appropriate plug. 44 / 52...
- Page 47 3/V Series AA - EA - FD AF - EF - FE AE - EE - FF AD - ED - FA TA - TE - TF OA - OE - OF TD - VA - VE OD - QA - QE VF - VD QF- QD input...
- Page 48 3/A Series AA - EA - FD TA - TE - TF OA - OE - OF AD - ED - FA AF - EF - FE AE - EE - FF TD- VA - VE OD - QA - QE VF - VD QF- QD 3/A 00 L2...
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Page 49: Annex 3 - Mounting Positions And Plug Positions
ANNEX 3 - MOUNTING POSITIONS AND PLUG POSITIONS 3_M_L - 3_L - 3_R Series A - E ALL GEARBOXES 300 - 325 , 310M - 318M Filling/breather oil plug Oil level plug Oil draining plug Brake port 1 STAGE INLINE GEARBOXES 1A Filling/breather oil plug 3A Oil draining plug 2 STAGE RIGHT ANGLE GEARBOXES... - Page 50 300 - 307 309 - 325 , 310M - 318M P0 - P1 - P2 - P3 R0 - R1 - R2 - R3 Q - O 300 - 321 , 310M - 318M 300 - 325 , 310M - 318M ALL GEARBOXES Brake port Transparent oil level hose...
- Page 51 3/V M - 3/V Series A - E ALL GEARBOXES 300 - 321 , 310M - 318M (planetary stages) Filling/breather oil plug Oil level plug Oil draining plug (worm reduction module) 1V Filling/breather oil plug 2V Oil level plug 3V Oil draining plug O - Q 300 - 321 , 310M - 318M 300 - 307...
- Page 52 3/A Series A - E ALL GEARBOXES 300 - 307 (planetary stages) Filling/breather oil plug Oil level plug Oil draining plug (helical bevel reduction module) 1A Filling/breather oil plug 2A Oil level plug 3A Oil draining plug O - Q 300 - 307 T - V 300 - 307...
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- Page 54 INDEX OF REVISIONS (R) BR_IOM_300_ATX-INC_ENG_R04_0 Description Added information about series 300M gearboxes. We reserve the right to implement modifications without notice. This catalogue cannot be reproduced, even partially, without prior consent. 52 / 52...
- Page 56 We have a relentless commitment to excellence, innovation & sustainability. Our team creates, distributes and services world-class power transmission & drive solutions to keep the world in motion. HEADQUARTERS Bonfi glioli Riduttori S.p.A. Via Giovanni XXIII, 7/A 40012 Lippo di Calderara di Reno Bologna (Italy) tel: +39 051 647 3111 fax: +39 051 647 3126...