BONFIGLIOLI HDP Series Installation Use And Service Manual
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BONFIGLIOLI HDP Series Installation Use And Service Manual

Gear unit
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NDUSTRY
ROCESS
A
S
AND
UTOMATION
OLUTIONS
Installation,
use and service manual
HDP

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Summary of Contents for BONFIGLIOLI HDP Series

  • Page 1 NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual...

  • Page 3: Table Of Contents

    CUSTOMER'S SHAFT series HDP ........... . . 37 Revisions Refer to page 38 for the catalogue revision index. Visit www.bonfiglioli.com to search for catalogues with up-to-date revisions.

  • Page 5: General Information

    1 GENERAL INFORMATION 1.1 PURPOSE OF THE MANUAL This manual has been compiled by the Manufacturer to provide information on the safe transport, handling, installation, maintenance, repair, disassembly and dismantling of the gear units. All purchasing and design criteria is provided in the Sales Catalogue. Apart from adhering to established engineering practices, the information given in this manual must be carefully read and applied rigorously.

  • Page 6: Equipment Identification

    1.2 EQUIPMENT IDENTIFICATION The gear unit bears the following nameplate. The nameplate bears all references and indispensable safety instructions. The gear unit’s identifying code is explained in the Sales Catalogue. If the gear unit is supplied complete with electric motor (gearmotor), all information regarding the motor itself is supplied in the motor manual.

  • Page 7: Requesting Technical Assistance

    1.4 REQUESTING TECHNICAL ASSISTANCE For any technical service needs, contact the Manufacturer’s sales network, quoting the information on the unit’s nameplate, the approximate hours of service and the type of defect. 1.5 MANUFACTURER’S LIABILITY The Manufacturer declines all liability for cases of: use of the gear unit in violation of local laws on safety and accident prevention at work.

  • Page 8: Technical Information

    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 Sales Catalogue.

  • Page 9: Safety Information

    3 SAFETY INFORMATION 3.1 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 specifically for the purpose with special abilities and experience in this area as well as being equipped with the appropriate tools and individual safety equipment (as per Legislative Decree 626/94).
  • Page 10 Various accessories (e.g. mounting flanges, ...) and/or electric motors coupled to the gear unit, may significantly alter the centre of gravity, thereby impairing the stability of the unit. Type of special danger Depending on the operating conditions, the outer surfaces of the gear unit may reach very high temperatures.

  • Page 11: Handling And Transport

    On receipt of the gear unit, check that the delivery item corresponds to the purchase order and that it is not damaged or faulty in any way. Refer any nonconformity to your BONFIGLIOLI RIDUTTORI dealer. Dispose of packaging materials as laid down by the provisions of law.

  • Page 12: Handling Instructions

    4.2 HANDLING INSTRUCTIONS 4.2.1 HANDLING INSTRUCTIONS Handle packages as per the Manufacturer’s instructions and those marked on the packages themselves. Since the weight and shape of packages may make manual handling unfeasible, special equipment must be used to avoid damage and injury. Persons authorised for this purpose must be trained and experienced in the work in question to safeguard his safety and that of all other persons involved.

  • Page 13: Storage

    5. Cover all machined external surfaces with a rustproofing product such as Shell Ensis or equivalent product with similar properties and application range. 6. Fill the unit with lubricating oil. For gear units equipped with a drywell seal system or equipped with labyrinth type non-contacting seals, consult the BONFIGLIOLI technical-sales service.

  • Page 14: Installation

    Check that there are no substances present in the place of installation that could cause corrosion of the gear unit or its component parts. If there are any aggressive substances in the environment, this situation must be communicated to the BONFIGLIOLI technical-sales service, which will provide suitable instructions.
  • Page 15 In case of installation outdoors and when fitted with an electric motor, protect the latter from direct sunlight and the weather by means of guards or a casing. Also make sure that the assembly is properly ventilated. Check on the gear unit nameplate that the configured mounting position corresponds to the position specified in the order.

  • Page 16: Gear Units Equipped With Solid Shaft

    5.1.2 GEAR UNITS EQUIPPED WITH SOLID SHAFT When installing external parts do not use hammers or other tools to avoid the risk of damaging the gear unit shafts and supports. On the contrary, proceed as shown in the following diagram, ideally preheating the part to be coupled. For further details refer to heading Bolt (1) and spacer (2) are to be supplied by customer.

  • Page 17: Gear Units With Shrink Disk

    The bolt (1) and spacer (2) are to be supplied by customer. Secure the hollow shaft to the machine shaft in an axial direction. Install suitable devices to secure the hollow shaft to the machine shaft in an axial direction and prevent accidental decoupling.

  • Page 18: Anchoring The Torque Arm

    Never run the gear unit when the shrink disc protective guard is not fitted. 5.1.5 ANCHORING THE TORQUE ARM For shaft-mounting solutions the gear unit can be equipped with a torque arm on request. This device, which is made of electrowelded steel and equipped with damper bushes, assures the highest guarantees of functionality of the assembly because it is designed and sized specifically for the job.

  • Page 19: Gear Unit Equipped With Fixing Flange

    5.1.7 GEAR UNIT EQUIPPED WITH FIXING FLANGE The gear unit can be equipped with a fixing flange on request. Thoroughly clean and degrease the mating areas between the gear unit flange and driven machine flange. The correct execution of this procedure is an important factor in the achievement of safe torque transmission.

  • Page 20: Installing Connecting Elements

    5.3 INSTALLING CONNECTING ELEMENTS Use the utmost caution when installing the various components, to ensure that no damage is caused to the gear unit and its parts, such as oil seals and mating surfaces, or internal parts such as gears and bearings.

  • Page 21: Using The Equipment

    In these circumstances, which are normally discussed at the contract stage, consult the BONFIGLIOLI RIDUTTORI sales department about the best type of lubricant to be used. If the gear unit is not used for a prolonged period following installation or run-in, it must be run at least once a month, either in no-load or loaded conditions.

  • Page 22: Maintenance

    The BONFIGLIOLI RIDUTTORI Sales Department is at your disposal for any requirements. Before performing any work on the unit, personnel must: deactivate the gear unit drive unit, setting it to "out of service"...

  • Page 23: Routine Maintenance

    6.2 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule specified by the Manufacturer. Good maintenance enables the unit to operate at its maximum performance over a long service life in compliance with safety regulations. Lift of checks to perform We recommend keeping a checklist of inspections so that any changes in individual control parameters can be identified rapidly and easily.

  • Page 24: Lubricants

    Lubrication interval Oil temperature t [°C] Synthetic Mineral oil t < 65 25000 8000 65 ≤ t < 80 15000 4000 80 ≤ t ≤ 95 12500 2000 6.3 LUBRICANTS Before putting the gear unit into service, check the oil level. This must be done with the gear unit in the mounting position in which it will be used in the application.

  • Page 25: Oil Change

    6.4 OIL CHANGE For lubricant change intervals refer to the maintenance heading. 1. Place an adequate container under the drain plug. 2. Remove the filler and drain plugs and allow the oil to drain out. The oil will drain better if it is warm. Adopt protection against contact with hot parts: risk of burns! 3.

  • Page 26: Service Plugs

    6.5 SERVICE PLUGS C = Filler plug with air breather T = Closed plug L = Level plug = No plug present S = Drain plug L* = Overflow level plug 2x - 3x HDP60...HDP90 2x - 3x HDP60...HDP90 2x - 3x HDP60...HDP90 2x - 3x HDP60...HDP90...

  • Page 27: Recommended/Permitted Oils

    6.6 RECOMMENDED/PERMITTED OILS 60...90 Tivela S 220 Tivela S 320 Tivela S 460 Cassida Fluid WG 320 Telium VSF 220 Telium VSF 320 Spartan EP 220 Spartan EP 320 Klübersynth GH 6 220 Klübersynth GH 6 320 Klübersynth UH1 6-460 Glygoyle HE 320 Glygoyle HE 460 Mobilgear SHC XMP 220...

  • Page 28: Cleaning

    6.8 CLEANING Clean all dust and process waste off the gear unit. Do not use solvents or other products which are incompatible with the construction material and do not direct high-pressure jets of water at the gear unit. 6.9 PAINT COATING In the factory, the cast-iron casing of the gear unit is magnetised and sprayed with polyester heat- setting resin which is then baked on.

  • Page 29: Installed Components

    7 INSTALLED COMPONENTS 7.1 AUXILIARY THERMAL DEVICES 7.1.1 FORCED VENTILATION A fan is keyed to the gear unit input shaft and protected against accidental contact by a guard. Never run the gear unit when the fan guard is not fitted. After each maintenance intervention refit the guards before restarting the gear unit.

  • Page 30: Oil Heater

    If a single heater is insufficient to heat the oil to the minimum required temperature, or if shorter warm- up times are required, consult Bonfiglioli's Technical Service. The thermostat is set to 25 ± 5°C. The electrical circuit connected to the thermostat must be set up in such a way that the heater is disconnected once the cut-out temperature has been reached.

  • Page 31: Lubrication System

    7.2 LUBRICATION SYSTEM 7.2.1 GENERAL INFORMATION The gear unit internal parts are usually lubricated with a mixed oil bath and oil splash system. In some configurations certain bearings may be grease lubricated and equipped with Nilos seal rings. A forced lubrication system can be supplied on request.

  • Page 32: Forced Lubrication With Motor Pump

    The inhibited direction of the backstop device can be changed by turning the cage. If you wish to change the inhibited rotation direction, first contact the BONFIGLIOLI RIDUTTORI sales service for information on the correct procedure to adopt.

  • Page 33: Drywell

    7.4 DRYWELL All work must be performed exclusively with the gear unit at a standstill. The motor must be protected against inadvertent starts (e.g. with a lockout on the main power switch or by removing the power fuses). For this purpose, also affix a notice to the motor indicating that work is in progress on the gear unit.

  • Page 34: Replacing Parts

    8 REPLACING PARTS 8.1 GENERAL INFORMATION Do not hesitate to replace parts and/or components if they are not able to guarantee safe and reliable operation. Never improvise repairs. The use of non-original spare parts not only voids the warranty but can compromise gear unit operation.

  • Page 35: Disassembling A Gear Unit Equipped With Hollow Output Shaft And Shrink Disc Coupling

    8.3 DISASSEMBLING A GEAR UNIT EQUIPPED WITH HOLLOW OUTPUT SHAFT AND SHRINK DISC COUPLING Unscrew the fixing screws gradually and then remove the shrink disc coupling Now extract the machine’s shaft as described in heading 8.2. 8.4 SCRAPPING THE GEAR UNIT This must only be done by operators trained in the observance of applicable laws on health and safety at work.

  • Page 36: Troubleshooting

    9 TROUBLESHOOTING The following information is intended to serve as an aid in identifying and correcting defects and faults. In some cases, such problems may be caused by the plant or machine onto which the gear unit is assembled, and hence, the cause and eventual solution can be found in the Manufacturer’s technical documentation for the machine/plant in question.

  • Page 37: Annex 1

    10 ANNEX 1 10.1 CHECKING OIL LEVEL OIL LEVEL SIGHT GLASS: To check the correct level of oil refer to the mid point of the sight glass. If the oil level is lower than the lower edge of the sight glass, replenish the oil and locate the cause for the fall in level. SPILL TYPE OIL PLUG: Gear units equipped with drywell or labyrinth seals are equipped with a spill type oil plug rather than an oil level sight glass.To check the oil level, first identify the yellow level plug.

  • Page 38: Annex 2

    11 ANNEX 2 11.1 METHOD OF LIFTING When lifting the unit use accessories such as eyebolts, shackles, snap hooks, harnesses, ropes, hooks, etc. that are fully certified and of sufficient capacity in relation to the load to be lifted. The weight of the unit to be handled is specified in the relative sales catalogue. When lifting gear units the slinging chain legs must be hooked to the four specific lifting eyes.

  • Page 39: Annex 3

    gear unit may significantly alter the centre of gravity, thereby impairing the stability of the gear unit. In such cases it may be necessary to use an additional anchor point. During lifting operations the load must not be allowed to swing beyond an arc of ± 15°. If greater swinging movements occur during the procedure, stop and repeat the prescribed operations in relation to the type of lifting system adopted.
  • Page 40 INDEX OF REVISIONS DOCUMENT SECTION DESCRIPTION COD. 1291 R0...
  • Page 42 NDUSTRY ROCESS UTOMATION OLUTIONS w w w . b o n f i g l i o l i . c o m...

This manual is also suitable for:

Hdp 60Hdp 70Hdp 80Hdp 90

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