BONFIGLIOLI 300 Series Installation Use And Service Manual
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BONFIGLIOLI 300 Series Installation Use And Service Manual

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E
OBILE
QUIPMENT
W
E
S
AND
IND
NERGY
OLUTIONS
I
P
NDUSTRY
ROCESS
A
S
AND
UTOMATION
OLUTIONS
Installation,
300
A T E X
INCLUDED
use and service manual

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Summary of Contents for BONFIGLIOLI 300 Series

  • Page 1 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual A T E X INCLUDED...

  • Page 2: Table Of Contents

    10.0 - TROUBLESHOOTING ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS ANNEX 2 - LUBRICANT CHARGE QUANTITY Revisions The catalogue revision list is given on page 42. The most recent versions of the catalogue are available at www.bonfiglioli.com.

  • Page 3: General Information

    1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL This Manufacturer’s manual provides information regarding the safe transport, handling, installation, mainte- nance, repair, disassembly and dismantling of the gear unit. All information for users and designers is given in the Sales Catalogue. As well as adhering to esta- blished engineering practices, the information given in this manual must be read carefully and rigo- rously applied.

  • Page 4: Product Identification

    RATIO 1/ SERIAL N° DRWG. N° DATE COD. N° MADE IN ITALY Manufacturer Product identification Bonfiglioli Trasmital product code Reduction ratio Serial number Installation drawing code. Date of manufacture Client product code Supplementary nameplate on ATEX-specified gear units EC-Cert. No.

  • Page 5: Glossary And Terminology

    1.6 - CONSIGNMENT CONDITIONS Gear units are supplied by BONFIGLIOLI TRASMITAL in the following conditions: • Configured for installation in the mounting position specified in the purchase order.

  • Page 6: Technical Information

    It is capable of satisfying a range of specific requirements in the mechanical, chemi- cal, agricultural and food industries, etc. BONFIGLIOLI TRASMITAL supplies a range of accessories and optionals to make their products as versati- le as possible. For further technical information and descriptions, refer to the corresponding Sales Catalo- gue.

  • Page 7: Safety Information

    Ambient conditions • Ambient temperature: min. - 20°C; max. + 40°C. • Do not use the gear unit, if not explicitly intended for the purpose, in a potentially explosive atmosphere or where the use of explosion-proof equipment is specified. The nameplate specifications regarding the maximum surface temperature, refer to readings ta- ken in normal ambient and installation conditions.

  • Page 8: 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 TRASMITAL reseller. Dispose of packaging materials as stipulated by applicable legislation.

  • Page 9: 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 attac- hment points and centre of gravity.
  • Page 10 Identify the attachment points for lifting the gear unit. Refer to the diagrams given below. 300 L ... 316 L 317 L ... 321 L Screw clamp Maximum permissible tilt during 1 Ring harness (use with harness) handling: 15° Snap hook 2 Rope and hooks (use with rope) 3 Open harness...
  • Page 11 300 R ... 316 R 317 R ... 321 R Screw clamp 1 Ring harness Maximum permissible (use with harness) tilt during handling: 15° Snap hook 2 Rope and hooks (use with rope) Eyebolt (already fitted 3 Open harness with eyelets on gear units 317-321)
  • Page 12 300 R ... 316 R 317 R ... 321 R Screw clamp 1 Ring harness (use with harness) Snap hook 2 Rope and hooks (use with rope) Maximum permissible Eyebolt (already fitted 3 Open harness tilt during handling: 15° with eyelets on gear units 317-321)
  • Page 13 3V 00 ... 3V 16 3V 17 ... 3V 21 Screw clamp Maximum permissible tilt during 1 Ring harness (use with harness) handling: 15° Snap hook 2 Rope and hooks (use with rope) Eyebolt (already fitted 3 Open harness with eyelets on gear units 317-321)
  • Page 14 300 L ... 321 L 300 R ... 321 R 3V 00 ... 3V 21 Screw clamp 1 Ring harness Maximum permissible tilt during (use with harness) handling: 15° 2 Rope and hooks Snap hook (use with rope) 3 Open harness Eyebolt (already fitted on gear units 317-321) with eyelets...

  • Page 15: Storage

    • Prepare the gear unit for lifting by attaching straps, hooks and screw clamps etc. to its attachment points. Alternatively, use a pallet to move the load. If using a crane, first lift the gear unit vertically out of its packa- ging.

  • Page 16: Installation

    8. If the work environment is corrosive for the gear unit or any of its parts, follow the special precautions re- quired for aggressive environments. In this case, contact the BONFIGLIOLI TRASMITAL sales service. 9. We recommend applying a protective paste to all gear unit/motor mating surfaces and other parts (Klüberpaste 46 MR 401 or other product with similar properties and application range) to ensure optimal...
  • Page 17 For machining the spigot on the driven machine, refer to the diagrams below: 300...307 gear units - male output shaft motor execution 300...307 0.1 / 100 B 0.15 0.15 309...321 gear units - male output shaft motor execution These gear units are fitted with two spigots. When machining the coupling flanges, one spigot may be suffi- cient if the output shaft is not subject to overhung loads or loads are less than 60% of the permissible load.

  • Page 18: Foot Mounting

    Mounting with hollow splined shaft Ensure that the gear unit and driven shaft are aligned and that the latter is not subject to flexing during ope- ration. See diagram below: 300...321 0.1 / 100 B B 0. 15 Flanged gear unit mounting bolts 300 301 303 304 305 306 307 309 310 311 313 314 315 316 317 318 319 321 Bolt M10 M10 M12 M12 M12 M14 M16 M16 M16 M16 M20 M20 M20 M20 M30 M24 M30 M30...

  • Page 19: Shaft Mounting

    5.1.3 - Shaft mounting Mount the torque arm with bolts of at least class 8.8 tightened to a torque of 70% of their failure stress. Clean and degrease both the internal coupling surface of the gear unit shaft and the external coupling surface of the machine’s driven shaft.

  • Page 20: Installing Accessories On Solid Input And Output Shafts

    Proceed with the installation as follows: 1. Place the gear unit in the vicinity of the installation area. 2. Mount the gear unit and secure it to the structure at the points provided. The gear unit should be secured to the structure at all the mounting points (bores) on the mount provided (feet or flange). 3.
  • Page 21 Shaft end: threads 300...315 HC-PC HC-PC DIN 332 HC-PC HC-PC HC-PC M12 M12 M20 M20 M20 M20 M20 – – – – – – – – – – – M16 M16 M20 M20 M20 M20 M20 M24 M24 M24 M24 M24 M24 –...

  • Page 22: Installing The Electric Motor

    Installing accessories on splined shafts Do not use hammers or other tools that might damage the gear unit’s shafts or bearings when mounting external parts. Instead, proceed as illustrated in the diagram below: 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 follo- wing precautions must also be observed:...

  • Page 23: 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 24: 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 fit- ting 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 4...
  • Page 25 Installing the gearmotor If a gearmotor is supplied fully assembled, follow the precautions and instructions given above when moun- ting to the machine. For the electrical and hydraulic connection, refer instead to the two sample diagrams below. These are gene- ric only since each specific installation has its own special requirements, which must be evaluated on a per case basis by the Manufacturer.
  • Page 26 Drive with TRASMITAL MG orbital hydraulic motor In addition to the instructions governing installation of the gear unit, the following instructions should also be observed when installing a hydraulic motor. 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 cen- tre or open type.
  • Page 27 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 28 c) Brake control For gearmotors equipped with brakes, there are two motor versions available, i.e. the B02P or P010 execu- tions. 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 29 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, pre- vent air pockets from forming which may affect pump suction during operation.

  • Page 30: 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.

  • Page 31: 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: • the machine incorporating the gear unit complies with the provisions of the “Machinery Directive” 98/37/EC and any other applicable safety legislation •...

  • Page 32: Maintenance

    8.0 - MAINTEN ANCE 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 am- bient 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 suspended loads or similar external factors).

  • Page 33: Routine Maintenance

    Component Type of check Action Check that the external Stop the machine and contact at start Gear unit casing temperature does not exceed Bonfiglioli Trasmital’s Technical 75-80 °C Service Original consignment Replace Replace with new lubricant lubricant after 200 hrs...

  • Page 34: Oil Changes

    8.2 - OIL CHANGES 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. 3. Wait for a few minutes until all the oil has drained out, then screw the drain plug back on after first chan- ging the plug seal.

  • Page 35: Replacing Parts

    9.0 - REPLACING PARTS • Immediately replace parts and components if they are not able to guarantee safe and reliable ope- ration. • Never improvise repairs. • The use of non-original spare parts not only renders the warranty null and void but can jeopardise the gear unit’s operation.

  • Page 36: Troubleshooting

    10.0 - TROUBLESHOOTING The following information is intended to serve as an aid in locating and eliminating defects and faults. In some cases, problems may be caused by the plant or machine to which the gear unit is assembled and hen- ce, the cause and remedy will be described in the Manufacturer’s technical documentation for the machi- ne/plant in question.

  • Page 37: 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 fitted with oil level check plugs. To check the oil level, first 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 38: Annex 2 - Lubricant Charge Quantity

    ANNEX 2 - LUBRICANT CHARGE QUANTITY 3_L Series Mounting position Mounting position N.B. Oil quantities are indicative. Check actual level after filling through the appropriate plug.
  • Page 39 3_R Series Mounting position Mounting position N.B. Oil quantities are indicative. Check actual level after filling through the appropriate plug.
  • Page 40 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 41 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...
  • Page 43 INDEX OF REVISIONS (R) We reserve the right to implement modifications without notice. This catalogue cannot be reproduced, even partially, without prior consent. COD. 7.998.3.3.01.7 R2...
  • Page 44 OBILE QUIPMENT NERGY OLUTIONS NDUSTRY ROCESS UTOMATION OLUTIONS w w w . b o n f i g l i o l i . c o m...

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