4- Installation; Installing The Gearbox - BONFIGLIOLI Riduttori AS Series Installation, Operation And Maintenance Manual

4 INSTALLATION

4.1 INSTALLING THE GEARBOX

All phases of installation and maintenance must be taken into consideration from the machine
design stage. Design personnel must, if necessary, implement a safety plan to protect the health
and safety of all persons directly involved and to ensure the rigorous application of all relevant
legislation.
It is essential for impact and stress to be avoided during the installation process.
Before installing a geared motor, also refer to the instructions contained in the installation and user
manual for the electric motor.
Before installing the gearbox:

Drain out the oil used for storage if it is not the same as the oil used for normal functioning and flush the inside
of the gearbox out thoroughly (see the "LUBRICATION" section in this manual).

Carefully remove all packaging and protective coatings from the gearbox suitable solvents. Take special care
when cleaning mating surfaces. Avoid getting solvents on the shaft seal rings.

Check that the data on the nameplate correspond to those specified in the order.

Ensure that the structure in which the gearbox is to be mounted is sufficiently robust and rigid to sup- port its
weight and operating forces. If normal service is likely to involve impacts, extended overloads or possible
seizures, fit the necessary hydraulic couplings, clutches, torque limiters, etc.

Check that the machine in which the gearbox is to be installed is switched off and cannot be accidentally started
up.

Check that all coupling surfaces are flat.

Check that the shaft/shaft or shaft/ bore are perfectly aligned for coupling.

Fit suitable guards to prevent accidental contact with rotating parts outside the gearbox.

If the work environment is corrosive for the gearbox or any of its parts, follow the special precautions required for
aggressive environments. Contact the manufacturer's technical assistance service for further details.

We recommend applying a protective paste such as Klüber paste 46 MR 401 (or a product with similar
properties and application range) to all key type couplings to ensure optimal coupling and protection
against fretting corrosion. Clean all friction couplings thoroughly but do not apply any protective pastes
to them.

Thoroughly clean all other contact surfaces (feet, flanges, etc.) and apply a suitable protective product
to them to prevent oxidation.

Mechanical organs keyed on to the solid gearbox output shafts must be machined to an ISO H7 tolerance to
prevent couplings from seizing and to prevent irreparable damage to the gearbox during installation. To ensure
effective coupling, driven shafts should be machined to the tolerances specified in the "PREPARING
CUSTOMER SHAFTS" section in this manual.

In outdoor installations, protect the gearbox and its motor from direct sunlight and inclement weather
by means of canopies or covers. Make sure that the assembly is properly ventilated.

Make sure that the casing of the gearbox is connected to the equipotential protection (earth/ground)
circuit of the machine in which it is installed.

Evaluate whether accessible surfaces may exceed the temperature limits established in EN ISO 13732-1 on
the basis of the gearbox conditions of use and ambient temperatures; if these limits can be easily reached or
exceeded, the surfaces in question must be protected to prevent contact (by means of guards and/or lagging).
Wherever impossible, signs bearing symbol 5041 of IEC standard 60417 "Warning! Hot surfaces" must be
displayed in such a way that they are clearly visible to machine operators (bearing in mind the position and
orientation of the gearbox). Refer to chapter "ALLOWED TEMPERATURE LIMITS" for further details.
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