Installation, use and service manual
Contents
1. Braking torque daNm 5 10 16 26 33 40 44 40 50 63 80 100 85 110 150 210 260 320 Minimum release bar 10 20 30 20 25 30 20 27 20 25 32 14 19 25 19 24 28 pressure Max pressure bar 320 Weight kg 10 18 35 NOTE The static torque is the maximum torque the brake can exert Under dynamic loads the braking torque is reduced The actual Mss values can vary from 5 to 15 of the rating given in the chart BONFIGLIOLI RIDUTTORI 23 2 a Z XN 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 Drive with electric motor U1 V1 W1 U1 V1 W1 BONFIGLIOLI 24 RIDUTTORI L Drive with TRASMITAL MG orbital hydraulic motor In a2. 23 5 5 LUBRICATION E 29 6 0 TESTING THE GEAR UNIT 30 7 0 USING THE EQUIPMENT 30 8 0 MAINTENANCE 31 8 1 ROUTINE MAINTENANGE 225 b oe eee ahaa oe ee ee ea 32 9 2 OIE CHANGES eit e NR Rx a eee LLL 33 8 3 CHECKING OPERATIONAL EFFICIENCY 1 800 33 dcc dlc 33 9 0 REPLACING PARTS 34 9 1 REMOVING THE MOTOR teer te stet pest dan beet ese basin dee aime 34 9 2 DECOMMISSIONING THE GEAR UNIT III III e el ee ne hls 2 00 00022222220 34 10 0 TROUBLESHOOTING 35 ANNEX 1 CHECKING THE OIL LEVEL ON ATEX SPECIFIED GEAR UNITS 36 ANNEX 2 LUBRICANT CHARGE QUANTITY 37 Revisions The catalogue revision list is given on page 42 The most recent versions of the catalogue are available at www bonfiglioli com D BONFIGLIOLI x TRASMITAL 2 a V X SN 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
3. A EC Cert No EX9 040753387 00 5 Gearbox compliant with O ATEX Directive 94 9 EC GROUP II 2G CATEGORY T4 Temperature 2D CATEGORY 135 C Temperature Readability of the nameplate The nameplate and the information on it must be readable and consequently must be cleaned from time to time Quote the nameplate data in all communications with the manufacturer for example when reque sting spare parts information and assistance D BONFIGLIOLI x TRASMITAL 2 em 1 3 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 Reactive maintenance The set of operations required to preserve the functionality and efficiency of the gear unit These operations are not scheduled by the Manufacturer and must be carried out by an expert maintenance technician Expert maintenance technician An authorised technician with the qualifications skills and mechanical and electrical training required to do repairs and non routine maintenance work on the gear unit Overhaul An overhaul consists in the replacement of bearings and other mechanical components which
4. Control valve closed center type Motor execution P010 Motor P010 execution a Liga II A Jh LIE d Hydraulic oil Use hydraulic mineral oil with viscosity ISO VG 46 46 Cst at t 40 C It is recommended the oil temperature should be between 30 C and 70 C filtering For reliable motor operation and long life it is important that the hydraulic circuit has a filter for a proper fil tering according to the following degree degree 9 NAS 1638 degree 6 SAE degree 18 15 SO DIS 4406 BONFIGLIOLI s RIDUTTORI 27 2 em 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 A B Supply lines T Drainage BONFIGLIOLI 28 RIDUTTORI
5. MOBILE EQUIPMENT B N LI AND WiND ENERGY SOLUTIONS INDUSTRY PROCESS AND AUTOMATION SOLUTIONS use and service manual Tas 7 ATE gs a A I ERIT k HI N G BONFIGLIOLI 1 0 GENERAL INFORMATION 2 1 1 PURPOSE OF THE MANUAL tas deese e re ote OSEE e ees e Ro deber 2 1 2 PRODUCT IDENTIFICATION eta Eo Neb NR FRE 3 1 3 GLOSSARY AND TERMINOLOGY teer eR C pe Ed no pad 4 1 4 REQUESTING TECHNICAL 56 2 0 202 et ee ete 00002220 4 1 5 MANUFACTURER S 2 2 2 5 25 3 3 3 22222222222 22 02 0 000 es n i enis 4 1 6 CONSIGNMENT CONDITIONS pet tied irt e esee tpe gent ele 4 2 0 TECHNICAL INFORMATION 5 2 1 DESCRIPTION OF THE GEAR UNIT 2 2 2 590 222222222222 00000 0 2 2222 20 5 2 2 ferte inate epson deer tete me tai wa te Paga eed Attias en rete onion ident te Du 5 2 3 OPERATING LIMITS AND 8 2 2 2 2022222020000 000022202202 5 3 0 SAFETY
6. 10 9 10 9 10 9 12 12 30 30 30 58 58 250 250 250 250 490 490 490 490 490 490 840 BONFIGLIOLI ae 18 RIDUTTORI Lan IN Q 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 Tighten down the mounting bolts and check that the service plugs are screwed down to the torques given in the chart AN 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 Instead proceed as illustrated in the diagram below Bolt 1 and spacer 2 are not included in the consignment To minimise the loads on the shaft bearings when mounting transmission mechanisms with asymmetrical hubs use the configuration shown in diagram A below Mounting pulleys Clean all parts before installing them When installing belt drive pulleys the shafts must be parallel with their pulleys aligned Do not over tension the drive belt
7. 3 1 SAFETY STANDARDS e 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 the area as well as being equipped with the appropria te tools and individual safety equipment as per Legislative Decree 626 94 Failure to meet these require ments constitutes a risk to personal health and safety The gear unit must only be used for the applications permitted by the Manufacturer Improper use can re sult in risks to personal health and safety and economic damages The applications permitted by the Manufacturer are the industrial applications for which the gear units have been designed gt Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good mainte nance ensures the unit s maximum performance extended service life and continued compliance with sa fety regulations When working on the unit in areas which are difficult to access or hazardous ensure that adequate safety precautions have been taken for the operator and others in compliance with established legislation on he alth and safety at work All maintenance inspection and repairs must only be carried out by an expert maintenance technician fully familiar with the attendant hazards
8. 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 whl b Version with gasket already mounted to the coupling In this case no special intervention is required to ensure an oil tight seal since this is already provided by the motor coupling Merely smear the motor shaft with grease In both cases clean the spigot and the coupling where the motor is to be fitted fit the motor and tighten down the flange mounting bolts Always use bolts rated to at least class 8 8 BONFIGLIOLI 22 RIDUTTORI 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 Brake 4 5 6 Characteristics
9. 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 lubricant replace the closed shipping plug with the A vent plug included in the shipment before installing it A1 Plug thread Pitch Tightening torque Plug thread Pitch Tightening torque Nm Nm M14 1 5 15 20 1 8 28 10 15 M16 1 5 15 20 1 4 19 10 15 18 1 5 15 20 20 1 5 20 30 3 8 19 15 20 M22 1 5 20 30 1 2 14 20 30 Mad 20 30 3 4 14 20 30 M30 2 30 40 M42 3 40 50 1 11 30 40 2 INDUSTRIAL PLANTS MOBILE MACHINES ISO standard EP grade SAE standard API GL5 grade T 10 C 30 C 10 C 45 C 20 C 60 C 20 C 30 C 10 45 C ISO VG 150 ISO VG 220 ISO VG 150 220 SAE 80W 90 SAE 85W 140 AGIP BLASIA150 BLASIA 220 BLASIA SX 220 ROTRA MP ROTRA MP ARAL DEGOL BG 150 DEGOL BG 220 DEGOL PAS 150 220 GETRIEBEOL HYP GETRIEBEOL HYP BP ENERGOL GR XP 150 ENERGOL GR XP 220 EVERSYN EXP 150 220 HYPOGEAR EP HYPOGEAR EP CASTROL ALPHA SP 150 ALPHA SP 220 ALPHASYN EP 150 220 HYPOY HYPOY CEPSA ENGRANAJES HP 150 ENGRANAJES HP 220 agis TRANSMISIO
10. 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 Mount the shrink disk to the gear unit s shaft after lightly lubricating its entire outer surface Snug down a first set of 3 bolts located at the corners of an equilateral triangle for example bolts in pos 1 5 9 of the dia gram below Fit the gear unit to the driven shaft Tighten down the bolts following the triangular pattern in a circular direction repeating the operation seve ral times until all bolts are tightened to the torque specified in chart 2 in accordance with the type of disk gear unit N B Do not tighten down diametrically opposed bolts in sequence 300 321 Fa an 4 Rt 16 um ig 1 Do not use molybdenum bisulphide or any other grease which could reduce the friction of the mating surfaces and affect the performance of the shrink disk 300 321 Shrink disk mounting bolts 300 301 303 304 305 306 307 309 310 311 313 314 315 316 317 318 319 321 Bolt M6 M6 M8 M8 M10 M10 M16 M16 M16 M16 M20 M20 M20 M20 M20 M20 M24 Quantity 10 12 12 12 9 12 10 10 42 12 15 18 21 24 21 Class 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9 10 9
11. Casing coupling seals inadequate Contact authorised workshop Gaskets worn Contact authorised workshop Gear unit does not run or runs with difficulty Oil viscosity too high Replace oil see recommended lubricant chart Oil level too high Check oil level Excessive load applied Redesign drive for actual load required Output shaft does not turn with motor running Gears damaged Contact authorised workshop D BONFIGLIOLI x TRASMITAL 35 2 A V X SN ANNEX 1 CHECKING THE OIL LEVEL ON ATEX SPECIFIED GEAR UNITS gt 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 Vertical position Use a rod to check that the oil level is between the MIN and MAX marks then screw the plug back in If the level is more than 3 mm below the spill level top up and check the reason for the drop in oil level 3mm N B MAKE SURE THE ROD IS POSITIONED FLAT AGAINST THE EDGE OF THE THREADED HOLE MIN Gear units conforming to Directive 94 9 EC and designed for a vertical mounting position are normally equipped with an oil expansion chamber fitted with service plugs for filling checking the oil level and venting internal overpressure 36 D BONFIGLIO
12. as this can damage the bearings BONFIGLIOLI RIDUTTORI 19 SS Shaft end threads 316 DIN 332 180 p I pa HC PC 340 1 d 150 250 BR 5 12xM20 2200 280 h6 I 309 310 315 316 MC M12 M12 M20 M20 M20 M20 M20 HC M16 M16 M20 M20 M20 M20 M20 M24 M24 M24 M24 M24 M24 M12 M16 M20 M20 M20 M20 M20 M24 M24 M24 M24 M24 M24 M20 M20 M20 M24 M24 M24 M24 M24 M30 M30 M30 E BONFIGLIOLI 20 RIDUTTORI L 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 2 2 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 Do not force the coupling and do
13. clamp use with harness Snap hook use with rope Eyebolt already fitted 8 on gear units 317 321 Maximum permissible tilt during handling 15 D BONFIGLIOLI W TRASMITAL 300R 316 R gt 5 Pub use with harness 6 Snap hook use with rope Eyebolt already fitted B on gear units 317 321 MAX 15 15 i 2 Rope and hooks Ring harness Screw clamp Maximum permissible tilt during handling 15 BONFIGLIOLI D TRASMITAL 11 Open harness with eyelets Ring harness 2 Rope and hooks 8 Open harness with eyelets Screw clamp Maximum permissible tilt during use with harness handling 15 Snap hook use with rope Eyebolt already fitted on gear units 317 321 9 BONFIGLIOLI TRASMITAL Ring harness Screw clamp Maximum permissible tilt during use with harness handling 15 2 Rope and hooks 6 Snap hook use with rope 8 Open harness Eyebolt already fitted with eyelets on gear units 317 321 D BONFIG
14. have worn to such an extent as to compromise the operation of the gear unit An overhaul also includes verification of the condition of all gear unit components keys seals gaskets vents etc If any such components are dama ged they must be replaced and the reason for the damage identified 1 4 REQUESTING TECHNICAL ASSISTANCE For any technical service needs contact the Manufacturer s sales network quoting the information indicated 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 in the event of use of the gear unit in contravention of local safety at work legislation incorrect installation disregard or incorrect application of the instructions provided in this manual incorrect or defective electrical hydraulic power supply gearmotors modifications or tampering work done on the unit by unqualified or unsuitable persons The safety of the gear unit also depends on scrupulous observance of the instructions given in this manual and in particular always operate the unit within its operating limits diligently observe the routine maintenance schedule only allow trained operators to inspect and service the unit only use original spare parts the configurations given in the gear unit catalogue are the only ones permitted do not attempt to use the unit in any other way the instructions given in this manual do not
15. may be unstable The load may sway or oscillate Slide the lifting ring to align it with the load s centre of gra vity as shown in the diagrams below Stabilise the moving load by i hand Solution u Lock the ropes below the ring with cable clamp or similar Observe all precautions regar device so as to prevent them ding the handling of loads sliding and lift the load Observe all precautions regar ding the handling of loads The load must be allowed to sway by more than 15 in any direction when being lifted If swaying exceeds this amount stop and repeat the lifting operation as instructed D BONFIGLIOLI x TRASMITAL T 5 Ring harness Screw clamp use with harness 2 Rope and hooks 6 Snap hook use with rope 8 Open harness Eyebolt already fitted with eyelets on gear units 317 321 Maximum permissible tilt during handling 15 D BONFIGLIOLI W TRASMITAL 300 316 Ring harness 2 Rope and hooks 8 Open harness with eyelets Screw
16. not use inappropriate tools during assembly Take care not to damage the flat cylindrical coupling surfaces Do not force the rotary coupling mechanisms with heavy overhung or thrust loads To facilitate assembly use a lubricating synthetic oil paste such as Kl berpaste 46 MR 401 or another pro duct with similar properties and application range Provided all the above checks have been performed and passed and all other instruc tions in this manual have been strictly observed an electric motor with ATEX rating equal to or greater than that of the gear unit may be installed thus forming a gearmotor which itself complies with the provisions of Directive 94 9 EC If instead the assembly of the motor to the gear unit requires actions other than those prescribed in this Manual or one or more of the manual s prescriptions have not been satisfied the User shall be responsible for analysing the risks attendant on this particu lar motor gear unit combination The risk analysis is in any case obligatory if the motor is powered by an inverter Only in this way and subject to self certification by the assembler shall the assembly including the gear unit itself be compliant with the requirements of Directive 94 9 EC BONFIGLIOLI RIDUTTORI 21 2 a Z XN
17. substitute but rather supplement the provisions of esta blished safety legislation 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 Not charged with lubricant and with internal components protected by a film of oil compatible with the recommended lubricant e All surfaces and mating parts are treated with rustproofing products Mating surfaces are not painted while the unit s exterior is treated with a coat of grey water based rustproofing primer RAL 7042 C441 Application of a top coat is the responsibility of the Client Tested to factory standards Packaged suitably for the final destination e BONFIGLIOLI x TRASMITAL L 2 0 TECHNICAL INFORMATION 2 1 DESCRIPTION OF THE GEAR UNIT The gear unit driven by an electric or hydraulic motor has been designed and constructed for integration into an assembly of interlocking parts or mechanisms as part of a specific application Depending on the requirements of the application the gear unit can be supplied in a variety of motor execu tions and configurations 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 fur
18. the motor s cooling fan The maximum temperature must not be more than 75 80 C nor may this value be exceeded during operation 32 D BONFIGLIOLI x TRASMITAL L 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 N 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 4 Fill with new oil until it reaches the level mark Do not mix oils of different makes or specifications and check that the oil is highly resistant to foaming and is EP rated 5 Tighten down the filler plug after changing its seal The gear unit may be supplied with or without lubricant as requested by the User The quan tity of charge oil required is specified in the Sales Catalogue This specification is however approximate and reference must always be made to the mark on the level plug the placement of which depends on the mounting position specified in the purchase order Life lubricated gear units which are not subject to external contamination do not normally require pe riodic lubricant changes If the same type of oil as that already in use is not available drain the gear unit casing completely and wash its interior thoroughly with a light solvent before refilling with the new lubricant If a leak is found identify the cause of th
19. through the appropriate plug BONFIGLIOLI TRASMITAL 37 3 R Series Mounting position Mounting position U_ P_ 4 P R2 1 2 1 7 1 5 R2 6 5 8 5 5 300 R3 1 5 2 0 1 8 309 R3 7 5 9 5 8 5 R4 1 8 2 3 2 1 R4 8 0 10 9 0 R2 1 6 2 1 1 9 R2 13 15 14 301 R3 1 9 24 2 2 310 R3 11 13 12 R4 2 2 2 7 2 5 R4 12 14 13 R2 2 2 2 8 2 6 R2 14 19 17 303 R3 2 5 3 1 2 9 311 R3 16 21 19 R4 2 8 3 4 3 2 R4 17 22 20 R2 2 3 2 9 2 7 R2 16 21 19 304 R3 2 8 3 4 3 2 313 R3 19 24 22 R4 3 1 3 7 3 5 R4 20 25 23 R2 2 5 3 1 2 9 R3 25 33 29 314 305 R3 3 0 3 6 3 4 R4 28 36 32 R4 2 9 3 9 3 7 R3 27 35 31 315 R2 4 0 5 0 4 8 R4 30 38 34 306 R3 4 8 5 8 5 6 R3 30 38 34 316 R4 5 1 6 1 5 9 R4 33 41 37 R2 6 0 8 0 7 0 R3 38 52 48 317 307 R3 7 0 9 0 8 0 R4 42 56 52 R4 7 5 9 5 8 5 318 R4 48 63 58 Oil quantities are indicative Check actual level after filling through the appropriate plug D AEH Series 0 AA 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 input input input input i
20. to heavy shock loads and inversions in the direction of rotation the counterflange must be drilled to accept the spigots At the time of installation move the spigots mounted on the gear unit forward into the counterflange by an amount equal to their diameter See diagram below 1 F3 309 321 2 101 100 R Y N 007 B B Y S 5 Z B o 15 2 VW E Ed N E N NN gt 309 310 315 Ss 0 20 317 319 9 SG 005 m 101 100 R 0 g R gt 60 Rn BONFIGLIOLI 16 RIDUTTORI 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 17100 E S T 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 Quantity 8 8 10 10 10 12 10 1
21. 2 15 24 20 20 30 24 32 30 36 Class 88 8 8 8 8 88 88 88 88 8 8 8 8 8 8 8 8 8 8 88 88 8 8 8 8 88 torque Ne 50 50 85 85 85 135 200 200 200 200 400 400 400 400 1400 700 1400 1400 For maximum transmitted torques greater than or equal to 70 of the torque indicated as Mamax and with fre quent inversions of the direction of rotation use at least class 10 9 bolts 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 Foot mounted gear unit mounting bolts 300 301 303 304 305 306 307 309 310 311 313 314 315 316 317 318 319 321 Bolt M16 M16 M16 M16 M16 M20 M24 M24 M24 M30 M30 M30 M30 M36 M30 M36 M48 M48 Quantity 41 414 4 8 Class 88 88 88 88 88 88 88 88 88 88 88 88 88 88 88 88 88 88 1 200 200 200 200 200 400 700 700 700 1400 1400 1400 1400 2500 1400 2500 6000 6000 BONFIGLIOLI RIDUTTORI 17 DS ea oS Ce 5 1 3 Shaft mounting Mount the torque arm with bolts of at least class 8 8 tightened to a torque of 70
22. A OE OF AD ED FA AF EF FE AE EE FF TD VA VE OD QA QE VF VD QF QD JJ 1 B B 3 A 00 L2 0 60 1 4 1 0 1 4 0 9 1 4 0 6 1 4 0 6 1 4 0 6 1 4 3 A 01 L2 0 80 2 3 1 2 2 3 1 1 2 3 0 8 2 3 0 8 2 3 0 8 2 3 03 L2 1 3 3 2 2 3 3 2 2 0 3 2 1 3 3 2 1 3 3 2 1 3 3 2 04 L2 1 4 3 8 2 4 3 9 22 3 9 1 4 4 5 1 4 5 0 1 4 42 05 12 1 6 4 0 2 6 4 1 2 4 4 1 1 6 4 7 1 6 5 2 1 6 4 4 3 A 06 L2 2 5 4 9 3 5 8 1 3 2 4 7 2 5 8 4 2 5 11 2 5 9 2 3 A 07 L2 3 5 6 8 5 0 8 1 4 5 12 3 5 15 3 5 18 3 5 15 Life lubrication NOTE In combined gear units lubrication of the planetary stage is separate from that of the worm 3 V or helical bevel 3 A stages BONFIGLIOLI 40 D TRASMITAL D BONFIGLIOLI x TRASMITAL 41 INDEX OF REVISIONS R R2 090320 We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent 42 COD 7 998 3 3 01 7 R2 e PLI MOBILE EQUIPMENT AND WIND ENERGY SOLUTIONS INDUSTRY PROCESS AND AUTOMATION SOLUTIONS ea Ly E mm 2 www bonfiglio
23. Do not re use parts or components which appear to be in good condition after they have been chec ked or replaced by qualified personnel and declared unsuitable for use D BONFIGLIOLI 34 x TRASMITAL Lan IN Q 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 FAULT CAUSE REMEDY Bearing temperature too high Oil level too low Top up oil level Oil spent Replace oil Defective bearings Contact authorised workshop Operating temperature too high Oil level too high Check oil level Oil spent Replace oil Contaminant in oil Replace oil Abnormal running noise Gears damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Excessive load applied Correct load to rated values given in Sales Catalogue Contaminant in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten bolts to specified torque Mounting bolts worn Replace bolts Oil leaks Oil level too high Check oil level
24. INFORMATION 6 SAFETY STANDARDS V eie ue eter t e eg et ee edu Etpe etie apr 6 4 0 HANDLING AND TRANSPORT 7 A TS PACKAGING a tee ET 7 4 2 ANDLING ARRS 7 4 2 I Movirig the PaCkageS eret mee fr pedet duties e ed nire neri 8 42 2 Moving the SQUIPMEME te dee eta cede n oad ona 8 A 3 STORAGE NM M 14 5 0 INSTALLATION 15 5 1 INSTALLING THE GEAR UNIT o etie saute autetn operit une ete e Per ag ERU 15 5 1 1 Flanged execution eot et E e best etm tee dt tase 15 ofi FOOL 10 0 1 c O MMmt 17 Shaftmoulitihg e Uu Dum e pL 18 5 1 4 Installing accessories on solid input and output 2 2 2 4 409 19 5 2 lt INSTALLING THE ELECTRIC MOTOR 2 PR E DRE tees 21 5 3 INSTALLING THE HYDRAUEIG MOTOR ete tne potest sate ep Pee 22 5 4 CONNECTING THE HYDRAULIC
25. It is therefore essential to implement operating procedures that ad dress potential hazards and their prevention for the entire machine The expert maintenance technician must always work with caution in observance of applicable safety standards During operation wear only the apparel and safety equipment indicated in the User Instructions provided by the Manufacturer or stipulated by legislation on safety at work Replace worn components with original spare parts Use the lubricants oil and grease recommended by the Manufacturer Do not dump polluting materials into the environment Dispose of all such materials as stipulated by appli cable legislation After replacing lubricants clean the gear unit s surfaces and the walk on surfaces around the work area D BONFIGLIOLI x TRASMITAL 1 If the gear unit is to be serviced in a potentially explosive atmosphere the operator must first switch off power to the gear unit and ensure that it is out of service as well as taking all neces sary precautions against it being accidentally switched on again or its parts moving without warning Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc 4 0 HANDLING AND TRANSPORT 4 1 PACKAGING The standard packaging if supplied and unless otherwise agreed is not proofed against rainfall and is inten ded for shipping by ground and not sea and for storage i
26. LI x TRASMITAL ANNEX 2 LUBRICANT CHARGE QUANTITY 3 L Series Mounting position Mounting position A T T L1 06 1 0 0 9 L1 50 6 5 6 0 L2 09 1 3 1 2 12 63 7 8 7 3 300 L3 12 1 6 1 5 x L3 74 8 6 8 1 LA 15 1 9 1 8 L4 74 8 9 8 4 L1 08 12 1 1 L1 70 12 10 L2 44 1 5 14 L2 90 14 12 301 L3 14 1 8 1 7 at L3 10 15 13 14 17 2 1 2 0 La 11 16 14 L1 13 23 2 0 L1 9 0 14 12 L2 16 2 6 2 3 L2 12 17 15 us 137 19 2 9 2 6 313 L3 13 18 16 L4 22 32 2 9 14 13 18 16 11714 2 4 22 L2 17 25 21 L2 1 9 2 9 27 314 L3 19 27 23 304 3 2 2 3 2 3 0 14 20 28 24 14 25 3 5 3 3 L2 19 27 23 L1 16 2 6 24 315 L3 21 29 25 EX 241 3 1 2 9 L4 22 30 26 3 L3 24 3 4 32 L2 22 30 26 L4 27 3 7 3 5 316 L3 24 32 28 11 25 3 5 3 2 14 25 33 29 12 33 4 3 4 0 L2 26 41 36 306 L3 3 6 4 6 4 3 317 L3 29 44 39 14 39 4 9 4 6 14 30 45 40 11 35 5 0 4 5 137 40 55 50 12 45 6 0 5 5 14 43 58 53 S L3 50 6 5 6 0 L3 50 70 60 L4 53 6 8 6 3 LA 53 73 63 L1 40 5 5 5 0 L3 56 76 66 L2 50 6 5 6 0 4 60 80 70 309 137 55 7 0 6 5 4 58 7 3 6 8 N B Oil quantities are indicative Check actual level after filling
27. LIOLI x TRASMITAL 13 2 a V X SN e 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 If using a lift truck or pallet truck remove the packaging and insert the truck s forks at the indicated posi tions First lift the load very slowly to check that it is stable Move the gear unit to the unloading area and lower it gently into position taking care not to tip it suddenly in transit If the gear unit is already equipped with an electric motor do not use the eyebolts on the mo tor casing for lifting unless expressly specified 4 3 STORAGE The following recommendations should be followed when storing the gear unit 1 e Do not store the unit in excessively humid conditions or where it is exposed to the weather do not store outdoors Do not place the gear unit directly on the ground Place the gear unit on a stable base and make sure that it is not subject to accidental displacement Store the packaged gear unit if allowed in accordance with the instructions on the packaging itself If the gear unit is to be stored for more than 6 months the following additional precautions must be taken 5 Cover all machined external surfaces with a rustproofing product such as Shell Ensis or other product with similar proper
28. NES EP TRANSMISIONES EP CHEVRON N L GEAR COMPOUNDS N L GEAR COMPOUNDS TEGRA SYNTHETIC RPM UNIVERSAL GEAR RPM UNIVERSAL GEAR EP 150 EP 220 GEAR EP 150 220 LUBRICANTS LUBRICANTS GEAR OIL GX GEAR OIL GX ESSO SPARTAN EP 150 SPARTAN EP 220 SPARTAN S EP 150 220 PONTONIC MP PONTONIC MP FUCHS RENOLIN CKC 150 RENOLIN CKC 220 jp porn TITAN SUPER GEAR TITAN SUPER GEAR KLUBERSYNT KLUBER KLUBEROIL GEM1 150 KLUBEROIL GEM1 220 EG 4 150 4 220 Q8 GOYA 150 GOYA 220 EL GRECO 220 MOBILGEAR MOBIL MOBILGEAR 600 XP 150 MOBILGEAR 600 XP 220 SHC XMP 150 220 MOBILUBE HD MOBILUBE HD MOLYCOTE L 0115 L 0122 L 2115 L 2122 SUPER TAURO REPSOL SUPER TAURO 150 SUPER TAURO 220 SINTETICO 150 220 SHELL OMALA EP150 OMALA EP220 TIVELA OIL S SPIRAXHD SPIRAX HD TOTAL CARTER EP 1500 CARTER EP 2200 CARTER SH 150 220 TRANSMISSION TM TRANSMISSION RS Polyalphaolefin synthetic oils PAO Brake lubrication The hydraulic multi disk brakes are lubricated with the same oil as the gear unit AN Only synthetic lubricants may be used on gear units conforming to European Directive 94 9 EC Refer to the above chart for the brand and type D BONFIGLIOLI x TRASMITAL 29 2 a yZ XN 6 0 TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer Before start up make sure that T the machine incorporating the gear unit complies with the provisions of the Machin
29. aintain internal pressure at the same level as the low pressure line A or B if the drain port is not connected to the tank Incorporated non return valves 1 If the drain port is connected up pressure at the shaft seal is always equal to the pressure in the drain line 2 If the drain port is closed off pressure at the shaft seal never exceeds pressure in the return line The maximum values for pressure in the drain line case 1 or return line case 2 are given in the following figure for continuous and intermittent operating conditions bar 250 225 200 175 150 125 int operation 100 75 50 25 max 0 Aj gt 0 100 200 300 400 500 600 700 800 min The drain port must always connected up when more motors operated in series BONFIGLIOLI 26 RIDUTTORI Lan IN Q c Brake control For gearmotors equipped with brakes there are two motor versions available i e the 2 or P010 execu tions In the BO2P 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 Open loop circuit Closed loop circuit Control valve open center type Motor B02P execution
30. carefully and rigo rously applied Failure to observe the information provided herein may result in risks to personal health and safety as well as economic damages This information provided in the Manufacturer s original language Italian is also available in other langua ges to meet legal and commercial requirements The documentation must be stored by a person charged to do so in a suitable location so as to be always available in good condition for consultation In case of loss or damage replacement documentation must be requested directly from the Manufacturer quoting the code of this manual This manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifications are highlighted by symbols whose meanings are explained below SYMBOLS DANGER WARNING Zi This symbol indicates situations of danger which if ignored may result in serious injury to the operator CAUTION ATTENTION This symbol indicates the need to adopt specific precautions to avoid personal injury and da mage as well as economic damages IMPORTANT This symbol indicates important technical information complying with ATEX Directive 94 9 The operations identified by these sy
31. ddition 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 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 Refer to the hydraulic circuit diagrams below Closed loop circuit Open loop circuit RV Closed centre control valve Open centre control valve RV pressure relief valves calibrated to pRV pmax If this is not possible because the circuit must also actuate other equipment at a higher pressure or the con trol valve is of the closed centre type and the motor drives components with high inertia auxiliary pressure relief valves must be installed as close as possible to the motor RV RV pressure relief valves calibrated to pRV lt pmax BONFIGLIOLI RIDUTTORI 25 2 a yZ XN 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 m
32. e fault and repair it before topping up the lubricant and operating the unit Lubricants solvents and detergents are toxic harmful to health they may cause irritation in direct contact with the skin N they may cause intoxication if inhaled they may be fatal if swallowed 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 Check the power absorption and voltage against the rated values given on the motor s nameplate Check the wear of the friction surfaces and braking gasket on the brake motors if fitted and if necessary adjust the gap Check for lubricant leaks from the gaskets seals plugs and casings Check all bolted couplings for wear deformation and corrosion and tighten them down fully but without over tightening 8 4 CLEANING Remove all dust and process waste from the gear unit Do not use solvents or other products that are incom patible with the unit s construction material and do not direct high pressure jets of water at the gear unit BONFIGLIOLI x TRASMITAL 33 2 a V X SN 9 0 REPLACING PARTS Immediatel
33. ed and constructed to conform with the Essential Health and Safety Requirements EHSR of Annex II of the ATEX Directive 94 9 EC and conform to the following classification e Equipment group Il Category Gas 2G Dust 2D Zone Gas 1 Dust 21 Maximum surface temperature temperature class T4 for 2G and 130 C for 2D 2 3 OPERATING LIMITS AND CONDITIONS N Modification of the motor execution or mounting position is only permitted if previously authorised by BONFIGLIOLI TRASMITAL s Technical Service Failure to obtain said authorisation renders the ATEX certification null and void BONFIGLIOLI x TRASMITAL 2 a a XN Ambient conditions e 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 Even minimal variations to said conditions e g smaller mounting cabinet may have a significant x effect on the unit s heat output Lighting If the unit is to be serviced in a poorly lit area use additional lamps and ensure that the work is done in compliance with the safety requirements of established legislation 3 0 SAFETY INFORMATION
34. ery Directive 98 37 EC and any other applicable safety legislation the gear unit s mounting position in the installation corresponds to that prescribed and indicated on the na meplate the electrical power supply is suitable and operational as prescribed in EN 60204 1 and is grounded as per EN 50014 the motor s electric power supply corresponds to that prescribed and is within 5 of the rated value the hydraulic system is suitable and operational and the oil in the hydraulic motor s lubrication circuit con forms to ISO VG 46 It must be filtered with a maximum grade of 10 um and contamination level less than or equal to class 9 as per NAS 1638 or 18 15 as per ISO DIS 4406 there are no signs of lubricant leaks from the plugs or gaskets the vent plug is not obstructed by dirt or paint the unit does not run noisily or with excessive vibration Before starting up the unit check and make sure that the unit is not assembled in a potentially explosive atmosphere oil acid gas vapour radia tion and is free of dust build ups greater than 5 mm in depth during operation the gear unit is sufficiently ventilated and is not subject to radiation from exter nal heat sources during operation the cooling air does not exceed 40 C the oil level check and filler plugs and the vent plugs are all easily accessible all accessories mounted to the gear unit are ATEX certified gear units with hollow shafts with or without shrink disk ha
35. li com BONFIGLIOLI
36. mbols must be executed by professionally qualified opera tors specially trained in the safety precautions required for working in potentially explosive atmo spheres Instructions marked by these symbols and highlighted in yellow apply exclusively to equipment 59 Failure to observe these instructions may result in serious safety and environmental risks D BONFIGLIOLI x TRASMITAL Lan IN Q 1 2 PRODUCT IDENTIFICATION The information identifying the product is shown on its nameplate Gearmotors are equipped with two name plates one on the gear unit which bears the gear unit data and one on the motor electric or hydraulic bea ring the motor data The drawing below illustrates the layout of the data The gear unit s identifying code is explained in the Sales Catalogue If the gear unit is supplied fitted with an electric motor gearmotor all information regarding the motor is supplied in the motor manual Nameplate data A BONFIGLIOL Gi BONFIGLIOLI Qe O RATIO 1 SERIAL N DRWG N COD N MADE ITALY Manufacturer Product identification Bonfiglioli Trasmital product code Reduction ratio Serial number Installation drawing code Date of manufacture 0 Client product code Supplementary nameplate on ATEX specified gear units
37. n areas which are under cover and not humid The material can be stored in suitable conditions for a period of two years under cover at a temperature between 15 and 50 C at a relative humidity not in excess of 80 Storage in all other conditions requires speci fic packaging The most frequent types of packaging are shown in the figures below Packaging on pallet with heat shrink film for ground shipping Packaging in wooden crate for shipping by sea or air 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 4 2 HANDLING INSTRUCTIONS Handle packages as per the Manufacturer s instructions and those marked on the packages themselves Since the weight and shape of the 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 avoid risks to themselves and others The person authorised to handle the product must take all necessary precautions to safe guard his safety and that of all other persons involved D BONFIGLIOLI x TRASMITAL 2 V X SN 4 2 1 Moving the packages Prepare a suitable delimited area with a level floor or
38. nd protective product residue from the gear unit Pay particular attention to the mating surfaces Check that the data on the nameplate correspond to those specified in the purchase order Ensure that the structure to which the gear unit is to be mounted is sufficiently robust and rigid to support its weight and operating stresses Check that the machine to which the gear unit is to be installed is switched off and cannot be accidentally switched on again Make sure all mating surfaces are flat Make sure the shaft shaft or shaft bore are perfectly aligned for coupling Fit suitable guards to protect against the gear unit s external moving parts 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 We recommend applying a protective paste to all gear unit motor mating surfaces and other parts Kl berpaste 46 MR 401 or other product with similar properties and application range to ensure optimal coupling and protection against fretting corrosion In the case of outdoor installations 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 5 1 1 Flanged execution Machine the coupling counterflange on the machine to which the gear unit is to be installed The flange
39. nput RQ S Q b S SN a i 5 J P IEC HS P IEC P IEC P IEC P IEC P IEC HS HS HS HS HS 3 V 00 L3 0 9 0 9 0 9 0 9 1 3 1 2 0 12 0 12 0 12 0 12 0 12 0 12 0 12 01 L3 1 1 1 1 1 1 1 1 1 5 1 4 03 L3 1 6 0 25 0 25 1 6 0 31 1 6 0 31 1 6 0 38 2 6 0 31 2 3 0 25 04 L3 1 9 1 9 1 9 1 9 2 9 2 7 0 38 0 38 0 43 0 43 0 52 0 52 0 38 05 2 1 2 1 2 1 2 1 3 1 2 9 06 L3 3 3 3 3 3 3 3 3 4 3 4 0 64 0 64 0 76 0 76 0 85 0 76 0 76 3 V 10 L4 7 1 7 1 7 1 7 1 8 6 8 1 07 L3 4 5 4 5 4 5 4 5 6 5 5 1114 10 2 4 2 8 10 2 6 10 2 6 10 1 7 15 1 9 13 1 9 1314 13 13 13 13 18 16 3 V 09 L3 5 5 5 0 5 6 5 6 3 V 10 L3 6 3 6 3 6 3 6 3 7 8 7 9 1414 19 4 3 4 5 19 3 9 19 3 9 19 3 0 27 3 5 23 3 5 15 L4 21 21 21 21 29 25 16 L4 24 24 24 24 32 28 11 L3 9 9 9 9 14 12 13 12 12 12 12 17 15 7 8 9 6 6 7 6 7 5 0 5 5 5 5 14 L3 17 17 17 17 25 21 17 L4 29 29 29 29 44 39 15 19 19 19 19 27 23 18 L4 40 11 15 40 8 9 40 9 4 40 7 5 55 9 5 50 9 5 19 L4 50 50 50 50 70 60 16 L3 22 22 22 22 30 26 3 V 17 L3 26 23 28 26 16 8 26 17 5 26 10 7 41 17 36 17 2114 56 56 56 56 76 66 Life lubrication NOTE In combined gear units lubrication of the planetary stage is separate from that of the worm 3 V or helical bevel 3 A stages D BONFIGLIOLI TRASMITAL 39 3 A Series AA FD TA TE TF O
40. o the environment Dispose of all such materials as specified by applicable legislation AN Observe the routine inspection and maintenance schedule to ensure the unit s correct opera tion and the effectiveness of the explosion protection Always apply fresh Loctite 510 or other product with similar properties and application range to all disassembled threads Before servicing or repairing internal components allow the gear unit to cool down completely before opening the casing so as to avoid burns from parts which are still hot On completion of maintenance work make sure that all safety measures and equipment have been applied and reset Clean the gear unit thoroughly after maintenance and repair work On completion of maintenance tighten all vent filler and level plugs to their specified torques chart A1 On completion of any maintenance work all seals must be refitted and sealed as prescribed Regardless of the type of gear unit whenever a seal ring is replaced its lips should be smea red with a thin layer of grease Fluorocarbon gel 880 ITP or other product with similar proper ties and application range before assembly Use only original spare parts for repairs D BONFIG x TRASM LIOLI ITAL 31 2 a yZ XN 8 1 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good maintenance ensures the unit s ma
41. s must be plane and machined with machine tools Connect the output shaft to the driven compo nent as indicated in the drawings below DIN 5480 e8 DIN 5482 e9 DIN 5480 H9 DIN 5482 H10 DIN 5480 H9 DIN 5482 H10 DIN 5480 e8 DIN 5482 e9 Recommended tolerances Loose coupling Coupling with interference Solid shaft Hollow shaft Solid shaft Hollow shaft d h6 D G7 d h6 D P7 d k6 d k6 D M7 d m6 D F7 d m6 DK7 d r6 D Qdr6 DH7 BONFIGLIOLI RIDUTTORI 15 2 a yZ XN For machining the spigot on the driven machine refer to the diagrams below 300 307 gear units male output shaft motor execution 300 307 1 0 1 100 B B Bjo 15 gee Z Eo E Z B 0 15 3 2 309 321 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 For heavier loads the mounting must use both spigots on the gear unit If the gear unit is instead required to transmit high torque or is subject
42. 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 If required this information is indicated on the package itself Harness heavy packages with chains belts and steel ropes after checking that they are suitable for the weight of the load which is always indicated When handling the load keep it level to avoid tipping and instability 4 2 2 Moving the equipment All the following operations must be carried out with care and caution and without sudden movements hooks etc which are certified and adequate for the load in question When lifting use accessories such as eyebolts screw clamps snap hooks straps ropes and The weight of the product to be lifted is given in the Sales Catalogue The following pages illustrate in detail the different attachment methods for the various product series sizes and configurations described in this Manual The most suitable solution for lifting and handling the product in safety is indicated for each Symbols Type of lifting Manual With mechanical equipment Symbol M A B Approximate weight lt 15 Kg gt 15 Kg Recommended method for po Recommended method for Instruction sitioning handling and positioning Warning The load
43. ther technical information and descriptions refer to the corresponding Sales Catalo gue The User is responsible for using the products recommended for installation and maintenance of SAFETY SPECIFICATIONS OF GEAR UNITS COMPLYING WITH DIRECTIVE 94 9 EC unit selection must be made with a higher safety service factor use only synthetic lubricants oil and grease oil plugs with aluminium washer oil seals with dust trap no metal moving parts external to the gear unit no plastic parts capable of building up an electrostatic charge or if present duly shielded for installations in zones 21 and 22 the User must schedule and implement a regular cleaning programme for all surfaces and recesses to avoid dust build ups of more than 5 mm in depth e seal rings vent plugs with spring loaded anti intrusion valve 2 2 CONFORMITY All gear units or gearmotors when supplied with electric motor are designed in compliance with the provi sions of applicable Essential Health and Safety Requirements the Machinery Directive 98 37 EC and if re quested can be supplied with a Manufacturer s Declaration Annex IIB as provided by said Directive All BONFIGLIOLI gearmotor electric motors conform to the provisions of the Low Voltage Directive 73 23 and the Electromagnetic Compatibility Directive 89 336 EEC Furthermore if specified for use in potentially explosive atmospheres the gear units are desi gn
44. ties and application range Fill the unit with lubricating oil and make sure the vent plug is positioned uppermost Before putting the unit into service the oil used for storage must be drained and replaced with the correct quantity of re commended operating lubricant gt PRECAUTIONS to be taken when returning the gear unit to service after storage The output shafts and external surfaces must be thoroughly cleaned of all rustproofing product contaminants and other impurities use a standard commercial solvent Do this outside the explosion hazard area The solvent must not touch the seal rings as this may damage them causing them to leak If the oil or protective material used during storage is not compatible with the synthetic oil used during the machine s operation the interior of the unit must be thoroughly cleaned before filling with the operating oil The service life of the bearing grease is reduced if the unit is stored for more than 1 year The bearing grease must be synthetic 14 D BONFIGLIOLI x TRASMITAL L 5 0 INSTALLATION 5 1 INSTALLING THE GEAR UNIT The entire installation process must be planned as early as the general design phase of the ma 90 s Or o chine The person authorised to do the work must if necessary set out a safety plan to protect the health and safety of all persons directly involved and apply all applicable legislation Carefully remove all packaging a
45. tions against it being accidentally switched on again or its parts moving without warning due to suspended loads or similar external factors Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc Before doing any maintenance work activate all the safety devices provided and if necessary inform per sons working in the vicinity Cordon off the area around the unit and prevent access to any equipment which if activated might be the cause of unexpected health and safety hazard Replace worn components with original spare parts Use the lubricants oil and grease recommended by the Manufacturer When working on the gear unit always replace all gaskets and seals with original new ones f a bearing requires replacement it is good practice to also replace the other bearing supporting the same shaft We recommend replacing the lubricating oil after all maintenance work The above instructions are aimed at ensuring efficient and safe operation of the gear unit The Manufacturer declines all liability for injury to persons and damage to components due to the use of non original spare parts and non routine work that modifies the safety requirements without the Manufactu rer s express prior authorisation Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn parts and maintenance waste int
46. ve been correctly mounted as de scribed in this manual the gear unit has been thoroughly cleaned after installation all guards are installed to prevent accidental contact between operators and the unit s rotary moving parts and seals are oil tight 0 USING THE EQUIPMENT Before putting the gear unit into service the User must ensure that the plant in which it is installed complies with all applicable directives especially those regarding health and safety at work The gear unit may not be used in areas and environments with highly corrosive abrasive vapours smoke or dust in direct contact with loose food products Danger zones and exposed persons The danger zone of the gear unit is the protrusion of the shaft which constitutes a hazard for exposed persons in direct contact with it crushing shearing trapping In particular when the gear unit is operating in automatic mode in an accessible area the shaft must be protected by a guard D BONFIGLIOLI x TRASMITAL Lan IN Q 8 0 MAINTENANCE A AN 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 precau
47. ximum performance extended service life and conti nued compliance with safety regulations A3 Frequency 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 after 200 hrs Original consignment lubricant Replace Replace with new lubricant External fasteners Check locking torque Tighten down to specified torque External seals and Check oil level Service or replace components gaskets ing of external seals Too hrs gaskets Check for leaks by eye as required 2500 hrs Lubricant Replace Replace with new lubricant 5000 hrs Gear unit seals and Inspect carefully for wear age Replace if aged worn Every 5000 hrs of operation Change the synthetic oil and bearing grease if the gear unit is not life lubricated Replace all externally accessible seal rings unless this has already been done as a result of problems occurring before the scheduled maintenance deadline Every 1000 hrs of operation or after 6 months For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid dust build ups of more than 5 mm in depth Measure the surface temperature at the coupling between the gear unit and motor and at the points which are most shielded from
48. y replace parts and components if they are not able to guarantee safe and reliable ope ration X 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 9 1 REMOVING THE MOTOR If during operation the mobile coupling between the motor and gear unit has not rusted significantly it should be possible to remove the motor without applying excessive force If instead it proves difficult to remove the motor do not use screwdrivers or levers to apply force as this may damage the flanges and mating surfaces but proceed as illustrated below DRILL AND THREAD IMPACT EXTRACTOR Drill and thread the motor shaft fan side Screw an impact extractor tool into the bore Undo the bolts fixing the motor to the gear unit Detach the motor by means of the inertial force of the extractor PONS 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 he alth and safety at work Do not dump non biodegradable products lubricants and non ferrous materials rubber PVC resins etc into the environment Dispose of all such materials as stipulated by established environmental legislation
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