BONFIGLIOLI 300 Series User manual

300
ATEX
INCLUDED
MOBILE EQUIPMENT
AND WIND ENERGY SOLUTIONS
INDUSTRY PROCESS
AND AUTOMATION SOLUTIONS
Installation, use and service manual

1
USE, INSTALLATION AND MAINTENANCE MANUAL
1.0 - GENERAL INFORMATION 2
1.1 - PURPOSE OF THE MANUAL ...................................................................................................................2
1.2 - PRODUCT IDENTIFICATION....................................................................................................................3
1.3 - GLOSSARY AND TERMINOLOGY ............................................................................................................4
1.4 - REQUESTING TECHNICAL ASSISTANCE .................................................................................................4
1.5 - MANUFACTURER’S LIABILITY.................................................................................................................4
1.6 - CONSIGNMENT CONDITIONS .................................................................................................................4
2.0 - TECHNICAL INFORMATION 5
2.1 - DESCRIPTION OF THE GEAR UNIT .........................................................................................................5
2.2 - CONFORMITY .......................................................................................................................................5
2.3 - OPERATING LIMITS AND CONDITIONS....................................................................................................5
3.0 - SAFETY INFORMATION 6
3.1 - SAFETY STANDARDS ............................................................................................................................6
4.0 - HANDLING AND TRANSPORT 7
4.1 - PACKAGING..........................................................................................................................................7
4.2 - HANDLING INSTRUCTIONS ....................................................................................................................7
4.2.1 - Moving the packages .....................................................................................................................8
4.2.2 - Moving the equipment ....................................................................................................................8
4.3 - STORAGE ...........................................................................................................................................14
5.0 - INSTALLATION 15
5.1 - INSTALLING THE GEAR UNIT................................................................................................................15
5.1.1 - Flanged execution........................................................................................................................15
5.1.2 - Foot mounting .............................................................................................................................17
5.1.3 - Shaft mounting ............................................................................................................................18
5.1.4 - Installing accessories on solid input and output shafts ........................................................................19
5.2 - INSTALLING THE ELECTRIC MOTOR .....................................................................................................21
5.3 - INSTALLING THE HYDRAULIC MOTOR...................................................................................................22
5.4 - CONNECTING THE HYDRAULIC BRAKE .................................................................................................23
5.5 - LUBRICATION......................................................................................................................................29
6.0 - TESTING THE GEAR UNIT 30
7.0 - USING THE EQUIPMENT 30
8.0 - MAINTENANCE 31
8.1 - ROUTINE MAINTENANCE .....................................................................................................................32
8.2 - OIL CHANGES .....................................................................................................................................33
8.3 - CHECKING OPERATIONAL EFFICIENCY ................................................................................................33
8.4 - CLEANING...........................................................................................................................................33
9.0 - REPLACING PARTS 34
9.1 - REMOVING THE MOTOR ......................................................................................................................34
9.2 - DECOMMISSIONING THE GEAR UNIT ....................................................................................................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.

2
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.
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
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.
Instructions marked by these symbols and highlighted in yellow, apply exclusively to equipment
complying with “ATEX” Directive 94/9/EC.
The operations identified by these symbols must be executed by professionally qualified opera-
tors specially trained in the safety precautions required for working in potentially explosive atmo-
spheres.
Failure to observe these instructions may result in serious safety and environmental risks.

3
TYPE
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
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.
Nameplate data
Supplementary nameplate on ATEX-specified gear units
EC-Cert. No.
Gearbox compliant with
ATEX Directive 94/9/EC-GR UP II
2G CATEG RY - T4 Temperature
2D CATEG RY - 135° C Temperature
EX9 04 07 53387 001
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.

4
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 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 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.
•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.

5
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)
•VITON®seal rings
•vent plugs with spring-loaded anti-intrusion valve
•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.
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 further 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
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/EEC and the Electromagnetic Compatibility Directive 89/336/EEC.
Furthermore, if specified for use in potentially explosive atmospheres, the gear units are desi-
gned 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:
•Equipment group: II.
•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
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.

6
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.
•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.
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
effect on the unit’s heat output.
The applications permitted by the Manufacturer are the industrial applications for which the
gear units have been designed.
3.0 - 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 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.
•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. 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.

7
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 in 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 °C 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.
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).
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.

8
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. 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.
When lifting, use accessories such as eyebolts, screw clamps, snap hooks, straps, ropes and
hooks etc. which are certified and adequate for the load in question.
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 MA B
Approximate weight £15 Kg >15 Kg
Instruction — Recommended method for po-
sitioning
Recommended method for
handling and positioning
Warning — The load may be unstable The load may sway or oscillate
Solution —
Slide the lifting ring to align it
with the load’s centre of gra-
vity as shown in the diagrams
below
Lock the ropes below the ring
with a cable clamp or similar
device so as to prevent them
sliding, and lift the load
Observe all precautions regar-
ding the handling of loads
Stabilise the moving load by
hand
Observe all precautions regar-
ding the handling of loads
The load must not 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.

9
300 L ... 316 L
1
1
1
1
1
1
1
1
1
P
F
H
317 L ... 321 L
P
F
H
1
2
3
1
2
3
2
3
1
1
2
3
1
2
3
2
3
1
1
2
3
2
3
1
1
2
3
Snap hook
(u e with rope)
Screw clamp
(u e with harne )
Eyebolt (already fitted
on gear unit 317-321)
3
Open harne
with eyelet
2
Rope and hook
1
Ring harne Maximum permi ible tilt during
handling: 15°
MAX
15°
15°
Identify the attachment points for lifting the gear unit. Refer to the diagrams given below.

10
300 R ... 316 R
1
1
1
1
1
11
1
1
P
F
H
317 R ... 321 R
P
F
H
2
3 1
2
3 1
2
3 1
2
3 1
2
3 1
2
3 1
2
3 1
2
3 1
2
3 1
3
Open harne
with eyelet
2
Rope and hook
1
Ring harne
Snap hook
(u e with rope)
Screw clamp
(u e with harne )
Eyebolt (already fitted
on gear unit 317-321)
Maximum permi ible
tilt during handling: 15°
MAX
15°
15°

11
300 R ... 316 R
317 R ... 321 R
P
F
H
1
1
1
1
1
1 1
1
1
P
F
H
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
Maximum permi ible
tilt during handling: 15°
MAX
15°
15°
Snap hook
(u e with rope)
Screw clamp
(u e with harne )
Eyebolt (already fitted
on gear unit 317-321)
3
Open harne
with eyelet
2
Rope and hook
1
Ring harne
2
3
1
2
3
1

12
3V 00 ... 3V 16
3V 17 ... 3V 21
P
F
H
1
1
1
1
1
1
P
F
H
1
1
1
Snap hook
(u e with rope)
Screw clamp
(u e with harne )
Eyebolt (already fitted
on gear unit 317-321)
3
Open harne
with eyelet
2
Rope and hook
1
Ring harne Maximum permi ible tilt during
handling: 15°
MAX
15°
15°
12
3
12
3
12
3
12
3
12
3
12
3
12
3
12
3
12
3

13
300 L ... 321 L
300 R ... 321 R
P F H
Snap hook
(u e with rope)
Screw clamp
(u e with harne )
Eyebolt (already fitted
on gear unit 317-321)
3
Open harne
with eyelet
2
Rope and hook
1
Ring harne Maximum permi ible tilt during
handling: 15°
MAX
15°
15°
2
32
3
P F H
2
3
12
3
1
3V 00 ... 3V 21
P F H
2
3
2
3
2
3
2
3
12
3

14
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.
•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. Do not store the unit in excessively humid conditions or where it is exposed to the weather (do not store
outdoors).
2. Do not place the gear unit directly on the ground.
3. Place the gear unit on a stable base and make sure that it is not subject to accidental displacement.
4. 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 properties and application range.
6. 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.

15
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-
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.
1. Carefully remove all packaging and protective product residue from the gear unit.
Pay particular attention to the mating surfaces.
2. Check that the data on the nameplate correspond to those specified in the purchase order.
3. 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.
4. Check that the machine to which the gear unit is to be installed is switched off and cannot be accidentally
switched on again.
5. Make sure all mating surfaces are flat.
6. Make sure the shaft/shaft or shaft/ bore are perfectly aligned for coupling.
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 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
coupling and protection against fretting corrosion.
10. 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 flanges 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
Æ d
ÆD
Loose coupling Coupling with interference
Solid shaft Hollow shaft Solid shaft Hollow shaft
Ødh6 ØDG7 Ødh6 ØDP7
Ødk6 ØDF7 Ødk6 ØDM7
Ødm6 ØDF7 Ødm6 ØDK7
Ødr6 ØDE7 Ødr6 ØDH7
Recommended tolerances

16
Ø f7/ H8 Ø j6 / F8 Ø h6 / F8
0.1 / 100 B
B
0.15
B
0.15
B
3.2
3.2
300...307
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 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:
0.07
B
B
R
0.15
B
0.1 / 100
B
Æ f7 Æ f7
3.2
Æ H8 Æ H8
3.2
3.2
b = d
d
b
0.1 / 100
B
B
R
0.15
B
Æ f7
3.2
Æ H8
3.2
309, 310, 315
0.20
B
0.05
B
317, 319
309...321
R³60% Rn
For machining the spigot on the driven machine, refer to the diagrams below:
300...307 gear units - male output shaft motor execution

17
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:
0.1 / 100 B
B 0. 15
Æ f7 / H8
3.2
3.2
300...321
Flanged gear unit mounting bolts
For maximum transmitted torques greater than or equal to 70% of the torque indicated as M2max, 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:
C
C 0. 15
3.2
0.2 100
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 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 12 15 24 30 20 20 30 24 32 30 36
Class 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8
Tightening
torque (Nm) 50 50 85 85 85 135 200 200 200 200 400 400 400 400 1400 700 1400 1400
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 444444444448888848
Class 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8 8.8
Tightening
torque (Nm) 200 200 200 200 200 400 700 700 700 1400 1400 1400 1400 2500 1400 2500 6000 6000

18
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.
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.
Rt £ 16 µm
C
R ³ 600 N/mm
2
Æ H7
Æ H7
Æ h6
Æ h6
3.2
3.2
3.2
3.2
C + 1
C + 1
300...321
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.
1
2
3
4
5
6
78
9
10
11
12
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 M8 M10 M10 M16 M16 M16 M16 M20 M20 M20 M20 M20 M20 M24
Quantity 8 10 12 12 12 9 12 8 8 10 10 12 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 10.9 10.9 10.9
Tightening
torque (Nm) 12 12 30 30 30 58 58 250 250 250 250 490 490 490 490 490 490 840

19
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:
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.
(A)
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 as this can damage the bearings.