We have a relentless commitment to excellence, innovation

& sustainability. Our team creates, distributes and services

world-class power transmission & drive solutions to keep
the world in motion.

300 - 300M Series

HEADQUARTERS
Bonfiglioli Riduttori S.p.A.
Via Giovanni XXIII, 7/A
40012 Lippo di Calderara di Reno
Bologna (Italy)
Installation, Operation
tel: +39 051 647 3111
fax: +39 051 647 3126
and Maintenance Manual
bonfiglioli@bonfiglioli.com
www.bonfiglioli.com

PRODUCTS &
SOLUTIONS

INCLUDED
 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........................................................................................................ 5
2.0 TECHNICAL INFORMATION 5
2.1 DESCRIPTION OF THE GEAR UNIT.............................................................................................. 5
2.2 CONFORMITY................................................................................................................................. 6
2.3 OPERATING LIMITS AND CONDITIONS........................................................................................ 6
2.4 ALLOWED TEMPERATURE LIMITS............................................................................................... 7
3.0 SAFETY INFORMATION 8
3.1 SAFETY STANDARDS..................................................................................................................... 8
4.0 HANDLING AND TRANSPORT 9
4.1 PACKAGING.................................................................................................................................... 9
4.2 HANDLING INSTRUCTIONS........................................................................................................... 9
4.2.1 Moving the packages.................................................................................................................... 10
4.2.2 Moving the equipment................................................................................................................... 10
4.3 STORAGE........................................................................................................................................ 17
5.0 INSTALLATION 18
5.1 INSTALLING THE GEAR UNIT........................................................................................................ 18
5.1.1 Flanged execution......................................................................................................................... 18
5.1.2 Foot mounting............................................................................................................................... 21
5.1.3 Shaft mounting.............................................................................................................................. 21
5.1.4 Installing accessories on solid input and output shafts................................................................. 23
5.2 INSTALLING THE ELECTRIC MOTOR............................................................................................ 25
5.3 INSTALLING THE HYDRAULIC MOTOR......................................................................................... 26
5.4 CONNECTING THE HYDRAULIC BRAKE...................................................................................... 27
5.5 LUBRICATION.................................................................................................................................. 33
6.0 TESTING THE GEAR UNIT 35
7.0 USING THE EQUIPMENT 35
8.0 MAINTENANCE 36
8.1 ROUTINE MAINTENANCE.............................................................................................................. 37
8.2 OIL CHANGES................................................................................................................................. 38
8.3 CHECKING OPERATIONAL EFFICIENCY...................................................................................... 39
8.4 CLEANING....................................................................................................................................... 39
9.0 REPLACING PARTS 40
9.1 REMOVING THE MOTOR............................................................................................................... 40
9.2 DECOMMISSIONING THE GEAR UNIT.......................................................................................... 41
10.0 TROUBLESHOOTING 41
ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS 42
ANNEX 2 - LUBRICANT CHARGE QUANTITY 43
ANNEX 3 - MOUNTING POSITIONS AND PLUG POSITIONS 47

Revisions
The catalogue revision list is given on page 52. The most recent versions of the catalogue are available at www.bonfiglioli.com.

1 / 52
 1.0 GENERAL INFORMATION

1.1 PURPOSE OF THE MANUAL

This Manufacturer’s manual provides information regarding the safe transport, handling, installa-
tion, maintenance, repair, disassembly and dismantling of the gear unit.
All information for users and designers is given in the Sales Catalogue. As well as adher-
ing to established engineering practices, the information given in this manual must be read
carefully and rigorously applied.
Failure to observe the information provided herein may result in risks to personal health and safe-
ty, as well as economic damages.
This information, provided in the Manufacturer’s original language (Italian), is also available in
other languages 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 Man-
ufacturer, 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 publication being for that reason considered inadequate.
Particularly significant sections of the manual and important specifications are highlighted by sym-
bols 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
damage, 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 2014/34/EU.
The operations identified by these symbols must be executed by professionally qualified operators
specially trained in the safety precautions required for working in potentially explosive atmos-
pheres.
Failure to observe these instructions may result in serious safety and environmental risks.

2 / 52
1.2 PRODUCT IDENTIFICATION

The information identifying the product is shown on its nameplate. Gearmotors are equipped with
two nameplates; one on the gear unit which bears the gear unit data, and one on the motor (elec-
tric or hydraulic), bearing 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 fit-
ted with an electric motor (gearmotor), all information regarding the motor is supplied in the motor
manual.

Nameplate data

Manufacturer Serial number

Product identification Date of manufacture

Product code Client product code

Specific symbols of Atex
Reduction ratio
marking

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
requesting spare parts, information and assistance.

3 / 52
 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 mainte-
nance technician.

Expert maintenance technician

An authorised technician with the qualifications, skills and mechanical and electrical training re-
quired 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 damaged 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 established safety legislation.

4 / 52
1.6 CONSIGNMENT CONDITIONS

Gear units are supplied by BONFIGLIOLI RIDUTTORI 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 wa-
ter-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.

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 executions and configurations. It is capable of satisfying a range of specific requirements in
the mechanical, chemical, agricultural and food industries, etc.
BONFIGLIOLI RIDUTTORI supplies a range of accessories and optionals to make their products
as versatile as possible. For further technical information and descriptions, refer to the corre-
sponding Sales Catalogue.
The User is responsible for using the products recommended for installation and maintenance of
BONFIGLIOLI RIDUTTORI gear units in an appropriate manner and in accordance with instructions.

SAFETY SPECIFICATIONS OF GEAR UNITS COMPLYING WITH DIRECTIVE 2014/34/EU

• unit selection must be made with a higher safety service factor

• use only synthetic lubricants (oil and grease)
• Use only fluoroelastomer seals.
• 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.

5 / 52
 2.2 CONFORMITY

All gearboxes or gearmotors (when supplied with motor) are designed as state of the art devices
in compliance with the provisions of applicable Essential Health and Safety Requirements.
All gearmotor motors conform to the provisions of the Low Voltage Directive 2006/95/EC and the
Electromagnetic Compatibility Directive 2004/108/EC.

Furthermore, if specified for use in potentially explosive atmospheres, the gear units are de-
signed and constructed to conform with the Essential Health and Safety Requirements (EHSR)
of Annex II of the ATEX Directive 2014/34/EU and conform to the following classification:

• Equipment group: II.

• Category: Gas 2G - Dust 2D.
• Zone: Gas 1 - Dust 21.
• Temperature class: T4 for 2G and 135°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 RIDUTTORI’s Technical Service.
Failure to obtain said authorisation renders the ATEX certification null and void.

Ambient conditions

• Do not use the gear unit, if not explicitly intended for the purpose, in a potentially explosive at-
mosphere or where the use of explosion-proof equipment is specified.

The nameplate specifications regarding the maximum surface temperature, refer to readings tak-
en 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.

• 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.

6 / 52
2.4 ALLOWED TEMPERATURE LIMITS

Value (*)
Symbols Description / Condition Synthetic Mineral
Oil Oil
ta Ambient temperature

tau min Minimum operating ambient temperature -30°C -10°C

tau Max Maximum operating ambient temperature +50°C +40°C

tas min Minimum storage ambient temperature -40°C -10°C

tas Max Maximum storage ambient temperature +50°C +50°C

ts Surface temperature

ts min Minimum gearbox surface temperature starting with partial load (#) -25°C -10°C

tsc min Minimum gearbox surface temperature starting with full load -10°C -5°C

Maximum casing surface temperature during continuous operation

ts Max +100°C +100°C (@)
(measured next to the gearbox input)

to Oil temperature

to Max Maximum oil temperature during continuous operation +95°C +95°C (@)

(*) = For further information about minimum and maximum values of different oil viscosity and for using hydraulic
circuits refer to the table “Selection of the optimal oil viscosity” on the catalog available on www.bonfiglioli.com

(@) = Continuous operation it is not advised if ts and to range is 80°C to 95 °C.

(#) = For full load start-up it is recommended to ramp-up and provide for greater absorption of the motor.
If needed, contact Bonfiglioli Technical Service.

7 / 52
 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 spe-
cifically for the purpose with special abilities and experience in the area as well as being equipped
with the appropriate tools and individual safety equipment (as per Legislative Decree 626/94).
Failure to meet these requirements 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 result 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.

• Keep the gear unit at its maximum efficiency by following the routine maintenance schedule.
Good maintenance ensures the unit’s maximum performance, extended service life and continued
compliance with safety regulations.
• When working on the unit in areas which are difficult to access or hazardous, ensure that ade-
quate safety precautions have been taken for the operator and others in compliance with estab-
lished legislation on health 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 address potential hazards and their prevention for the entire machine. The expert
maintenance technician must always work with caution in observance of applicable safety stand-
ards.
• 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) recom-
mended by the Manufacturer.
• Do not dump polluting materials into the environment. Dispose of all such materials as stipulated
by applicable legislation.
• After replacing lubricants clean the gear unit’s surfaces and the walk-on surfaces around the
work area.

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 necessary
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).

8 / 52
4.0 HANDLING AND TRANSPORT

4.1 PACKAGING

The standard packaging, if supplied and unless otherwise agreed, is not proofed against rainfall
and is intended for shipping by ground and not sea, and for storage in areas which are under cov-
er and not humid. The material can be stored in suitable conditions for a period of two years under
cover at a temperature within the limits specified in the chapter “ALLOWED TEMPERATURE
LIMITS” and at a relative humidity not in excess of 80%. Storage in all other conditions requires
specific 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 RIDUTTORI 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.

9 / 52
 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 attachment 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.

Type of lifting Manual With mechanical equipment

Symbol M A B
Approximate
weight ≤ 15 Kg > 15 Kg

Recommended method for Recommended method for handling

Instruction —
positioning and positioning

Warning — The load may be unstable The load may sway or oscillate

Slide the lifting ring to align it with the

load’s centre of gravity as shown in
the diagrams below
Stabilise the moving load by hand
Lock the ropes below the ring with a
Solution — cable clamp or similar device so as
Observe all precautions regarding
to prevent them sliding, and lift the
the handling of loads
load

Observe all precautions regarding

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.

10 / 52
 Identify the attachment points for lifting the gear unit. Refer to the diagrams given below.

Horizontal positions

300 L ... 316 L , 310M L ... 316M L

317 L ... 325 L , 317M L , 318M L

Ring harness Screw clamp (use with Maximum permissible tilt during
harness) handling: 15°
Rope and hooks Snap hook (use with rope)

Open harrness with Eyebolt (already fitted on gear

eyelets units 317-325 , 317M , 318M)

11 / 52
 300 R ... 316 R , 310M R ... 316M R

317 R ... 321 R , 317M R , 318M R

Ring harness Screw clamp (use with Maximum permissible

harness) tilt during handling: 15°
Rope and hooks Snap hook (use with rope)

Open harrness with Eyebolt (already fitted on gear

eyelets units 317-321 , 317M , 318M)

12 / 52
 300 R ... 316 R , 310M R ... 316M R

317 R ... 321 R , 317M R , 318M R

Ring harness Screw clamp (use with

harness)
Rope and hooks Snap hook (use with rope)
Maximum permissible
Open harrness with Eyebolt (already fitted on gear tilt during
eyelets units 317-321 , 317M , 318M) handling: 15°

13 / 52
 3V 00 ... 3V 16 , 3V 10M ... 3V 16M

3V 17 ... 3V 21 , 3V 17M , 3V 18M

Ring harness Screw clamp (use with Maximum permissible

harness) tilt during handling: 15°
Rope and hooks Snap hook (use with rope)

Open harrness with Eyebolt (already fitted on gear

eyelets units 317-321 , 317M , 318M)

14 / 52
 3A 00 ... 3A 07

Ring harness Screw clamp (use with Maximum permissible

harness) tilt during handling: 15°
Rope and hooks Snap hook (use with rope)

Open harrness with

Eyebolt
eyelets

15 / 52
 Vertical positions

300 L ... 325 L , 310M L ... 318M L

300 R ... 321 R , 310M R ... 318M R

3V 00 ... 3V 21 , 3V 10M ... 3V 18M

3A 00 ... 3A 07

Ring harness Screw clamp (use with Maximum permissible

harness) tilt during handling: 15°
Rope and hooks Snap hook (use with rope)

Open harrness with Eyebolt (already fitted on gear

eyelets units 317-325 , 317M , 318M)

16 / 52
 • Prepare the gear unit for lifting by attaching straps, hooks and screw clamps etc. to its attach-
ment points. Alternatively, use a pallet to move the load. If using a crane, first lift the gear unit
vertically out of its packaging.
• If using a lift truck or pallet truck, remove the packaging and insert the truck’s forks at the indicat-
ed positions.
• 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
motor 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 recommended operating lubricant.

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.

17 / 52
 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
machine. 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 required for aggressive environments. In this case, contact the BONFIGLIOLI RIDUT-
TORI 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 component as indicated in the drawings below.

Recommended tolerances
Loose coupling Solid shaft
Coupling with Coupling with
Hollow shaft Hollow shaft
interference interference
Ø d h6 Ø D G7 Ø d h6 Ø D P7
Ø d k6 Ø D F7 Ø d k6 Ø D M7
Ø d m6 Ø D F7 Ø d m6 Ø D K7
Ø d r6 Ø D E7 Ø d r6 Ø D H7

18 / 52
For machining the spigot on the driven machine, refer to the diagrams below:

300...307 gear units - male output shaft motor execution

300...307

309...321 , 310M...318M gear units - male output shaft motor execution

With R> 60 % Rn2, the output shaft inflection con be higher than 0.5 mm, measured at the end of
the shaft. lf the application requires a lower deformation, it is recommended to use both centering
on the gear units.
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.

309...315 , 310M...315M
0.1 / 100 B

0.07 B
B

B 0.15

3.2
3.2

Threaded hole only

3.2

R 60% Rn

316...321 , 316M...318M
0.1 / 100 B

B 0.15

3.2

Threaded hole only

3.2

19 / 52
 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 operation. See diagram below:

300...325
310M...318M

Flanged gear unit mounting bolts

310 311 313 314 315 316 317 318
300 301 303 304 305 306 307 309 319 321 323 325
310M 311M 313M 314M 315M 316M 317M 318M
Bolt M10 M10 M12 M12 M12 M14 M16 M16 M16 M16 M16 M20 M20 M20 M30 M27 M30 M30 M42 M42
Quantity 8 8 10 10 10 12 10 12 15 24 30 20 20 30 24 32 30 36 36 36
Class 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9
Tightening
torque [Nm] 85 85 145 145 145 230 350 350 350 350 350 690 690 690 2350 1750 1750 1750 6750 6750

For applications in areas that do not permit/allow this class, please contact the Technical Service
of the Manufacturer.

Customer’s shaft axial mounting version FDK (300-310 , 310M) and FZP (311-325 , 311M-318M)

VERSION SIZE BOLTS x4

300 M4
301
303 / 304 / 305 M6
FDK 306
307
309 M8
310 / 310M
311 / 311M
313 / 313M
314 / 315 / 314M / 315M M8
316 / 316M
317 / 317M
FZP
318 / 318M
M10
319
321 M12
323
M20
325

• Remove the two axial mounting half-rings (1) from the gear unit
• Make the customer shaft (2) as indicated in the technical catalogue (see www.bonfiglioli.com for
up-to-date version)
• Properly lubricate both the shaft and its housing, then connect the shaft to the gear unit
• Apply the two axial mounting half-rings, by placing them in the respective circumferential housing
on the shaft
• Assemble the fixing screws (3) by screwing them gradually and diametrically, applying the tight-
ening torque indicated in the “Dimensions” section of the technical catalogue (see www.bonfiglioli.
com for up-to-date version)
• To remove the shaft, loosen all the screws. Procure additional 4 screws (as shown in the table,
not provided with the gear unit) and screw them in the threaded holes on the two half-rings, react
on the gear unit up to the release of the shaft.

20 / 52
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
310M...318M

Foot-mounted gear unit mounting bolts

310 311 313 314 315 316 317 318

300 301 303 304 305 306 307 309 319 321
310M 311M 313M 314M 315M 316M 317M 318M
Bolt M16 M16 M16 M16 M16 M20 M24 M24 M24 M30 M30 M30 M30 M36 M30 M36 M48 M48
Quantity 4 4 4 4 4 4 4 4 4 4 4 8 8 8 8 8 4 8
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

5.1.3 Shaft mounting

Mount the torque arm with bolts of class and torque as indicated in the table below:

300...325
310M...318M

310 311 313 314 315 316 317 318

300 301 303 304 305 306 307 309 319 321 323 325
310M 311M 313M 314M 315M 316M 317M 318M
Bolt M10 M10 M12 M12 M12 M14 M16 M16 M16 M16 M16 M20 M20 M20 M30 M27 M30 M30 M42 M42
Quantity 8 8 10 10 10 12 10 12 15 24 30 20 20 30 24 32 30 36 36 36
Class 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9 12.9
Tightening
torque [Nm] 85 85 145 145 145 230 350 350 350 350 350 690 690 690 2350 1750 1750 1750 6750 6750

21 / 52
 Clean and degrease both the internal coupling surface of the gear unit shaft and the external cou-
pling surface of the machine’s driven shaft.
Mount the shrink disk to the gear unit’s shaft after lightly lubricating its entire outer surface.

Mounting sequence for shrink discs with gear units sizes 300-313 , 310M-313M
• 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 diagram below). Fit the gear unit to the driven shaft.
• Tighten down the bolts (following the triangular pattern) in a circular direction, repeating the op-
eration several times until all bolts are tightened to the torque specified in table 2, in accordance
with the type of disk/gear unit.

Mounting sequence for shrink discs with gear units sizes 314-325 , 314M-318M
• Tighten 4 screws equally spaced at 50% of the value of the tightening torque indicated in table 2,
crosswise. (example: screws 1-7-4-10)
• Tighten 4 screws equally spaced at 100% of the value of the tightening torque indicated in table
2, crosswise. (example: screws 2-8-5-11)
• Tighten all the screws continuously up to the point that, by applying the tightening torque indicat-
ed in table 2, these no longer have any movement.
• Check the effective alignment of the inner and outer ring of the coupling.

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...313 314...325
310M...313M 314M...318M

Disassembly sequence
Gradually unlock the fixing screws in a circular direction. Do not completely remove the screws to
avoid violent separation of the coupling rings.
If it is still not possible to disassemble the gearbox from the customer shaft, use the holes de-
scribed here to introduce oil under pressure (see the following image).

N.2 HOLES 1/8” BSP (316 - 319) AND 1/4” BSP (323 - 325)
FOR THE INTRODUCTION OF PRESSURIZED OIL
TO FACILITATE REMOVING THE CUSTOMER SHAFT

22 / 52
 Shrink disk mounting bolts

(2) 310 311 313 314 315 316 317 318

300 301 303 304 305 306 307 309 319 321 323 325
310M 311M 313M 314M 315M 316M 317M 318M
Bolt M6 M6 M8 M8 M8 M10 M10 M16 M16 M16 M16 M20 M20 M20 M20 M20 M24 M27 M30 M30
Quantity 8 10 12 12 12 9 12 8 8 10 10 15 15 15 16 20 18 16 21 24
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 12.9 12.9 12.9 10.9 10.9 10.9 10.9
Tightening
torque [Nm] 12 12 30 30 30 58 58 250 250 250 250 490 490 570 570 570 840 1250 1640 1640

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.

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:

23 / 52
 Mounting pulleys

Clean all parts before installing them. When installing belt drive pulleys, the shafts must be paral-
lel with their pulleys aligned.
Do not over tension the drive belt as this can damage the bearings.

Shaft end: threads

300...315 316 , 316M 317 , 317M

310M...315M HC-PC HC-PC

318 , 318M 319 321

HC-PC HC-PC HC-PC

310 311 313 314 315 316 317 318

300 301 303 304 305 306 307 309 319 321
310M 311M 313M 314M 315M 316M 317M 318M
MC M12 M12 M20 M20 M20 M20 M20 — — — — — — — — — — —
HC M16 M16 M20 M20 M20 M20 M20 M24 M24 M24 M24 M24 M24 4xM16 6xM16 4xM24 12xM20 12xM20
PC M12 M16 M20 M20 M20 M20 M20 M24 M24 M24 M24 M24 M24 4xM16 6xM16 4xM24 12xM20 12xM20
VK — — M20 M20 M20 M24 M24 M24 M24 M24 M30 M30 M30 — — — — —

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:

24 / 52
 MZ-HZ

Always use the stop end plate supplied with the gear unit.

5.2 INSTALLING THE ELECTRIC MOTOR

Further to all the precautions indicated above, when installing a standard IEC 72-1 electric motor,
the following precautions must also be observed:
• Do not force the coupling and do 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 Klüberpaste 46 MR 401 or
another product with similar properties and application range.

• Provided all the above checks have been performed and passed and all other instructions
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 2014/34/EU.

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 particular
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 2014/34/EU.

25 / 52
 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.

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 pro-
vided 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.

26 / 52
5.4 CONNECTING THE HYDRAULIC BRAKE

On gear units designed for coupling to hydraulic motors and fitted with a brake, connect the brake
control fitting 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 A B D F H K L B C E G K B C E G K L
Braking
torque [ ]
Nm
Mbs ±10% 50 100 160 260 330 400 440 400 500 630 800 1000 850 1100 1500 2100 2600 3200
Minimum
release bar 10 20 30 20 25 30 33 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 Mbs is the maximum torque the brake can exert.
Under dynamic loads the braking torque is reduced. The actual Mbs values can vary from -5% to
+15% of the rating given in the chart.

27 / 52
 Installing the gearmotor

If a gearmotor is supplied fully assembled, follow the precautions and instructions given above
when mounting to the machine.
For the electrical and hydraulic connection, refer instead to the two sample diagrams below.
These are generic 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.

Drive with TRASMITAL MG orbital hydraulic motor

In addition to the instructions governing installation of the gear unit, the following instructions
should also be observed when installing a hydraulic motor.

28 / 52
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 centre 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

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 control 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 = pressure relief valves calibrated to pRV < pmax.

29 / 52
 b) Connecting drain port T

These motors have a 1/8” G drain hole in the centre of the cover. The motor is supplied with the
port closed by a metal plug (see figure below).
Two non-return valves are incorporated in the motor casing to maintain internal pressure at the
same level as the low pressure line A or B if the drain port is not connected to the tank.

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).

The drain port must always be connected up when more motors are operated in series.

30 / 52
c) Brake control

For gearmotors equipped with brakes, there are two motor versions available, i.e. the B02P or
P010 executions.
In the B02P version, the motor has an in-built, direct brake control system.
In the P010 version, an auxiliary branching is required to control the brake.
See the following diagram.

Open loop circuit Closed loop circuit

Control valve open center type Control valve closed center type

Motor Motor Motor

execution execution execution

d) Hydraulic oil

Use hydraulic mineral oil with viscosity ISO VG 46 (46 Cst at t = 40°C).

e) Oil filtering

For reliable motor operation and long life, it is important that the hydraulic circuit has a filter for a
proper oil filtering according to the following degree:

degree 9 NAS 1638

degree 6 SAE
degree 18/15 SO DIS 4406

31 / 52
 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, prevent air pockets from forming which may affect pump suction during operation.

A - B = Supply lines
T = Drainage

32 / 52
 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 vent plug included in the shipment before
installing it.
(A 1) Tightening torque Tightening torque
Plug thread Pitch Plug thread Pitch
[Nm] [Nm]
M14 1.5 15 - 20 1/8" 28 10 - 15
M16 1.5 15 - 20 1/4" 19 10 - 15
M18 1.5 15 - 20 3/8" 19 15 - 20
M20 1.5 20 - 30 1/2" 14 20 - 30
M22 1.5 20 - 30 3/4" 14 20 - 30
M24 1.5 20 - 30 1" 11 30 - 40
M30 2 30 - 40
M42 3 40 - 50

Ta -10 °C / + 30 °C + 10 °C / + 30 °C - 20 °C / + 30 °C 0 °C / + 60 °C
Industrial plantsISO VG 150 ISO VG 220 ISO VG 150 ISO VG 220/320
Omala S4 WE 150 Omala S4 WE 320
Shell
(A 2) Omala S2 G 150 Omala S2 G 220 Omala S4 GX 150 Omala S4 GX 220

Mobilgear XMP 150 Mobilgear XMP 220 Mobil SHC 629 Mobil SHC 630
Mobil
Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobil SHC XMP 150 Mobil SHC XMP 220

Kluber Kluberoil GEM1-150 Kluberoil GEM1-220 Klubersynt EG 4 150 Klubersynt EG 4 220

Mobil Glygoyle (USDA H1)
Klübersynth UH1 6

Klübersynth GEM2
Klübersynth GH 6

Mobil SHC GEAR

Alphasyn PG 320
AGIP Blasia 150 Blasia 220 Blasia SX 150 Blasia SX 220
Mobilgear XMP
Klüberoil GEM1
Omala S4 GXV

Mobil SHC 600

Mobil Glygoyle

Nevastane SY
Omala S4 WE

Omala S2 GX

Carter SG
Blasia SX

Blasia S

Aral Degol BG 150 Degol BG 220 Degol PAS 150 Degol PAS 220
Blasia

BP Energol GR XP 150 Energol GR XP220 Eversyn EXP 150 Eversyn EXP 220

Castrol Alpha SP 150 Alpha SP 220 Alphasyn EP 150 Alphasyn EP 220

Cepsa Engranajes HP 150 Engranajes HP 220 Engranajes HPX 150 Engranajes HPX 220
HDP
300
Chevron N.L. Gear Compounds EP 150 N.L. Gear Compounds
F EP 220 Tegra Synthetic gear EP 150 Tegra
F Synthetic gear EP 220
* * * * * * * * F
HDO
300M
Fuchs Renolin CKC 150 Renolin CKC 220 Renolin unisyn CKC 150 Renolin unisyn CKC 220

Molycote L-0115 L-0122 L-2115 L-2122

F Food grade.
Q8 Goya 150 Goya 220 El Greco 150 El Greco 220
Recommended use.
Repsol Super Tauro 220 Super Tauro Sintetico 150 Super Tauro Sintetico 220
* Permitted use. The manufacturer cannot guarantee the quality or suitability of lubricants. Characteristics
Total Carter EP 150 Carter EP 220 Carter SH 150 Carter SH 220
must be verified directly with the manufacturer of the chosen lubricant (or ask Bonfiglioli Technical
Service for oil certification).
Oils of different bases should not be mixed together
PAG base oilGlycol
PolyAlkylene (Poliglycole) for applications
(PAG) synthetic oil (APIwith operating
group V) temperatures above the indicated range
PAO base oil (Polyalphaolefin) for demanding applications, for the average power committed and /
PolyAlphaOlefi n (PAO) synthetic
or operating temperatures, withinoilthe
(API group IV)
indicated range
Mineral oil with EP additives
Mineral oil with EP additives

33 / 52
 Mobile machines
(A 3)
SAE standard .. API GL5 grade

Ta -20°C / +30°C +10°C / +45°C

SAE 80W/90 SAE 85W/140

Shell Spirax HD Spirax HD

Mobil Mobilube HD Mobilube HD

AGIP Rotra MP Rotra MP

Aral Getriebeol HYP Getriebeol HYP

BP Hypogear EP Hypogear EP

Castrol Hypoy Hypoy

Cepsa Transmisiones EP Transmisiones EP

Chevron RPM Universal Gear Lubricants RPM Universal Gear Lubricants

Fuchs Titan Super Gear Titan Super Gear

Total Transmission TM Transmission RS

Brake lubrication

The hydraulic multi-disk brakes are lubricated with the same oil as the gear unit.

Only synthetic lubricants may be used on gear units conforming to European Directive
2014/34/EU. Refer to the above chart for the brand and type.

34 / 52
6.0 TESTING THE GEAR UNIT

The gear unit has been factory tested by the Manufacturer. Before start-up, make sure that:
• this partly completed machinery must not be put into service until the final machinery into which
it is to be incorporated has been declared in conformity with the provisions of the “Machinery
Directive” 2006/42/EC
• the gear unit’s mounting position in the installation corresponds to that prescribed and indicated
on the nameplate
• 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 conforms to ISO VG 46. It must be filtered with a maximum grade of 10 µm and contamina-
tion 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, radiation)
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
• the temperature of the cooling air does not exceed the values indicated in the chapter “AL-
LOWED TEMPERATURE LIMITS”.
• 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, have 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

7.0 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 ex-
posed 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.

35 / 52
 8.0 MAINTENANCE

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
ambient problems attendant on the installation.

Before doing any work on the unit, the operator must first switch off power to the gear unit
and ensure that it is out of service, as well as taking all necessary precautions against it
being accidentally switched on again or its parts moving without warning (due to suspend-
ed loads or similar external factors).
Furthermore, all additional environmental safety precautions must be taken (e.g. elimina-
tion of residual gas or dust, etc).

• Before doing any maintenance work, activate all the safety devices provided and, if necessary,
inform persons 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.
• If 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 Manufacturer’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 into the environment.
Dispose of all such materials as specified by applicable legislation.

• Observe the routine inspection and maintenance schedule to ensure the unit’s correct operation
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 smeared
with a thin layer of grease (Fluorocarbon gel 880 ITP or other product with similar properties and
application range) before assembly.
• Use only original spare parts for repairs.

36 / 52
 8.1 ROUTINE MAINTENANCE

Keep the gear unit at its maximum efficiency by following the routine maintenance schedule.
Good maintenance ensures the unit’s maximum performance, extended service life and
continued compliance with safety regulations.

(A 4)
Inspection parameter Frequency
Oil changes see specific table
Oil pressure (if there are a circuits) 24 h
Noise, vibration 24 h
External condition of gearbox (fouling, oil deposits) 170 h ... 720 h
Oil leaks, external seals and gaskets 720 h
Oil level 720 h
Oil filter contamination indicator (where required) 720 h
Regrease bearing (where required) see specific table
Vent filter (where required) 2200 h
Tightness of fixing bolts, connecting flanges and torque transmission
2000 h ... 4000 h
components
Check the elastic elements in all joints for wear (where required) 2000 h ... 4000 h
Regrease the Drywell device (on series where provided) and seals (where required) 2000 h … 4000 h

Check cup springs for wear and adjust the torque arm 3000 h

Condition of torque arm polymer bushes (aging, cracking) 3000 h

Alignment of gearbox shafts with respect to coupled machine shafts
9000 h ... 18000 h
at each oil change
Cleanliness of electric motor fan and fan cowling (if present) and cleanliness
at each oil change
of gearbox body

Depending on the temperature reached by the lubricant, it should be replaced at the intervals
indicated in the table below.

(A 5)
Interval replacement [h]
Average oil opera-
ting temperature mineral oil synthetic oil
[C°]
EP(*) PAO PAG

to < 65 8000 25000 25000

65 < to < 80 4000 15000 15000

80 < to < 95 2000 (@) (#) 12500 12500

(*) = Replacement within 1 year

(@) = It is not advised continuous operation in this range of oil temperature: 80°C to 95 °C

(#) = Recommended checking every 6 months

37 / 52
 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.

Every 1000 hrs. of operation or after 6 months:

• Measure the surface temperature at the coupling between the gear unit and motor, and at the
points which are most shielded from the motor’s cooling fan. The maximum temperature must not
exceed the values given in the chapter “ALLOWED TEMPERATURE LIMITS”, nor may this value
be exceeded during operation.

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.

8.2 OIL CHANGES

1. Place an adequate container under the drain plug.

2. Remove the filler and drain plugs and allow the oil to drain out.

The oil will drain better if it is warm.

3. Wait for a few minutes until all the oil has drained out, then screw the drain plug back on after
first changing the plug seal.
4. Fill with new oil until it reaches the level mark. Do not mix oils of different makes or specifi-
cations 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
quantity 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 periodic lubricant changes. If the same type of oil as that already in use is not avail-
able, 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 the 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
- they may cause intoxication if inhaled
- they may be fatal if swallowed.

38 / 52
 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 incompatible with the unit’s construction material and do not direct high pressure jets of water
at the gear unit.

39 / 52
 9.0 REPLACING PARTS

• Immediately replace parts and components if they are not able to guarantee safe and reliable
operation.
• Never improvise repairs.
• The use of non-original spare parts not only renders the warranty null and void but can jeopard-
ise 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 significant-
ly, 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

1. Drill and thread the motor shaft (fan side).

2. Screw an impact extractor tool into the bore.
3. Undo the bolts fixing the motor to the gear unit.
4. Detach the motor by means of the inertial force of the extractor.

40 / 52
 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 health 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 envi-
ronmental legislation.

Do not re-use parts or components which appear to be in good condition after they have been
checked or replaced by qualified personnel and declared unsuitable for use.

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 hence, the cause and remedy will be described in the Manufacturer’s technical
documentation for the machine/plant in question.

FAULT CAUSE REMEDY

Oil level too low Top up oil level
Bearing temperature too
Oil spent Replace oil
high
Defective bearings Contact authorised workshop
Oil level too high Check oil level
Operating temperature too
Oil spent Replace oil
high
Contaminant in oil Replace oil
Gears damaged Contact authorised workshop

Bearing axial backlash too high Contact authorised workshop

Abnormal running noise Bearings defective or worn Contact authorised workshop

Correct load to rated values given in

Excessive load applied
Sales Catalogue

Contaminant in oil Replace oil

Abnormal noise at gear unit Mounting bolts loose Tighten bolts to specified torque
mounting
Mounting bolts worn Replace bolts
Oil level too high Check oil level

Oil leaks Casing/coupling seals inadequate Contact authorised workshop

Gaskets worn Contact authorised workshop

Replace oil (see recommended
Oil viscosity too high
lubricant chart)
Gear unit does not run or
Oil level too high Check oil level
runs with difficulty
Excessive load applied Redesign drive for actual load required

Output shaft does not turn

Gears damaged Contact authorised workshop
with motor running

41 / 52
 ANNEX 1 - CHECKING THE OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS

Gear units are normally fitted with oil level check plugs.
To check the oil level, first identify the level plug.

- Horizontal position:
Remove the plug and insert a bar of the right size in the hole and of the shape shown in the
figure.

- 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.

N.B.: MAKE SURE THE ROD IS POSITIONED FLAT

AGAINST THE EDGE OF THE THREADED HOLE

Gear units conforming to Directive 2014/34/EU 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.

42 / 52
ANNEX 2 - LUBRICANT CHARGE QUANTITY

3_L Series

Mounting position Mounting position

A T O A T O
L1 0.6 1.0 0.9 L1 5.0 6.5 6.0
L2 0.9 1.3 1.2 310 L2 6.3 7.8 7.3
300 310M L3 7.1 8.6 8.1
L3 1.2 1.6 1.5
L4 1.5 1.9 1.8 L4 7.4 8.9 8.4

L1 0.8 1.2 1.1 L1 7.0 12 10

L2 1.1 1.5 1.4 311 L2 9.0 14 12

301 311M L3 10 15 13
L3 1.4 1.8 1.7
L4 11 16 14
L4 1.7 2.1 2.0
L1 9.0 14 12
L1 1.3 2.3 2.0
313 L2 12 17 15
L2 1.6 2.6 2.3
303 313M L3 13 18 16
L3 1.9 2.9 2.6
L4 13 18 16
L4 2.2 3.2 2.9 L2 17 25 21
L1 1.4 2.4 2.2 314
L3 19 27 23
L2 1.9 2.9 2.7
314M
L4 20 28 24
304
L3 2.2 3.2 3.0 L2 19 27 23
L4 2.5 3.5 3.3
315
L3 21 29 25
315M
L1 1.6 2.6 2.4 L4 22 30 26
L2 2.1 3.1 2.9 L2 22 30 26
305 316
L3 2.4 3.4 3.2 L3 24 32 28
316M
L4 2.7 3.7 3.5 L4 25 33 29

L1 2.5 3.5 3.2 L2 26 41 36

317
L3 29 44 39
L2 3.3 4.3 4.0 317M
306 L4 30 45 40
L3 3.6 4.6 4.3
L4 3.9 4.9 4.6
318 L3 40 55 50
318M L4 43 58 53
L1 3.5 5.0 4.5
L3 50 70 60
L2 4.5 6.0 5.5 319
307 L4 53 73 63
L3 5.0 6.5 6.0
L3 56 76 66
L4 5.3 6.8 6.3 321
L4 60 80 70
L1 4.0 5.5 5.0 L3
L2 5.0 6.5 6.0 323 Contact Bonfiglioli Riduttori
L4
309 Technical Service
L3 5.5 7.0 6.5 L3
325
L4 5.8 7.3 6.8 L4

N.B. Oil quantities are indicative. Check actual level after filling through the appropriate plug.

43 / 52
 3_R Series

Mounting position Mounting position

B0 U_ P_ B0 U_ P_

R2 1.2 1.7 1.5 R2 13 15 14

310
300 R3 1.5 2.0 1.8 R3 11 13 12
310M
R4 1.8 2.3 2.1 R4 12 14 13

R2 1.6 2.1 1.9 R2 14 19 17

311
301 R3 1.9 2.4 2.2 R3 16 21 19
311M
R4 2.2 2.7 2.5 R4 17 22 20

R2 2.2 2.8 2.6 R2 16 21 19

313
303 R3 2.5 3.1 2.9 R3 19 24 22
313M
R4 2.8 3.4 3.2 R4 20 25 23

R2 2.3 2.9 2.7 R3 25 33 29

314
304 R3 2.8 3.4 3.2 314M R4 28 36 32

R4 3.1 3.7 3.5 R3 27 35 31

315
R2 2.5 3.1 2.9 315M R4 30 38 34

305 R3 3.0 3.6 3.4

316 R3 30 38 34

R4 3.3 3.9 3.7 316M R4 33 41 37

R2 4.0 5.0 4.8 R3 38 52 48

317
306 R3 4.8 5.8 5.6 317M R4 42 56 52

R4 5.1 6.1 5.9 318

R4 48 63 58
318M
R2 6.0 8.0 7.0
319 R4 55 70 65
307 R3 7.0 9.0 8.0
321 R4 60 75 70
R4 7.5 9.5 8.5

R2 6.5 8.5 7.5

309 R3 7.5 9.5 8.5

R4 8.0 10 9.0

N.B. Oil quantities are indicative. Check actual level after filling through the appropriate plug.

44 / 52
 3/V Series

oil [l]
AA - EA - FD AF - EF - FE AE - EE - FF AD - ED - FA TA - TE - TF OA - OE - OF
TD - VA - VE OD - QA - QE
VF - VD QF- QD
input input input input input input

P(IEC) HS P(IEC) P(IEC) P(IEC) P(IEC) P(IEC)

HS HS HS HS HS
3/V 00 L3 0.90 0.90 0.90 0.90 1.3 1.2
0.12 0.12 0.12 0.12 0.12 0.12 0.12
3/V 01 L3 1.1 1.1 1.1 1.1 1.5 1.4
3/V 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
3/V 04 L3 1.9 0.38 0.38 1.9 0.43 1.9 0.43 1.9 0.52 2.9 0.52 2.7 0.38
3/V 05 L3 2.1 0.38 0.38 2.1 0.43 2.1 0.43 2.1 0.52 3.1 0.52 2.9 0.38
3/V 06 L3 3.3 3.3 3.3 3.3 4.3 4.0
0.64 0.64 0.76 0.76 0.85 0.76 0.76
3/V 10 L4 , 10M L4 7.1 7.1 7.1 7.1 8.6 8.1
3/V 07 L3 4.5 4.5 4.5 4.5 6.0 5.5
3/V 11 L4 , 11M L4 10 2.4 2.8 10 2.6 10 2.6 10 1.7 15 1.9 13 1.9
3/V 13 L4 , 13M L4 13 13 13 13 18 16
3/V 09 L3 5.0 5.0 5.0 5.0 6.5 6.0
3/V 10 L3 , 10M L3 6.3 6.3 6.3 6.3 7.8 7.3
3/V 14 L4 , 14M L4 19 4.3 4.5 19 3.9 19 3.9 19 3.0 27 3.5 23 3.5
3/V 15 L4 , 15M L4 21 21 21 21 29 25
3/V 16 L4 , 16M L4 24 24 24 24 32 28
3/V 11 L3 , 11M L3 9.0 9.0 9.0 9.0 14 12
3/V 13 L3 , 13M L3 12 12 12 12 17 15
7.8 9.6 6.7 6.7 5.0 5.5 5.5
3/V 14 L3 , 14M L3 17 17 17 17 25 21
3/V 17 L4 , 17M L4 29 29 29 29 44 39
3/V 15 L3 , 15M L3 19 19 19 19 27 23
3/V 18 L4 , 18M L4 40 11 15 40 8.9 40 9.4 40 7.5 55 9.5 50 9.5
3/V 19 L4 50 50 50 50 70 60
3/V 16 L3 , 16M L3 22 22 22 22 30 26
3/V 17 L3 , 17M L3 26 23 28 26 16.8 26 17.5 26 10.7 41 17 36 17
3/V 21 L4 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.

45 / 52
 3/A Series

oil [l]
AA - EA - FD TA - TE - TF OA - OE - OF AD - ED - FA AF - EF - FE AE - EE - FF
TD- VA - VE OD - QA - QE
VF - VD QF- QD

3/A 00 L2 0.60 1.4 1.0 1.4 0.90 1.4 0.60 1.4 0.60 1.4 0.60 1.4

3/A 01 L2 0.80 2.3 1.2 2.3 1.1 2.3 0.80 2.3 0.80 2.3 0.80 2.3

3/A 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

3/A 04 L2 1.4 3.8 2.4 3.9 2.2 3.9 1.4 4.5 1.4 5.0 1.4 4.2

3/A 05 L2 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.

46 / 52
 ANNEX 3 - MOUNTING POSITIONS AND PLUG POSITIONS

3_M_L - 3_L - 3_R Series

ALL GEARBOXES 300 - 325 , 310M - 318M A-E

1 Filling/breather oil plug 4 1A
2 Oil level plug
3 Oil draining plug
3A
4 Brake port
1A
1 STAGE INLINE GEARBOXES 4

1A Filling/breather oil plug 300

-
3A Oil draining plug 3A
307
2 STAGE RIGHT ANGLE GEARBOXES
1B Filling/breather oil plug
3B Oil draining plug

300 - 321 , 310M - 318M B1 - B3 - I1 - I3

4
309
-
325
300 - 321 , 310M - 318M B2 - I2
310M
1B 1B 1B
-
318M

4
3
4
3
3

300 - 321 , 310M - 318M B0 - I0

300
-
307

1
1 2 2
1
4
4
2

3B 3B 3B

309
-
325
310M
-
318M

47 / 52
 300 - 307 309 - 325 , 310M - 318M

2 2 2
3
3 4
3 3 4 3
4 3 3 3
4

P0 - P1 - P2 - P3 R0 - R1 - R2 - R3 Q-O
300 - 321 , 310M - 318M 300 - 325 , 310M - 318M

ALL GEARBOXES 2A 4 Brake port

Transparent oil level hose
1 Filling/breather oil plug 5 Oil tank, for gearboxes in
2 Oil level plug 3 Oil draining plug industrial application

U0 - U1 - U2 - U3 W0 - W1 - W2 - W3 T-V
300 - 321 , 310M - 318M 300 - 325 , 310M - 318M

4 4
1 1 1
2 1
2 2 2
1 2 1
4 2
4

303 - 315 300 - 307 309 - 325 , 310M - 318M

310M - 315M

48 / 52
 3/V M - 3/V Series

ALL GEARBOXES 300 - 321 , 310M - 318M A-E

(planetary stages)
1 Filling/breather oil plug
2 Oil level plug
3 Oil draining plug

(worm reduction module)

1V Filling/breather oil plug
2V Oil level plug
3V Oil draining plug

300 - 321 , 310M - 318M O-Q

300 - 307 309 - 321 , 310M - 318M

300 - 321 , 310M - 318M T-V

300 - 307 309 - 321 , 310M - 318M

49 / 52
 3/A Series

ALL GEARBOXES 300 - 307 A-E

(planetary stages)
1 Filling/breather oil plug
2 Oil level plug
3 Oil draining plug

(helical bevel reduction module)

1A Filling/breather oil plug
2A Oil level plug
3A Oil draining plug

300 - 307 O-Q

300 - 307 T-V

50 / 52
51 / 52
INDEX OF REVISIONS (R)

BR_IOM_300_ATX-INC_ENG_R05_0

Description

19 Updated information for 309...321 , 310M...318M gear units - male output shaft motor execution.

22 Updated information for the installation of shaft mounting gear units.

37 Updated table for routine maintenance.

2020 06 30

We reserve the right to implement modifications without notice.

This catalogue cannot be reproduced, even partially, without prior consent.

52 / 52
We have a relentless commitment to excellence, innovation
& sustainability. Our team creates, distributes and services
world-class power transmission & drive solutions to keep
the world in motion.

300 - 300M Series

HEADQUARTERS
Bonfiglioli Riduttori S.p.A.
Via Giovanni XXIII, 7/A
40012 Lippo di Calderara di Reno
Bologna (Italy)
Installation, Operation
tel: +39 051 647 3111
fax: +39 051 647 3126
and Maintenance Manual
bonfiglioli@bonfiglioli.com
www.bonfiglioli.com

PRODUCTS &
SOLUTIONS

INCLUDED