Bonfiglioli F series gearbox spare parts identification and replacement guide

Bonfiglioli F series gearbox spare parts identification and replacement guide

In the full lifecycle management of industrial transmission equipment, spare parts management is a key link to ensure the continuous operation of equipment and shorten downtime. However, when faced with the intricate gear system, bearing assembly, and sealing system inside the gearbox, on-site engineers often face the dilemma of how to quickly and accurately identify the parts that need to be replaced? How to ensure that the ordered spare parts match the on-site equipment perfectly?

The Bonfiglioli F series gearbox spare parts list manual is a professional technical document designed to address this pain point. This article is based on the detailed spare parts data in the manual (covering the entire series from F 10 to F 90, including multiple output configurations, input interfaces, and additional options), providing a systematic guide for spare parts identification and replacement operations for on-site maintenance engineers, helping to efficiently and accurately complete maintenance tasks.

The structural system and usage logic of spare parts list

1.1 Modular spare parts index

The F-series spare parts manual adopts a modular indexing system, categorizing all spare parts by functional sub components rather than simply listing them by part type. Engineers first need to determine the corresponding spare parts table based on the equipment model when using it.

The spare parts table index (Quadro d'unione) on the homepage of the manual clearly displays the combination relationship between different input configurations and output configurations:

The input type is applicable to the spare parts table number corresponding to the F-series model

F 60 3 / F 60 4 F 60 8 + 22

F 70 3 / F 70 4 F 70 10 + 22 + 24

F 80 3 / F 80 4 F 80 10 + 20 + 22 + 24

F 90 3 / F 90 4 F 90 10 + 22 + 24

Engineering suggestion: Before consulting the spare parts manual, it is necessary to confirm the complete model identification of the equipment (model code on the nameplate), and then refer to the index table to find the corresponding spare parts table number combination.

1.2 Engineering value of Exploded View

The core content of the manual is the Exploded View of each sub component, which is a three-dimensional diagram that decomposes an assembly into independent parts. For on-site maintenance engineers, the value of explosion views lies in:

Intuitive presentation of assembly relationships: Clearly display the relative positions and installation sequence of each component

Clear part boundaries: Each replaceable part has a unique part number (Pos.) identification

Assisted disassembly and assembly: providing visual guidance for maintenance operations

Detailed explanation of spare parts for Output Sub assemblies

The output sub component is the core part of the F series reducer connected to the load end, and it is also the component that bears the maximum torque and radial load. Its spare part identification is the most critical.

2.1 Output configuration types

The F series offers multiple output shaft configurations, each with a different composition of spare parts:

Typical Application Scenarios of Output Code Meaning

Hollow shaft directly connects to user shaft, saving space

NH hollow shaft with tightening disc for high torque transmission, easy to install and disassemble

The R solid shaft has the strongest universality and is suitable for various types of couplings

Solid shaft high reliability connection with NR tightening disc

The S-shaped solid shaft is suitable for sliding fit or quick replacement scenarios

2.2 Core spare parts for output sub components (examples of F 10/F 20)

Taking the output sub components of F 10 and F 20 as an example, the manual lists the following key spare parts and their specifications:

Item number, part name, F 10 specification, F 20 specification, engineering description

152 Housing 6200 6200 gearbox housing, cast parts

221 Pinion gear 6200 6300 input stage active gear

222 gear 6200 6200 final driven gear

871 output shaft - transmits torque to load

951 plug-in output shaft 8 × 7 × 20 A 6.35 × 6.35 × 44.5 solid shaft with keyway

2.3 Comparison of Bearing and Oil Seal Specifications

The manual provides a detailed list of the specifications for each type of bearing (Cuscinetto) and oil seal (Guanizione), which is the most commonly queried information during on-site replacement.

Comparison Table of F 25/F 31/F 41/F 51 Series Bearings (Key Tag 5451-5468):

Model Tag 5451/5452 Bearing Tag 5453 Bearing Tag 5454 Bearing Oil Seal Specification

F 25 2 30302 6011 6011 42×7

F 25 3 6302 6011 6011 42×7

F 31 2 30303 6011 6211 47×7

F 41 2 30304 6013 6213 62×7

F 51 2 32206 6015 6215 72×10

Note: Bearings marked with * (such as 6211-2RS) are suitable for H6 installation position (vertical installation) and use double-sided sealed bearings to prevent grease leakage.

Spare parts for output sub components of size 2.4 F 60 and larger

The output sub component structures of the F 60, F 70, F 80, and F 90 series are more complex, involving more gear stages and bearing groups.

F 60 core spare parts:

Tag number, part name, specification/model, remarks

5451 Bearing 30306/32207 Conical Roller Bearing

5453 bearings 30305/32206 are paired with 5451 for use

5454 bearing 32018X four point contact ball bearing

5457 bearing 32208 output end support bearing

5460 oil seal 90 × 110 × 12 DL double lip oil seal

5871 key bar 8 × 7 × 30 C output shaft key

Oil seal specification:

The DL suffix indicates Double Lip sealing, suitable for environments with high dust levels

CAL. Ø 90 indicates that the inner diameter of the oil seal is 90mm

Engineering tip: When replacing the oil seal, be sure to confirm the installation direction of the oil seal - the lip faces the lubricating oil side, and the dust lip faces the outside. Incorrect installation direction will result in oil seal failure.

Input Module spare parts identification

The input sub component is the connecting bridge between the power source (motor) and the gearbox gear system. The F series supports multiple input interfaces, each with a different composition of spare parts.

3.1 IEC Motor Input Module (P (IEC))

Suitable for input modules of standard IEC flange motors, covering P63 to P250 motor interfaces.

F 51-F 90 IEC input module core spare parts:

Item number, part name, specification description, engineering significance

The 23 input shaft depends on the motor specifications and is connected to the motor shaft through a key

21 Cover - Protect bearings and oil seals

24 motor adapter flange corresponding to P160/P180/P200 and motor flange docking

151 Pinion gear: The first stage driving gear is directly coupled to the motor shaft

32 Bearing holder - carrying input shaft bearings

34 oil seal liner - protect input oil seal

Comparison of input bearings for different motor specifications:

Motor specification input bearing model oil seal specification key strip specification

P160 6016 / 6216 80×110×10 L 8×7×45 A

P180 6016 / 6216 80×110×10 L 8×7×45 A

P200 6216 / 3216 80×110×10 L 14×9×57 C

3.2 NEMA Motor Input Module

For the input interface of NEMA standard motors in the North American market, the spare part structure is similar to the IEC version, but the size standards are different. The manual separately lists the spare parts list for NEMA interfaces from N56TC to N320TC.

Key Differences:

The specification of the fastening thread is imperial (such as 3/8-16 × 1 ", 1/2" -13 × 1 ")

The dimensions of bearings and oil seals are different from the IEC version

Adapt flange size according to NEMA standards

Engineering tip: When repairing the F series gearbox with NEMA interface, it is necessary to use imperial tools to avoid damaging bolts or threaded holes. When replacing bearings, the NEMA specific bearing model indicated in the manual (such as 6008-2RS corresponding to N56TC interface) should be used.

3.3 HS/NHS input module

HS (solid shaft input) and NHS (solid shaft input with shrink disc) are another common input configuration of the F series, suitable for scenarios where the prime mover is directly connected through a coupling.

F 10-F 60 HS/NHS input module spare parts:

Tag number, part name, F 10 specification, F 31 2/3 specification

42 Input shaft -6207

41 end cover——

151 Small Gear——

45/46 Spacer Ring——

5041 bearing (input side) 3206-2RS 6207

5043 bearing (output side) 6206-2RS 6306-2RS

5046 oil seal (HS version) 35 × 62 × 7 L 30 × 52 × 7 DL

Special spare parts for the Tightening Disc version (NHS): The NHS version is equipped with a tightening disc component on the input shaft, and its spare parts list includes additional tightening disc parts (part number 5044, etc.), which require special attention when replacing.

Additional Gear Module spare parts

When the F series reducer requires more reduction stages, an additional gear module will be configured. The manual provides a detailed list of additional module spare parts for F 20 3, F 25 4, F 31 4, F 41 4, F 51 4, F 60 4, F 70 4, F 80 4, and F 90 4.

4.1 Additional Module Structure

An add-on module is essentially an additional planetary or parallel axis gear stage installed between the main housing and the input module. Its core spare parts include:

Item number, part name, function description

101 additional module housing accommodates additional gear stages

102 Pinion Drive Gear

103 large gear driven gear

The joint surface between 104 gasket sealing modules

151 small gear (input stage) connected to the previous stage or input shaft

4.2 Bearing specifications for different types of additional modules

Model: Bearing (part number 5101) Bearing (part number 5102) Oil Seal Specification

F 20 3 6201 2Z 6004 42×?

F 25 4 6201 2Z 6004 42×?

F 31 4 6006 6305 45×55×2 "R"

F 41 4 NJ202 3206-2RS —

F 51 4 NJ203 6008 —

F 60 4 6010 5080 —

F 70 4 6304 6304 —

F 80 4 6404 6304 —

F 90 4 6306 6630 —

Engineering Tip: The gasket (part number 104) between the additional module and the main box must be replaced after disassembly and cannot be reused. During installation, LOCTITE 574 or equivalent sealant should be applied to the joint surface to ensure oil tightness.

Anti reverse device (AL/AR Option) spare parts

For applications that pose a risk of reverse rotation such as hoisting and lifting, the F series offers an Anti run back device option. The device automatically locks the output shaft when the motor is powered off, preventing the load from falling.

5.1 Core spare parts of reverse check device

Item number, part name, function description

601 Reverse Check Support Fixed Reverse Check Mechanism

603 anti reverse bushing cooperates with output shaft to achieve locking

604 washer axial positioning

5.2 Specification of spare parts for different types of reverse check devices

Model Tag Number 5521/5522 Tag Number 5523 Tag Number 5524/5526

F 31 2 DC 3034 M8×20 5×5×32 B

F 31 3 DC 3034 M8×20 5×5×36 B

F 41 2 DC 4127 M8×20 6×6×35 B

F 41 3 DC 4127 M8×20 6×6×45 B

F 51 3/4 BF 50z38 M8×20 —

Engineering Tip: When installing the reverse check device, attention should be paid to the rotation direction - it must match the output rotation direction of the reducer. Incorrect installation direction can cause the device to malfunction and even damage the equipment. The manual clearly indicates the use of LOCTITE 243 (or equivalent performance thread locking adhesive) for anti loosening treatment of fastening bolts.

Oil label and breathable component spare parts

6.1 Expansion Tank

For the F series reducers (especially F 70, F 80, F 90) operating in high-temperature environments, the manual provides a spare parts list for the expansion tank. The function of an expansion tank is to accommodate the volume increase of the oil after thermal expansion, preventing excessive pressure inside the tank.

Item number, part name, specification description

3 Expansion tank body -

4 breathable screws USIT 33.9/M6 × 18

5 end caps -

9 Bends -

10 Rotating Rings -

6.2 Breathable plug components

USIT 33.9: A breathable plug with a sealing gasket, specification 33.9mm

M6 × 18/M8 × 20: Breathable screw specifications

Engineering tip: The ventilation screw (part number 4) of the expansion tank must be kept unobstructed and not blocked by paint or dust, otherwise it will lose its pressure relief function and may cause the oil seal to be washed away.

Suggestions for on-site maintenance spare parts replacement operation

7.1 Key points for bearing replacement

Confirm bearing model: Based on the reference table of manual tag numbers 5451-5468, confirm the complete model of the bearing (such as 30306, 6207-2RS, etc.).

Check the wear of the bearing seat: Before replacing the bearing, check whether the bearing seat hole is worn or scratched.

Heating installation: For bearings with interference fit, it is recommended to use induction heaters to heat the inner ring of the bearing before installation. Hammer striking is strictly prohibited.

Simultaneously replace coaxial bearings: The manual recommends that if one bearing is damaged, the paired bearings on the same shaft should be replaced simultaneously.

7.2 Key points for oil seal replacement

Confirm oil seal specifications: The labeling format for oil seal specifications in the manual is "inner diameter x outer diameter x thickness DL", such as 90 x 110 x 12 DL.

Check journal wear: Before replacing the oil seal, check whether the mating journal is worn or scratched. If there are grooves, repair or replace the output shaft with a shaft sleeve.

Lubrication lip: Before installing a new oil seal, apply a small amount of lubricating grease (such as the recommended grease in the manual) to the lip to prevent dry friction.

Pay attention to the installation direction: The sealing lip of the oil seal should face the lubricating oil side.

7.3 Key strip replacement points

The specification labeling format for the key bar in the manual is "width x height x length [tolerance level]", such as 8 x 7 x 30 C representing a width of 8mm, height of 7mm, length of 30mm, C-shaped key (round head flat key).

When replacing the key strip, check whether the keyway is deformed or worn.

The new key strip should be able to slide smoothly into the keyway without being too tight or too loose.

Suggestions for spare parts ordering process

Record complete information on the nameplate: model, serial number, manufacturing date.

Determine the damaged part number: refer to the manual explosion view and spare parts list.

Check the specifications of the new parts: Ensure that the model, size, and tolerance level are consistent with the original.

Prioritize the use of original spare parts: The manual clearly warns that non original spare parts will void the warranty and may pose safety hazards.