Bondioli&Pavesi 399CEBR15_A: instruction

BP COMPONENTES HIDRÁULICOS E MECÂNICOS

CAXIAS DO SUL - RS - BRASIL

MADE IN BRAZIL

399CEBR015/A



BP COMPONENTES HIDRÁULICOS E MECÂNICOS

CAXIAS DO SUL - RS



MADE IN BRAZIL

G1 G2 G4 G5 G7

2013 2014 2015 2016

399FXBR05

1

ROTATING DRIVE SHAFT

CONTACT CAN CAUSE DEATH

KEEP AWAY!

DO NOT OPERATE WITHOUT-

ALL DRIVELINE GUARDS, TRACTOR

AND EQUIPMENT SHIELDS IN PLACE

DRIVE SHAFT SECURELY

ATTACHED AT BOTH ENDS

DRIVE SHAFT GUARDS THAT TURN

FREELY ON DRIVE SHAFT

READING OPERATOR’S MANUAL

DO NOT USE PTO ADAPTORS

399141000

Cod 399141000

33

BP COMPONENTES HIDRÁULICOS E MECÂNICOS

CAXIAS DO SUL - RS

MADE IN BRAZIL

G1 G2 G4 G5 G7

2013 2014 2015 2016

399CEBR05

Cod 399CEBR05

Cod 399USR05

2 255

4

8

5

9

6

10

L

L

1/2 L

7

11

3

12

16

13

17

14

18

15

19

4

20

24

21

25

22

26

23

27

5

28

32

29

33

30

34

31

35

6

36

37

T

80

80

T

7

42

43

44

45

8

38

39

40

41

47

48

49

9

46

50

51

52

53

ENG

NOMINAL POWER Pn and NOMINAL TORQUE Mn

-1

-1

540 min

1000 min

Pn Mn Pn Mn

kW CV-HP-PS N∙m kW CV-HP-PS N∙m

G1 12 16 210 18 25 172

G2 15 21 270 23 31 220

G3 26 35 460 40 55 380

G4 26 35 460 40 55 380

G5 35 47 620 54 74 520

G7 47 64 830 74 100 710

G8 61 83 1080 96 130 917

All rotating parts must be shielded.

5

The tractor master shield, the driveline guard, and the implement shield all

work together for your safety.

Do not operate without all driveline, tractor and implement shields in place.

6

Damaged or missing parts must be repaired with original spare parts or

replaced before using the driveline. The driveline must be securely attached at

both ends. Guards must turn freely on the driveline.

Disengage the PTO, turn off the tractor engine, remove the key and ensure

7

that all rotating parts have stopped before approaching the implement or

performing maintenance work.

Keep clear of the work area and rotating parts. Do not wear loose clothing,

8

jewelry, or hair that could become entangled with the driveline. Contact with

rotating parts can cause serious injury or death.

Do not stand on the driveline. Do not step over, or go under, the driveline.

9

Telescoping tubes must always overlap by at least 1/2 of their length in normal

10

operation and at least 1/3 of their length in all working conditions. During

maneuvers, when the driveline is not rotating, the telescoping tubes must have a

suitable overlap to maintain the tubes aligned and allow them to slide freely.

Use STATIONARY MACHINERY (pumps, elevators, generators, dryers, etc.)

11

only when hitched to the tractor.

Brake the tractor, placing blocks under the wheels if necessary. The tractor must

be hitched to the implement and positioned so that the angles of the joints are

minimal and equal.

CARDAN JOINTS

12

When operating, ensure that joint angles are small and equal: a1 = a2.

During turns or other short duration maneuvers, the maximum recommended joint

angle is 45°. Disengage the PTO if the angles are too large or not identical.

CONSTANT VELOCITY JOINTS

13

For normal operations, it is best to keep the CV joint aligned or with the

smallest joint angle possible. During turns or other short duration maneuvers, the

maximum joint angle is 50°, 70° (Constant Velocity Joint 652) or 80° according to

the design of the CV joint. When the driveline includes a CV joint on the tractor side

and a single U-joint on the implement side, the maximum recommended angles of

-1

-1

the U-joint are 16° at 540 min

and 9° at 1000 min

to avoid drive irregularities.

16

ENG

When used at night or in poor visibility, illuminate the driveline operating

14

area.

Friction clutches may become hot during use. Do not touch! Keep the area

15

around the friction clutch clear of any material which could cause a fire and

avoid prolonged slipping of the clutch.

INSTALLATION

Always wear adequate safety equipment when performing any maintenance

16

or repair work.

The tractor stamped on the shield indicates the tractor end of the driveline.

17

Any torque limiter or overrunning clutch should always be installed on the

implement end.

Ensure that the driveline is securely attached to the tractor and the implement

18

before operating.

Check that all fixing screws are tight.

Attach the driveline guard restraints (chains). Best results are achieved when

19

chains are attached nearly perpendicular to the driveline guard. Adjust the

length of the chains to allow enough slack for full movement of the driveline during

turns, operation, and transport. Avoid excessive slack, which could cause the

chains to roll around the driveline.

If the length of the chain is not adjusted correctly and tension is excessive,

20

for example during implement maneuvers, the “S” hook will detach from the

locking ring and the chain will disconnect from the shield.

In this case, the chain must be replaced.

The “S” hook of the new chain must be inserted in the eye of the base cone and

it must be closed to prevent it from becoming disengaged, maintaining its round

shape.

If the length of the chain with device for separation from the base cone is

21

not adjusted correctly and chain tension increases excessively, for example

during implement maneuvers, the spring hook will detach from the locking ring and

the chain will disconnect from the shield.

In this case, the chain is easily reconnected as described in the following procedure.

Open the retaining ring, unscrewing the screw and moving the plate.

22

Insert the chain in the locking ring and reposition the plate.

23

Close the plate by means of the screw.

24

Never use the safety chains to transport or support the driveline when you

25

have finished using it for storage. Always use the support provided on the

implement.

Clean and grease the tractor PTO and implement shaft before installing the

26

driveline.

Keep the driveline horizontal during handling to prevent the halves from

27

sliding apart, which could cause injury or damage the shielding. Use suitable

means to transport heavy drivelines.

17

ENG

PUSH-PIN

28

Push the pin and slide the yoke onto the PTO shaft so that the pin engages

the groove on the PTO. Make sure that the pin returns to its initial position after

attachment to the shaft.

BALL COLLAR

29

Align the yoke on the PTO. Slide the collar to the open position. Slide the

yoke onto the splined shaft. Release the collar and pull or push the yoke along the

shaft until the balls engage the groove and the collar returns to its original (closed)

position. Make sure the collar returns to its initial (closed) position and the yoke is

properly attached to the shaft.

AUTOMATIC BALL COLLAR

30

Pull the collar back until it locks in the open position. Use both hands to slide

the yoke onto the shaft - the collar will automatically unlock. Push or pull the yoke

along the shaft until the balls engage the groove and the collar returns to its original

(closed) position. Make sure the collar returns to its initial (closed) position and the

yoke is properly attached to the shaft.

TAPER PIN

31

Slide the yoke onto the PTO and insert the pin so that the tapered profile fits

into the groove on the shaft.

Recommended tightening torque:

- 150 Nm (110 ft lbs) for 1 3/8” Z6 or Z21 spline.

- 220 Nm (160 ft lbs) for 1 3/4” Z6 or Z20 spline.

Use only Bondioli & Pavesi taper pins for replacements.

CLAMP BOLT

32

Slide the yoke onto the PTO and insert the bolt.

Recommended tightening torque: - 90 Nm (65 ft lbs) for M12 bolts;

- 140 Nm (100 ft lbs) for M14 bolts.

SHEAR PINS

33

Use only bolts of the size and class shown in the implement handbook.

Choose the bolt length in such a way as to minimize protrusion.

LUBRICATION

Always wear adequate safety equipment when performing any maintenance

34

or repair work.

Replace worn or damaged parts with genuine Bondioli & Pavesi spare parts.

35

Do not modify or tamper with any part of the driveline. For any operations not

explained in this instruction manual, consult your implement dealer or manufacturer,

or your local Bondioli & Pavesi representative.

LUBRICATION OF TELESCOPING TUBES

36

If grease fittings are not provided, separate the two halves of the driveline,

and manually lubricate the telescoping tubes.

18

ENG

Check that all components are in good condition and properly lubricated

37

before using the driveline. Clean and lubricate the driveline at the end of

seasonal use. Lubricate each part after the number of hours shown on the chart.

The amounts of grease indicated in the manual are recommended for an interval of

50 hours. Particularly severe applications in an aggressive environment may

require lubrication more frequently than at 50-hour intervals.

Amounts indicated in grams (g). 1 ounce (oz.) = 28.3 g (grams).

Pump grease into the crosses until it purges from the bearing caps.

Inject the grease gradually and avoid pumping the grease gun violently with

resulting high delivery pressure. Use NLGI grade 2 grease.

Before storage at the end of the season remove any grease that has accumulated

inside the CV joint shield.

LUBRICATION OF THE 80° CONSTANT VELOCITY JOINT

38

Align the holes in the CV shield with the grease fittings of the crosses and of

the central body of the constant velocity joint. The grease injected into the body

of the constant velocity joint also lubricates the shield support ring through an

internal channel. Every 50 hours, inject at least the amount of grease indicated in

the table in point 37.

TORQUE LIMITER AND OVERRUNNING CLUTCH

RA - OVERRUNNING CLUTCH.

39

This device prevents transmission of inertial loads from implement to the

tractor during deceleration or stopping of the PTO.

Keep clear of the implement until all parts have stopped moving. Lubricate

every 50 hours of use and after storage.

SA - LN RATCHET TORQUE LIMITER.

40

This device interrupts the transmission of power when the torque exceeds

the setting.

Immediately disengage the PTO when ratcheting sounds are heard.

Lubricate every 50 hours of use and after storage.

LB – SHEAR BOLT TORQUE LIMITER.

41

This device interrupts the transmission of power by shearing a bolt when the

torque exceeds the setting.

Replace the sheared bolt with the same diameter, length and grade as the original.

Lubricate the LB limiters with grease fittings at least once every season and after a

period of disuse.

LR - AUTOMATIC TORQUE LIMITER

42

Interrupts power transmission when the torque exceeds the set value.

During the intervention of the device, power transmission is interrupted but it may

be automatically resumed by running the driveline at a low speed after having

removed the blockage.

This device is sealed - no additional lubrication is required.

GE – SHOCK ABSORBING CLUTCH

43

Absorbs shock loads and vibrations, and smoothes transmission of an

alternating or pulsating load. No maintenance is required.

19

ENG

FRICTION TORQUE LIMITERS

Check the condition of the friction linings when installing the clutch or after periods

of storage.

• If the edges of the clutch plates are exposed (see g. 44) the clutch is either type

FV with Belleville spring or FFV with helicoil springs. Measure and record the spring

height as shown in gure 45. If the clutch plates are covered by a metal band (see

gure 46) the clutch is type FT.

If the clutch discs are exposed and the bolts have cap nuts, the clutch is of

the FK type.

Following seasonal use, relieve the spring pressure and keep the clutch in a dry

place. Check the condition of friction disks and restore spring pressure before

using the clutch. If the clutch overheats due to frequent or prolonged slipping,

consult your equipment dealer or manufacturer, or your local Bondioli & Pavesi

representative.

FV – FRICTION TORQUE LIMITER.

44

The torque transmitted to the implement is limited by allowing the clutch

plates to slip relative to each other. Torque peaks or short duration overloads are

limited when the clutch is used and adjusted properly.

It can be used as an overload clutch, or to help start implements with high inertial

loads.The torque setting is adjustable by adjusting the working height of the spring.

The edges of the linings and plates are exposed in an FV clutch.

The torque setting is adjusted by increasing or decreasing the height “h”

45

of the springs. To increase/decrease the torque setting tighten/loosen the

eight nuts by 1/4 of a turn and check for correct operation. Repeat the procedure if

necessary. Avoid excessive tightening of the bolts - implement, tractor, or driveline

damage may occur.

FT - FK FRICTION TORQUE LIMITERS

46

The torque transmitted to the machine is limited by allowing the clutch plates

to slip relative to each other. Torque peaks or short duration overloads are limited

when the clutch is used and adjusted properly. It can be used as an overload

clutch, or to help start implements with high inertial loads. The FT has a metal

band around its circumference. The bolts should be tightened until the metal band

around the circumference of the clutch touches the spring, then loosen each nut

by 1/4 turn. Avoid excessive tightening of the bolts - implement, tractor, or driveline

damage may occur.

The FK clutch has bolts with cap nuts. The spring compression is correct

when the nuts are fully screwed on. Use only special B&P bolts and nuts.

If the clutch has four socket head set screws in addition to the eight hex

47

head bolts on the ange yoke, it is equipped with the Spring Release system.

Spring pressure is relieved when these four set screws are screwed into the ange

yoke. See the instruction leaet enclosed with clutches with the Spring Release

system installed. The Spring Release System enables checking of the condition

of the friction clutch and reduces spring pressure on the disks during storage.

Friction clutches equipped with the Spring Release System are supplied with

an additional instruction sheet. Read this information for proper use of the

Spring Release System.

FFV - FRICTION TORQUE LIMITER

48

The torque transmitted to the implement is limited by allowing the clutch plates to

slip relative to each other. Torque peaks or short duration overloads are limited when the

clutch is used and adjusted properly. It can be used as an overload clutch, or to help start

20

ENG

implements with high inertial loads.The torque setting is adjustable by adjusting the working

height of the springs.The edges of the linings and plates are exposed in an FFV clutch.

The torque setting is adjusted by increasing or decreasing the height “h”

49

of the springs. To increase/decrease the torque setting tighten/loosen the

eight nuts by 1/4 of a turn and check for correct operation. Repeat the procedure if

necessary. Avoid excessive tightening of the bolts - implement, tractor, or driveline

damage may occur.

FNT - FNV - FFNV - FNK COMBINATION FRICTION AND OVERRUNNING

50

CLUTCH Clutch that combines the functional characteristics of a friction

clutch and an overrunning clutch. Used on machines with high inertial loads.

Keep clear of the implement until all parts have stopped moving.

Lubricate every 50 hours of use and after storage.

Friction clutches may become hot during use. Do not touch! To avoid the

51

risk of fire keep the area around the clutch free of inflammable material and

avoid prolonged slipping of the clutch.

SHIELD DISASSEMBLY

Remove the Philips head screws.

52

Remove the base cone and the shield tube.

53

Remove the outer cone and the bearing ring.

54

SHIELD ASSEMBLY

Grease the bearing groove on inner yokes.

55

Fit the bearing ring into the groove with the reference pin facing the drive

56

tube.

Fit the outer cone, inserting the reference pin of the bearing in the hole

57

provided in the cone.

Fit the base cone with the tube, inserting the reference pin and the grease

58

tting of the bearing in the holes provided in the cone.

Tighten the Philips head screws.

59

Use of electric powered screwdrivers is not recommended.

CV JOINT SHIELD DISASSEMBLY

Remove the screws arranged radially around the circumference of the CV

60

cone.

Remove the screws from the base cone.

61

Remove the base cone and the shield tube.

62

Remove the CV cone.

63

21

ENG

Disengage the retaining spring, leaving it inserted in one of the two holes of

64

the bearing ring to avoid losing it.

Spread the bearing rings and remove from their groove.

65

CV JOINT SHIELD ASSEMBLY

Grease the seats and install the shield support bearings.

66

Fit the bearing ring onto the inner yoke with the reference pin facing the

drive tube.

Install the bearing ring on the CV body with the reference pins facing the

67

inner yoke. The bearing ring is equipped with a grease tting, used only for

50° CV joints. This grease tting is not used with 80° CV joints.

Connect the retaining spring to the two edges of the bearing ring.

68

Insert the shield aligning the radial holes with the reference pins of the bearing

69

ring and the hole on the bottom with the reference pin of the small bearing.

The grease tting of the bearing must be aligned with the holes on the shield.

Check that the radial holes in the shield are aligned with the holes in the

70

reference pins of the bearing ring and that the reference pin is inserted.

Tighten the 6 anged screws of the shield. Use of an electric screwdriver is not

recommended.

Fit the base cone with the tube, inserting the reference pin of the bearing in

71

the hole provided in the base cone. The grease tting of the bearing is in the

hole of the base cone.

Tighten the 3 screws. Use of electric powered screwdrivers is not recommended.

72

HOW TO SHORTEN THE DRIVE SHAFT

Bondioli & Pavesi advises against altering its products. If modifications are required,

we recommend that you consult your implement dealer or a qualified service center

before proceeding. If the driveline is too long adopt the following procedure.

Remove the shielding.

73

Shorten the drive tubes by the required length.

74

Telescoping tubes must always overlap by at least 1/2 of their length in

normal operation and at least 1/3 of their length in all working conditions.

During maneuvers, when the driveline is not rotating, the telescoping tubes must

have a suitable overlap to maintain the tubes aligned and allow them to slide freely.

Carefully deburr the ends of the tubes with a file and remove all filings from

75

the tubes.

Shorten shield tubes one at time by cutting the same length that was cut

76

from the drive tubes.

22

ENG

Grease the internal drive tube and reassemble the shielding on the driveshaft.

77

Check the length of the driveshaft at its minimum and maximum extensions

78

on the implement.

TROUBLESHOOTING

WEAR OF YOKE EARS

79

EXCESSIVE WORKING ANGLE

• Reduce the working angle.

• Disengage PTO when joint angle exceeds 45°.

DEFORMATION OF YOKES

80

EXCESSIVE TORQUE PEAK OR SHOCK LOAD

• Avoid overloading or engaging PTO when under load.

• Check the efficiency of the torque limiter.

CROSS ARM BROKEN

81

EXCESSIVE TORQUE PEAK OR SHOCK LOAD

• Avoid overloading or engaging PTO when under load.

• Check function of torque limiter.

ACCELERATED WEAR OF CROSS ARMS

82

EXCESSIVE LOAD

• Do not exceed the speed or power limits indicated in the instruction manual.

INSUFFICIENT LUBRICATION

• Follow instructions in point 37.

SEPARATION OF TELESCOPING TUBES

83

EXCESSIVE EXTENSION OF DRIVELINE

• Do not extend driveline to the point that the tubes separate.

• For stationary machinery, position the tractor so the telescoping tubes overlap

as illustrated in point 10.

TWISTING OR BENDING OF TELESCOPING TUBES

84

EXCESSIVE TORQUE PEAK OR SHOCK LOAD

• Avoid overloading or engaging PTO when under load

• Check the efficiency of the torque limiter.

• Check that driveline does not come into contact with tractor or implement

components during manoeuvres.

ACCELERATED WEAR OF TELESCOPING TUBES

85

INSUFFICIENT LUBRICATION

• Follow instructions in the chapter on Lubrication

INSUFFICIENT TUBE OVERLAP

• See instructions in point 10.

PREMATURE WEAR OF THE PROTECTIVE BEARINGS

86

INSUFFICIENT LUBRICATION

• Follow the instructions in point 37.

RESTRAINT CHAIN NOT CORRECTLY FIXED

• See instructions in point 19.

All the plastic parts of Bondioli & Pavesi drivelines are totally recyclable.

87

Protect the environment by disposing of used plastic parts properly at the

time of replacement.

23