Installation, Maintenance, and Troubleshooting Guide for Bonfiglioli 300/300M Series Gearboxes

Dust environment cleaning: Gearboxes installed in zones 21/22 must develop and implement regular cleaning plans to prevent dust accumulation exceeding 5mm.

Oil level check: ATEX gearboxes installed vertically are usually equipped with expansion chambers and dedicated oil level check rods. During inspection, the inspection rod should be placed at the edge of the threaded hole to ensure that the oil level is not lower than 3mm below the overflow port.

Motor installation: Only motors with ATEX rating equal to or higher than the gearbox can be installed, and the compliance of the entire machine after installation is the responsibility of the final assembler.

Lubrication management

1. Lubricating oil selection

Choose the appropriate type and viscosity of lubricating oil based on work schedule and environmental temperature:

Industrial applications: Mineral oil (EP additive), PAO synthetic oil, or PAG synthetic oil can be selected. Specific recommended brands can be found in the manual charts (Shell, Mobil, Total, etc.).

Mobile machinery: Select according to SAE grade (80W/90, 85W/140) and API GL5 grade.

2. Oil filling

The gearbox does not contain lubricating oil when it leaves the factory (unless specifically specified at the time of ordering). Users need to add the corresponding amount of oil according to the installation position on the nameplate and the table in Annex 2 of the manual. The oil level is based on the mark on the oil level plug, and the data in the table is for reference only.

3. Oil change cycle

The oil change interval depends on the type of oil and operating temperature:

Average oil temperature mineral oil PAO synthetic oil PAG synthetic oil

< 65°C 8,000 h 25,000 h 25,000 h

65-80°C 4,000 h 15,000 h 15,000 h

80-95 ° C 2000 h (within 1 year) 12500 h 12500 h

Attention: It is not recommended to operate continuously within the oil temperature range of 80-95 ° C. Oil temperature exceeding 95 ° C is considered a fault state.

Long Term Stock

For gearboxes with an expected storage period exceeding 6 months (up to 2 years), Bonfiglioli offers specialized long-term storage options:

Packaging method: The gearbox is sealed in a VpCI (vapor phase anti rust) bag, and the outside is a BBOX cardboard box or wooden box. The four walls of the box are marked with "OPEN ONLY BEFORE THE INSTALLATION".

Rust proof fluid: Add anti-corrosion protective fluid inside the gearbox instead of standard lubricating oil.

Compatibility:

SLM option: Rust inhibitor is compatible with all mineral oils and PAO synthetic oils.

SLP option: Rust inhibitor is compatible with all PAG synthetic oils.

Pre operation processing:

If the working oil is compatible with the rust inhibitor: simply add the working oil to the specified level and replace the vent plug.

If not compatible: first drain the rust inhibitor, add 20% oil for "cleaning operation", and then add new working oil after draining.

Extended storage period: After 2 years of storage, it needs to be inspected by Bonfiglioli service center before it can be stored for another 24 months.

Installation of hydraulic motor and hydraulic brake

1. Installation of hydraulic motor

There are two sealing methods between the motor installation flange and the gearbox: O-ring sealing or motor built-in sealing.

Clean the positioning stopper and mating surface before installation, apply lubricating grease, install the motor, and tighten the flange bolts (not lower than grade 8.8).

Drain Port: If a leaking oil pipe is connected, the pressure at the shaft seal is equal to the pressure of the leaking pipeline; If closed, the shaft seal pressure is the average of the inlet and outlet pressures. When multiple motors are connected in series, a leaking oil pipe must be connected.

2. Hydraulic brake

The minimum release pressure of the brake is shown in Table 8 of the manual (e.g. about 10 bar for type 4 brake and about 20 bar for type 6 brake), and the maximum pressure does not exceed 320 bar.

The static braking torque (Mbs) is at its maximum value and may decrease slightly under dynamic conditions. The actual value fluctuates between -5% and+15% of the rated value.

Common faults and troubleshooting

Possible causes and solutions for the fault phenomenon

Bearing temperature too high, oil level too low, oil aging, bearing damage, oil replenishment, oil change, contact authorized maintenance

Operating temperature too high, oil level too high, oil aging, impurities in oil. Check oil level, change oil, change oil

Abnormal operation noise, gear damage, excessive axial clearance of bearings, bearing wear, overload, impurities in oil. Contact authorized maintenance, correct load to rated value, oil change

Abnormal noise at the installation site. Loose or worn installation bolts. Tighten and replace bolts according to torque

Oil leakage, high oil level, seal failure, gasket aging. Check the oil level and contact authorized maintenance

The gearbox does not rotate or has difficulty operating. If the oil viscosity is too high, the oil level is too high, the gear is overloaded, or the gear is damaged, replace the recommended oil, check the oil level, redesign the transmission, and contact authorized maintenance