Bonfiglioli 300 series reducer installation, maintenance, and troubleshooting guide

3.3 Compatibility Scheme for Two LTS Oil Products

The equipment is filled with anti-corrosion protective fluid (non lubricating oil) inside when it leaves the factory. According to the type of lubricating oil that the customer plans to use in the future, LTS is divided into two options:

Scheme A - SLM (LTS_Small Oil Compatible)

Corrosion protection fluid is compatible with all mineral oil-based lubricants

Applicable oils include Shell Omala S2 GX, Mobilgear XMP, etc

Operation: Directly add compatible mineral oil lubricant to the specified oil level, and install the matching breathable plug

Scheme B - SLP (LTS_SPEG oil compatible)

Anti corrosion protective solution compatible with all PAG (polyethylene glycol) synthetic oils

Applicable oils include Shell Omala S4 WE, Mobil Glygoyle, Castrol Alphason PG, etc

Operation:

Drain the anti-corrosion protective solution

Add approximately 20% of compatible lubricating oil to the horizontal installation position

Perform a no-load 'cleaning operation' to fully wet the interior with oil and flush out residual protective fluid

Drain the cleaning oil

Add sufficient compatible lubricating oil to the specified oil level

Key restriction: Neither LTS option shall be used for equipment that uses Food Grade lubricants.

Technical points of key installation processes

4.1 General Preparation Before Installation

Thoroughly clean: Remove all packaging materials and rust resistant protective layer residues, paying special attention to mating surfaces.

Nameplate verification: Confirm that the nameplate data is consistent with the order, especially the mounting position identification. For ATEX equipment, changing the installation location must be authorized by Bonfiglioli's technical department in advance, otherwise ATEX certification will be invalidated.

Base inspection: The installation structure must be sturdy enough to withstand the weight and operational stress of the equipment.

Flatness requirement: When installing the footrest, the flatness error of the base should not exceed 0.2mm/100mm.

4.2 Flanged Execution

Flange installation is the most common installation method for the 300 series. Key operational points:

Collaborative flange processing: The mating flange on the user side must be machined to ensure flatness.

Output shaft connection:

For the 300-307 series with external spline output shaft, the output shaft needs to be inserted into the internal spline hole on the user end.

For the 309-321 and 310M-318M series, when the radial load exceeds 60% of the allowable radial load Rn ₂, it is recommended to use spigot positioning to reduce the deflection deformation at the end of the output shaft.

Tightening bolts: The bolt specifications, quantity, and tightening torque table provided in the manual must be followed. For example, the 300 series flange installation bolts are M10 × 8, with a tightening torque of 85Nm and a strength grade of 12.9.

4.3 Shrink Disk Installation - The Most Error prone Step

For the installation method of the hollow shaft belt tightening disc, the following operational details directly affect the transmission reliability:

Preparation before installation:

Clean and degrease the mating surfaces of the hollow shaft inner hole of the gearbox and the outer circular mating surface of the user shaft

Lightly apply lubricating oil on the outer surface of the tightening disc (note: not the mating surface)

Installation sequence (300-313 and 310M-313M series):

Pre install the tightening disc onto the gearbox shaft

Pre tighten 3 bolts in a triangular pattern (such as positions 1-5-9) first

Insert the gearbox into the user's shaft

Tighten the bolts in a circular motion until all bolts reach the specified torque

Installation sequence (314-325 and 314M-318M series):

First, tighten the 4 evenly distributed bolts (such as 1-7-4-10) with 50% torque in a cross pattern

Cross tighten the other 4 evenly distributed bolts (such as 2-8-5-11) with 100% torque

Finally, tighten all bolts continuously to the specified torque, ensuring that there is no relative movement between the inner and outer rings

Prohibited item: Do not use molybdenum disulfide or other lubricating grease to apply to the mating surface, otherwise it will reduce the friction coefficient and cause the tightening disc to fail to provide the rated clamping force.

Dismantling method:

Gradually loosen the fastening bolts along the circumference, and do not completely unscrew them to prevent the ring from suddenly popping open and injuring people

If it still cannot be detached, you can use the 1/8 "BSP or 1/4" BSP oil injection hole reserved on the tightening plate to inject high-pressure oil to assist in disassembly (316-319 uses 1/8 ", 323-325 uses 1/4")

4.4 Breathable plug replacement - a safety action often overlooked

At the factory, the top of the equipment is equipped with a closed plug for transportation. Before the device is powered on, the user must replace it with the Vented plug that comes with the box. Forgetting to replace can lead to the accumulation of pressure inside the box as the temperature rises, ultimately damaging the oil seal, causing oil leakage and lubrication failure.