Bonfiglioli 300 series reducer installation, maintenance, and troubleshooting guide

4.5 Installation boundary conditions for motors and hydraulic motors

Installation of electric motor:

If a motor with ATEX rating ≥ gearbox ATEX rating is installed and operated strictly according to the manual, the combination can still maintain ATEX compliance

If the installation operation deviates from the manual requirements, the user needs to conduct a risk analysis on their own

Variable frequency drive scenario: Risk analysis must be conducted, which is a mandatory requirement

Installation of hydraulic motor:

Pay attention to distinguishing between two sealing configurations: the version with O-ring sealing, and ensure that the O-ring is correctly positioned and not damaged during installation; The version that has been pre installed on the coupling for sealing only requires applying lubricating grease to the motor shaft

All fastening bolts must be at least grade 8.8

The minimum release pressure of hydraulic brake refers to the technical parameter table in the manual

Refined operation of lubrication management

5.1 Mandatory lubrication requirements for ATEX equipment

For 300 series equipment that complies with ATEX 2014/34/EU, only synthetic lubricants (including PAO and PAG types) can be used, and mineral oils are explicitly prohibited. This is in stark contrast to non ATEX equipment.

5.2 Lubricating oil replacement cycle

The replacement cycle of lubricating oil depends on the average oil temperature, not just the number of operating hours:

Average oil temperature range Mineral oil replacement cycle PAO Synthetic oil PAG Synthetic oil

T ₀<65 ° C 8000 hours 25000 hours 25000 hours

65 ° C<t ₀<80 ° C 4000 hours 15000 hours 15000 hours

80 ° C<t ₀<95 ° C 2000 hours (within 1 year) 12500 hours 12500 hours

Important note: The manual does not recommend continuous operation within the oil temperature range of 80 ° C to 95 ° C. If the oil temperature is within this range, it is recommended to conduct oil testing every 6 months.

5.3 Oil level inspection method

For horizontal installation: Remove the oil level check plug, insert a specially shaped gauge rod into the hole, ensure that the gauge rod is placed tightly against the edge of the threaded hole, and read the oil level height.

For vertical installation: Use a dipstick to check if the oil level is between the MIN and MAX marks. If the oil level is more than 3mm below the overflow port, it is necessary to replenish the oil and investigate the cause of the oil level drop.

Regular maintenance checklist

According to the manual, the on-site maintenance team should perform inspection tasks at the following frequency:

Check project frequency

Noise and vibration inspection every 24 hours

External condition of the box (pollution, accumulation of oil stains) 170-720 hours

Oil level check for 720 hours

Oil seal leakage inspection for 720 hours

Tightening bolt torque inspection for 2000-4000 hours

Wear inspection of coupling elastic components for 2000~4000 hours

Condition of torque arm polymer liner (aging, cracking) 3000 hours

Axis alignment check every time the oil is changed

ATEX Zone 21/22 special requirements: Users must develop and implement a regular cleaning plan to remove all surface dust accumulation, with a dust depth not exceeding 5mm.

Common troubleshooting checklist

The following is a high-frequency fault, cause analysis, and countermeasures based on the manual:

Possible causes and countermeasures of the fault phenomenon

Bearing temperature too high, oil level too low/oil deterioration/bearing damage, oil replenishment/replacement/contact authorized repair point

Operating temperature too high, oil level too high/oil contamination/oil deterioration Adjust oil level/oil change/oil change

Abnormal operation noise, gear damage/excessive axial clearance of bearings/bearing wear/excessive load/oil contamination. Contact authorized repair point/adjust to rated load/change oil

Abnormal noise in installation position. Loose/worn installation bolts. Tighten/replace bolts according to specified torque

Oil leakage, high oil level/damaged seals/gasket aging, adjust oil level/contact authorized repair point

The reducer does not rotate or has difficulty operating. The oil viscosity is too high/the oil level is too high/the load is too heavy/the gear is damaged. Recommended oil for replacement/oil level adjustment/redesign of transmission plan/contact authorized repair point

Operation specifications for lifting and handling

The lifting method of the 300 series varies depending on the series and specifications, and the manual provides detailed lifting diagrams for different models:

General principle: During lifting, the load deviation should not exceed 15 °, otherwise it should be stopped and restarted

Motor configuration: It is strictly prohibited to use the lifting ring bolts on the motor housing to lift the entire machine, unless explicitly allowed

300L-316L and 310ML-316ML series: Special lifting fixtures are required to ensure that the lifting rings are aligned with the center of gravity

Rated lifting weight: refer to the corresponding sales catalog