Bonfiglioli A-series gearbox selection and maintenance

5. Rust prevention and protection

Clean the mating surface and apply an antioxidant (such as Mobilarma 248) before installation.

When painting, it is necessary to protect the oil seal lip and processing surface to prevent the paint from hardening and causing seal failure.

Lubrication Management and Maintenance Strategy

The A-series small machine bases (A102~A303) use synthetic oil for lifelong lubrication (long life), without the need for oil change; Other models require users to add mineral oil or synthetic oil.

1. Lubricating oil selection

According to the ambient temperature and load, refer to Table A3: ISO VG 150 mineral oil or ISO VG 150 synthetic oil is used for light loads (0-20 ℃); Medium load (20-40 ℃) using ISO VG 220 or 320; Overload recommendation ISO VG 400/460.

Mineral oil and synthetic oil cannot be mixed.

2. First oil change cycle

After running for about 300 hours for the first time, the lubricating oil should be replaced and the interior should be rinsed with a cleaning agent to remove wear particles during running in.

Then divided by oil temperature: when the oil temperature is below 65 ℃, change the oil every 8000 hours; 4000 hours at 65-80 ℃; 2000 hours at 80-95 ℃ (synthetic oil can be extended to 15000-25000 hours).

3. Oil level inspection

Regularly check the oil level through the oil level plug (the gearbox must be in the correct installation position). If the oil level is low, add oil of the same brand and model.

4. Long term storage protection

If stored for more than 60 days, the processing surface needs to be coated with rust proof oil; After more than 6 months, the ventilation plug should be placed at a high position and filled with an appropriate amount of oil (if not pre filled before leaving the factory). Before use, replace it with the correct amount and viscosity of oil.

Radial load and axial load verification

The manual provides a complete radial load calculation method to ensure the service life of the shaft and bearings.

1. Radial load calculation

Determined by the transmitted torque M ₁ (input) or M ₂ (output), sprocket/gear/pulley pitch diameter d, and load factor K ᵣ (sprocket K=1, gear K=1.25, V-belt K=1.5~2.5):

R꜀ = (2000 × M × Kᵣ) / d [N]

2. Allow radial load

The selection tables in the manual provide the allowable radial loads R ₙ₁ (input shaft) and R ₙ₂ (output shaft) at the midpoint of the standard shaft extension. If the load application point is not at the midpoint (x from the shoulder), it needs to be converted according to the formula:

R ₓ=R ₙ× a/(b · x) (where x<c, a, b, c are constants, refer to Table B8)

Verification condition: R ꜀ ≤ R ₓ.

3. Axial load

Allowable axial load A ₙ=0.2 × R ₙ (input or output). If the axial load is large or acting simultaneously with the radial load, contact the technical department.

Engineering Tip: If the allowable radial load of the selected model is insufficient, you can choose the option of reinforced bearings (A series can choose "Reinforced bearings"), or increase the machine base size.

Thermal power and heat dissipation verification

For continuous operation or high ambient temperature conditions, it is necessary to verify the thermal power P ₜ of the reducer (Table B15). When the mechanical input power exceeds P ₜ, auxiliary heat dissipation measures (such as forced fans, cooling coils) need to be taken. The manual provides the thermal power values of each machine base in the A series at different input speeds, for example, A102 has a P ₜ=3.5 kW at 1400 min ⁻¹ and 3.0 kW at 2800 min ⁻¹.

Verification: If the actual transmitted power P ₁>P ₜ, a larger machine base or additional cooling device needs to be selected.

Anti run back option

For inclined conveyors or elevators, an optional backstop (option AL or AR) can be installed to prevent the output shaft from reversing. The manuals B10a and B10b specify the applicable machine bases (A102 to A904) and their corresponding rotation directions. When placing an order, the rotation direction should be specified (AL is counterclockwise, AR is clockwise, observe the output shaft end). If not specified, default AR.

Attention: The backstop is only suitable for unidirectional rotation and cannot be used to prevent reverse rotation caused by electrical reverse connection.

Common troubleshooting reference

Phenomenon 1: High oil temperature (>95 ℃)

Check if the oil level is too high or too low; Check if the thermal power exceeds the standard; Confirm if the ambient temperature exceeds 40 ℃ (with a derating of 2.5%/K required).

Check for external heat source radiation or poor ventilation.

Phenomenon 2: Oil leakage from the output shaft

Check whether the oil seal is aging or the shaft neck is worn; Confirm if the ventilation valve is blocked, causing an increase in internal pressure; Verify if the installation orientation is correct (incorrect oil plug position configuration).

When replacing the oil seal, be sure to protect the shaft neck to avoid scratches.

Phenomenon 3: Abnormal vibration or increased noise

Check if the anchor bolts are loose; Check if the coupling alignment exceeds the tolerance; Check if the gears are damaged due to overload or foreign objects entering.