Bonfiglioli AS Series Reducer Installation and Maintenance Guide

Oil temperature<65 ℃: mineral oil for 8000h, synthetic oil for 25000h.

Oil temperature of 65-80 ℃: mineral oil for 4000h, synthetic oil for 15000h.

Oil temperature 80-95 ℃: Mineral oil for 2000h, synthetic oil for 12500h (continuous operation is not recommended in this range).

Practical suggestion: The liquid level of the dipstick or oil sight glass should be checked after operation. For AS 45 and above models, if the LO (with oil) option is selected, the Dummy Plug installed during transportation must be replaced with the included Breather Plug before formal use. In addition, when flushing or changing oil, please be sure to clean the metal powder adsorbed by the magnet on the drain plug, which is the most intuitive basis for judging the degree of gear wear.

Temperature control and vibration acceptance: beyond the practical standards of the manual

1. The "75 ℃ Red Line" for surface temperature rise

On pages 11 and 27 of the manual, it is repeatedly mentioned that the difference between the surface temperature (t_casting) and the ambient temperature (t_ambient) measured at the box closest to the motor joint surface shall not exceed 75 ℃. If the temperature difference approaches or exceeds this value after running at full load for 3 hours, the machine must be stopped immediately.

Typical solution: If the temperature difference is too large, the gearbox should not be suspected of overload immediately. Instead, it should be checked first:

Whether the environmental ventilation is obstructed (especially for outdoor installations with ceilings).

Has it been exposed to external heat source radiation.

Is the viscosity of the oil too high (according to the fault table on page 34 of the manual, high viscosity can cause a sharp increase in operating resistance and temperature).

2. Quantitative determination of noise and vibration

Noise: According to page 24 of the manual, the allowable meshing noise during load operation measured at a distance of 1 meter is 85 dB (A). Any sharp periodic abnormal noise may be a precursor to tooth surface damage or bearing pitting.

Vibration: The acceptance limit for vibration velocity (r.m.s.) depends on the shaft speed. For example, at a speed of 1500 r/min, the boundary of Zone B/C is 5.3 mm/s. If the vibration exceeds the standard, first check the alignment of the coupling, including axial clearance (Gap) and radial misalignment.

Comprehensive troubleshooting: quick investigation of causes and countermeasures

Based on the fault tree on page 34 of the manual (TROUBLESHOOTING), combined with practical cases, we have organized the logical chain of high-frequency faults:

Fault phenomenon 1: Rapid increase in bearing temperature (accompanied by metal friction sound)

Possible reasons: Insufficient lubrication due to low oil level, or fatigue peeling of the bearing itself.

Action plan: If the temperature still rises after refueling, it is necessary to disassemble and inspect the bearings. Remember the suggestion on page 28 of the manual: replace the other bearing on the same shaft to balance the wear cycle.

Fault phenomenon 2: The output shaft does not rotate, but the motor is running

Logical chain: This is almost certainly due to the connection key being cut or the gear tooth breaking.

Root cause analysis: In addition to material fatigue, the actual load torque (Required Torque M2) usually exceeds the design rated torque (Rated Torque Mn2) by more than twice.

Repair Red Line: Page 22 of the manual clearly states that the redesigned transmission system must match the actual load, and simply replacing the gears is ineffective.

Fault phenomenon 3: Normal operating noise, but oil leakage on the joint surface of the box body

Neglected detail: Most oil leaks are not caused by aging sealing rings, but by blockage of breathable plugs leading to excessive pressure inside the box, squeezing oil out of the labyrinth seal.

Quick disposal: Check if the one-way valve of the breathable plug is blocked by oil or paint, and clean or replace it if necessary.

Anti corrosion strategy for long-term shutdown

If the gearbox needs to be shut down for more than a month (such as seasonal production), simply shutting it down is not enough. Warning on page 28 of the manual:

Regular turning: Run at least once a month to re-establish the oil film on the bearings and gears.

Rust prevention protection: If turning is not possible, the box must be filled with new oil of the same model (instead of the normal oil level) to isolate moisture; Alternatively, apply anti rust wax such as Shell Ensis SX to the exposed shaft end on the outside.

Be cautious of condensation water: Changes in temperature can cause water vapor to condense and mix into the oil. On page 30 of the manual, it is required to check for Contaminants, especially water, in the oil every 2000-9000 hours. If the water content exceeds the standard, it must be replaced even before the oil change cycle.