Installation, Maintenance, and Troubleshooting Guide for Bonfiglioli HDP/HDO Series Heavy duty Gearboxes

ATEX requirement: When reinstalling the protective cover, apply Loctite 5366 to the centering and end fitting surfaces, and Loctite 510 to the bolt threads.

Disassembly tip: If disassembly is difficult, you can use the oil pressure injection hole (1/8 "or 1/4" BSP) on the gearbox to inject pressurized oil for assistance.

Special requirements for ATEX explosion-proof environment

For gearboxes designated for use in potentially explosive environments, the following requirements must be strictly followed:

Only synthetic lubricants (PAG or PAO) are allowed, mineral oils are not suitable.

Only fluororubber (Viton) is allowed to be used ®） Sealing element.

All external bolts and plugs must be coated with thread locking adhesive.

Equipped with breathable plugs with anti intrusion valves.

Install irreversible thermal sensors (TG or PT100) to monitor oil temperature.

Regular cleaning plan: Gearboxes installed in zones 21/22 must undergo regular cleaning to prevent dust accumulation exceeding 5mm.

After installation, thoroughly clean the gearbox and ensure that all protective devices are installed in place.

Only install motors with ATEX rating not lower than the gearbox.

The motor shall not exceed the maximum input speed of the gearbox (1500 min ⁻¹).

Lubrication management

1. Lubricating oil selection

Only use lubricants recommended by the manufacturer (synthetic oil PAG/PAO or mineral oil with EP additives).

It is strictly prohibited to mix different brands or specifications of oil products.

Recommended synthetic oil brands include Shell Omala S4 WE (PAG), Shell Omala S4 GVX (PAO), Mobil SHC Gear, Kl ü bersynth GH 6, etc.

2. 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

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.

3. 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 oil level table in the manual. The table data is for reference only, and the actual value is based on the oil level plug mark or the midpoint of the oil gauge.

4. Replacement of breathable plug

The gearbox is equipped with a closed transport plug when it leaves the factory. Before formal operation, it must be replaced with the breathable plug that comes with the box, otherwise the internal pressure will increase and cause damage to the oil seal.

Auxiliary cooling/heating system configuration

1. Compulsory ventilation (FANL/FANR/FANLR - FAN/FANJ)

The fan is directly installed on the input shaft and protected by a protective cover.

It is strictly prohibited to operate the gearbox without installing the fan protective cover.

When the input speed is below 900 min ⁻¹, the forced ventilation efficiency significantly decreases, and auxiliary cooling devices need to be considered.

Regularly clean the dust on the fan blades and protective grille.

2. Independent cooling units (MCRW.../MCRA...)

MCRW (water oil cooler): equipped with electric pump, filter, water oil heat exchanger, solenoid valve, and temperature controller. Cooling water temperature ≤ 20 ° C, maximum pressure 10 bar.

MCRA (Air Oil Cooler): Equipped with an electric pump, filter, air oil heat exchanger, and fan. Ensure at least 1 meter of free space around the heat exchanger to ensure air circulation.

Control logic: Start cooling when the oil temperature reaches 60 ° C; Trigger an alarm and shut down as soon as possible when reaching 90 ° C.

ATEX components: Please refer to the manufacturer's separate catalog and manual.

3. Cooling coil (SR)

Non removable cooling coil installed in the gearbox oil tank.

Cooling water temperature ≤ 20 ° C, maximum pressure 8 bar. Flow requirement: HDP 60-90 is 5 L/min; HDP 100-140 is 10 L/min.

It is recommended to install a thermostatic valve in the cooling water circuit and only allow water to flow when the oil temperature reaches 70 ° C.

4. Oil heater (HE)

Used when the ambient temperature is too low and the oil viscosity is too high (oil viscosity exceeds 1500 cSt at startup).

The heating element is installed below the oil level, and the standard power supply is 220V AC.

The heater must be turned on only when the oil completely covers the heating element, and should only be used during preheating. It should not be powered on for a long time to prevent oil carbonization.

The thermostat setting temperature is usually 25 ° C ± 5 ° C.

Long Term Stock

For gearboxes with a storage period exceeding 6 months (up to 2 years):

Packaging: The gearbox is sealed in a VpCI rust proof bag, and the outer packaging is a BBOX cardboard box or wooden box labeled "OPEN ONLY BEFORE THE INSTALLATION".

Rust proof fluid: Add anti-corrosion protective fluid internally instead of standard lubricating oil.