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

Compatibility:

SLM option: Rust inhibitor is compatible with all mineral oils and PAO synthetic oils.

SLP option: Rust inhibitor is compatible with all PAG synthetic oils.

Pre operation treatment: If the working oil is compatible with the rust inhibitor, simply add the working oil and replace the breathable plug; If not compatible, first drain the rust inhibitor, add 20% oil for "cleaning operation", and then add new working oil after draining.

After storing for 2 years, it needs to be inspected by Bonfiglioli service center before it can be stored for another 24 months.

Backstop and torque arm

1. Reversing device (A CW/A CCW)

Ensure that the gearbox rotates only in one direction to prevent load reversal.

It is strictly prohibited for the motor to rotate in the opposite direction, otherwise it may damage the backstop or gear system.

When running continuously, it is recommended to input a speed higher than the minimum exceedance speed (n1min) specified in the manual to ensure the normal operation of the centrifugal separation mechanism.

2. Torque arm (TA)

Shaft mounted gearboxes need to be equipped with torque arms to withstand counter torque.

The torque arm must be installed stress free during installation and adjusted according to the specified gap G before starting.

Regularly check the wear of the cup-shaped spring and the condition of the polymer liner (aging, cracking).

Common faults and troubleshooting

Possible causes and solutions for the fault phenomenon

Bearing temperature too high, oil level too low, oil aging, bearing failure, oil replenishment, oil change, contact authorized maintenance

Operating temperature too high, oil level too high, oil aging, oil pollution. Check oil level, change oil, change oil

Abnormal operation noise, gear damage, excessive bearing clearance, bearing wear, overload, contact authorized repair, load correction, oil change

Abnormal noise at the installation site. Loose or worn installation bolts. Tighten and replace bolts according to the specified torque

Oil leakage, high oil level, seal failure, gasket aging. Check the oil level and contact authorized maintenance

The gearbox does not rotate or has difficulty operating. The oil viscosity is too high, the oil level is too high, it is overloaded, the gear is damaged, the oil needs to be replaced, the oil level needs to be checked, the transmission needs to be redesigned, and authorized maintenance needs to be contacted

Key nodes of maintenance plan

Every 24 hours: Check the oil pressure (if there is a hydraulic circuit), noise, and vibration.

Every 720 hours: Check for external seal leaks, oil level, and oil filter contamination indicators.

Every 2000-4000 hours: Check the torque of all fastening bolts, wear of coupling elastic components, and re lubrication of Drywell seals.

Every time the oil is changed: check the alignment status between the gearbox and the coupling equipment.

Every 5000 hours: Replace synthetic oil and bearing grease (non lifetime lubrication type).

Surface temperature measurement: During the first operation, measure the surface temperature of the shell after continuous full load operation for 3 hours, and Δ T should not exceed 75K.