Installation, maintenance, and troubleshooting of Bonfiglioli HF series reducers for hoisting applications

If the anti-corrosion fluid is compatible with lubricating oil (for mineral oil or PAO synthetic oil): directly add compatible oil to the specified oil level and install the breathable plug that comes with the box.

If the anti-corrosion solution is not compatible (for PAG polyethylene glycol oil): a cleaning procedure needs to be performed——

Drain the anti-corrosion protective solution

Add approximately 20% of compatible lubricating oil to the horizontal installation position

Perform a no-load 'cleaning operation' to fully wet the interior with oil and flush out residual protective fluid

Drain the cleaning oil

Add sufficient compatible lubricating oil to the specified oil level

Warning: LTS option is not applicable to equipment that will use food grade lubricants.

Key points of installation technology: from bolt torque to tightening disc

3.1 Comprehensive preparation before installation

Before lifting and installing, the following preparatory work must be completed:

If the storage oil is different from the operating oil, the inside of the box should be emptied and thoroughly flushed.

Thoroughly remove all packaging materials and anti rust coatings (using appropriate solvents) to avoid solvent contact with the oil seal.

Confirm that the rigidity and strength of the installation structure are sufficient to withstand the weight and operating load of the gearbox. If there is a possibility of impact, long-term overload, or jamming, hydraulic couplings, clutches, or torque limiters should be installed.

Check the flatness of all mating surfaces to ensure accurate alignment between shafts or shafts holes.

Apply Kluberbaste 46 MR 401 and other anti micro corrosion protective paste to the key connection, but do not apply any lubricant to the friction connection (such as the shrink disc).

When installing outdoors, it is necessary to install protective devices to prevent direct sunlight and rainwater from entering, and ensure good ventilation.

Connect the gearbox housing to the equipotential protection (grounding) circuit of the equipment.

Assess whether the temperature of the touchable surface may exceed the limit specified in EN ISO 13732-1, and if it exceeds the limit, protective measures must be installed or a "hot surface" warning sign must be posted.

3.2 Tightening bolt torque - an uncompromising hard indicator

The HF series manual provides a detailed bolt tightening torque table, divided into two categories: fixed bolts (installation bolts) and oil/vent plugs.

Installation fixing bolt torque (partial excerpt):

Bolt specification 8.8 level torque [Nm] 10.9 level torque [Nm]

M10 50 73

M12 87 127

M16 210 314

M20 432 615

M30 1500 2130

Key Tip:

Under normal operating conditions, 8.8 grade bolts are sufficient. If using grade 10.9 bolts, it is necessary to ensure that the installation structure has sufficient strength.

Aluminum installation components (shells, flanges, or footrests) are strictly prohibited from using bolts higher than grade 8.8.

All oil plugs and vent plugs must also be tightened to the torque specified in Table 2 (e.g. 20-30 Nm for 1/2 "BSP plugs and 15-20 Nm for M14 × 2 plugs).

3.3 Output shaft flange connection (connection between winch frame and drum)

The HF series is commonly used in winch applications, where the output shaft is connected to the drum through a spline flange, and the reducer itself is connected to the lifting frame through a flange. During installation:

Do not use hammering or impact tools to install external parts to avoid damaging bearings and gears.

The screws (1) connecting the spline output flange to the drum and the screws (2) connecting the gearbox to the frame should be tightened in the order shown in the manual and reach the specified torque.

Clean and lubricate the spline mating surface before installation (using appropriate grease) to ensure accurate axial positioning.

5.4 Breathable plug replacement - the most easily overlooked fatal mistake during installation

When the HF series reducer leaves the factory, a closed oil plug is installed on the top to avoid oil leakage during transportation. Before the equipment is put into operation, the user must replace it with the Breather Plug that comes with the box. The manual specifically states that this operation is illustrated in detail in the "LUBRICATION" chapter. Forgetting to replace it will cause the internal pressure of the box to accumulate with the temperature rise, ultimately destroying the oil seal, causing oil leakage and lubrication failure.

Refined operation of lubrication management

4.1 Selection of Lubricating Oil Types

The HF series recommends using mineral oil or synthetic oil (PAO or PAG) with EP (extreme pressure) additives, as shown in the lubricant selection chart in the manual. The manual explicitly prohibits mixing different brands or specifications of oil products. If the same type of oil cannot be obtained, it must be thoroughly emptied and the inside of the tank must be flushed with new oil.

Compatible lubricating grease (for bearings, sealing rings, and mating surfaces):

Bearing lubrication: Kl ü ber Staburags NBU 8 EP

Cylinder assembly: Kl ü berpaste 46 MR 401