Installation, operation, and maintenance of Bonfiglioli 300-300M series reducers

Installation, operation, and maintenance of Bonfiglioli 300-300M series reducers

The official IOM manual for Bangfeili 300/300M heavy-duty planetary gear reducer (including ATEX explosion-proof version) covers usage, product identification, safety, storage and transportation, installation, motor/hydraulic motor assembly, lubrication, commissioning, operation, maintenance, troubleshooting, and appendices. This manual is intended for safe operation throughout the entire lifecycle of the equipment, and ATEX explosion-proof equipment has additional mandatory requirements.

Technical Information

2.1 Product Description

Can be equipped with motors or hydraulic motors, integrated into the overall equipment, used in industries such as machinery, chemical, agriculture, etc; A complete set of optional accessories can be selected.

Special Hardware Requirements for ATEX Explosion proof Models (2014/34/EU)

Selection requires a higher safety service factor;

Only synthetic lubricating oil (oil/grease) is allowed;

Use fluororubber seals;

Spring anti intrusion ventilation plug;

Aluminum gasket oil plug; Equipped with dust-proof lip oil seal;

No exposed movable metal parts;

Plastic parts are not allowed to accumulate static electricity and must be shielded;

21/22 Dust area: Customers must regularly clean the surface, and the thickness of dust accumulation should not exceed 5mm.

2.2 Compliance

Ordinary models comply with mechanical instructions; Equipped with a motor to meet low voltage and EMC requirements; ATEX model: Group II, 2G gas/2D dust; Suitable for gas zone 1 and dust zone 21; Temperature level T4 (gas, maximum 135 ℃), dust 2D maximum 135 ℃.

It is prohibited to modify the installation posture/motor configuration without authorization, otherwise the ATEX certificate will be directly invalidated, and written permission from Bangfeili Technology is required.

2.3 Use of boundary conditions

Not suitable for use in non designed explosive environments; The temperature of the shell is affected by the cabinet and heat dissipation conditions;

The maintenance of the dark field requires additional lighting.

2.4 Temperature Limit Table

Project Synthetic Oil Mineral Oil

Minimum working environment temperature -30 ℃ -10 ℃

Maximum working environment temperature+50 ℃+40 ℃

Storage environment temperature -40~+50 ℃ -10~+50 ℃

Maximum continuous surface temperature of the shell+100 ℃+100 ℃

Maximum continuous oil temperature+95 ℃+95 ℃

It is not recommended to operate continuously at a temperature of 80-95 ℃ for a long time; It is recommended to start at full load and increase the load for operation.

Safety Regulations

Operators must undergo specialized training and be equipped with labor protection tools;

Can only be used for industrial purposes permitted by the manufacturer;

Strictly implement the maintenance plan;

Maintenance and repair can only be carried out by professional maintenance technicians;

Explosion hazardous area operation: The power must be completely cut off and locked to prevent accidental start-up; Eliminate combustible gas dust on site;

Only original spare parts and recommended lubricants from the factory are allowed; Dispose of waste oil and waste according to regulations.

Handling, Transportation, and Storage 

4.1 Packaging

Standard packaging is suitable for indoor storage by land, not rainproof, and not suitable for direct sea transportation; Indoor storage for up to 2 years, relative humidity ≤ 80%; Sea and air transportation require wooden crate packaging. Verify the order upon receipt and inspect for any damages.

4.2 Handling and Lifting

Lifting equipment must be used for weights greater than 15 kg;

The lifting ring of the reducer body is prohibited from using the motor lifting ring to lift the entire machine;

Maximum allowable tilt angle of 15 °;

Provide lifting diagrams for different horizontal and vertical installation postures; Use suspenders, lifting rings, and shackles; Before lifting, gently lift to confirm stability and prevent swinging.

4.3 Storage

Prohibited from storing outdoors in damp conditions, not directly on the ground, and using pallets for cushioning;

Additional requirements for storage>6 months:

Apply rust inhibitor to the machined shaft extension;

Fill the tank with stored oil and place the vent plug at the highest position of the tank;

When resuming operation, all stored oil must be drained and replaced with formal working oil; Solvent cleaning of shaft extension, strictly prohibit solvent contact with oil seal, as it may damage the seal;

If stored for more than 1 year, the lifespan of the bearing grease will decrease, and synthetic grease should be prioritized.

LONG-TERM-STOCK long-term warehousing option

BBOX cardboard or wooden box packaging, with the box printed with "OPEN ONLY BEFORE THE INSTALLATION"; Internal VpCI gas-phase rust proof bag;

Storage conditions: Dry and dark at -10~+40   ℃, unpacking can only be done before installation and operation;

The longest storage period is 2 years; Upon expiration, it must be sent to Bangfeili Service Center for testing; If it passes the inspection, it can be stored for another 2 years.

Installation

Pre installation planning should be done during the overall design phase; Equipment power-off locking to prevent accidental startup; The base/flange must have sufficient rigidity.

5.1 Installation of reducer body

There are three installation forms: flange installation, foot installation, and torsion arm shaft installation.

Clean all anti rust protective layers; Check the nameplate; Base flatness ≤ 0.2   mm/100   mm;

Alignment requirement: coaxial axis to avoid misalignment; Moving parts must be equipped with safety shields;

It is recommended to use anti micro dynamic corrosion lubricant (Kl ü berpaste 46 MR401) for the contact surface; Outdoor installation of motors should be protected from sun and rain, and ensure ventilation.

5.1.1 Flange installation

Provide fitting tolerances (hollow shaft/solid shaft, interference fit/clearance fit); Specification and strength grade of flange bolts 12.9, tightening torque table; FDK/FZP axial locking hollow shaft (shrink disc): step-by-step diagonal tightening; Use protruding threaded holes during disassembly; Prohibit the use of molybdenum disulfide for lubrication, as reducing friction can lead to locking failure.

5.1.2 Foundation installation

Requirements for flatness of the base and torque table for anchor bolts.

5.1.3 Torque arm shaft installation

Specification and torque of torque arm bolts, installation angle of torque arm.

5.1.4 Installing pulleys and couplings on solid shafts

It is strictly prohibited to use a hammer to strike the shaft end; The installation of the pulley ensures that the belt is parallel and the belt tension cannot be too high; Provide thread specifications for each machine base shaft end.

5.1.5 No motor supply version

Before disassembling the protective cover plate A, the gearbox must be placed in a vertical position to prevent internal parts from falling off.

5.2 Assembly of IEC motors

Prohibit forced installation of couplings; Apply anti-corrosion paste on the mating surface; Bolt ≥ 8.8 grade;

ATEX requirement: The explosion-proof rating of the optional motor should not be lower than that of the gearbox;

The ATEX whole machine driven by a frequency converter motor must undergo a risk assessment for the installation formula, and the installation formula must declare that the whole machine is explosion-proof and compliant.

5.3 Assembling Hydraulic Motor

Two sealing forms (with built-in O-ring/flange with built-in sealing); Bolt ≥ 8.8 grade; Provide assembly diagram.

5.4 Hydraulic brake wiring

Minimum release pressure of the brake, maximum pressure of 320 bar; Provide braking torque parameters for different machine bases.

Hydraulic motor system: schematic diagram of open/closed circuit; Sealing pressure limit of oil outlet T; Oil requirements ISO VG46; Filtering level NAS 1638 class9.

5.5 Lubrication (key)

Add the specified amount of oil to the corresponding installation position before operation; The sealing oil plug for factory transportation must be replaced with the accompanying ventilation plug;

Specification and tightening torque of oil plug thread; Industrial equipment and mobile machinery oil selection table;

ATEX explosion-proof models can only use synthetic oil;

Long Term Storage Models:

SLM rust inhibitor is compatible with mineral oil and PAO synthetic oil;

SLP rust inhibitor is compatible with PAG polyethylene glycol oil;

Operation processing: compatible with directly adding working oil; Incompatibility requires draining the anti rust solution, rinsing the box for a short period of time, and then adding formal oil.

Tests

Factory testing has been conducted before leaving the factory, and confirmation has been made before on-site operation:

The reducer cannot be put into operation separately and must be integrated into the entire machine, which meets the 2006/42 mechanical instructions;

The actual installation posture is consistent with the nameplate;

Electrical grounding complies with EN60204-1; Hydraulic oil filtration meets the standard;

No oil leakage; The ventilation plug is not blocked by paint or dust;

No abnormal noise or vibration; ATEX equipment dust accumulation ≤ 5mm; good ventilation and heat dissipation; The protective cover is complete.

Equipment Operation

Prohibit environments with strong corrosion, abrasion, gas, and dust; Prohibit direct contact with loose food materials;

The rotating shaft extension belongs to the dangerous squeezing and shearing area, and the exposed shaft must be protected with a cover.

Maintenance and upkeep 

Cut off all power before maintenance, lock, and ensure that high-temperature equipment is completely cooled before opening the cover; Eliminate flammable media in the explosion area.

Only use original spare parts; The sealing gasket must be replaced when disassembling and assembling; It is recommended to replace bearings in pairs; Suggest changing the oil after repair; Apply Loctite 510 thread sealant again after disassembling and reassembling the threads; Apply special lubricating grease to the lip of the oil seal assembly;

Routine maintenance: oil level check, appearance leakage, vibration noise;

Oil change maintenance; Clean the shell;

It is not allowed to directly discharge waste oil into the environment;

After maintenance, tighten all oil plugs according to the specified torque and check the seal.

Parts Replacement, Scrap and Disassembly

Motor disassembly steps; Component replacement; Complete machine scrapping and dismantling; Compliant disposal of hazardous waste.