Habasit Rossi A Series User manual

series A, E, G, H, L, P, SR
Operating instructions

Operating instructions − UTD.045.09-2021.00_EN 3
Contents
1 - General safety instructions 4
1.1 - Disposal and recycling 4
1.2 - Safety 4
1.2.1 - Residual risks 5
2 - Operating conditions 6
3 - How supplied 6
3.1 - Receipt 6
3.2 - Name plate 6
3.3 - Painting 6
3.4 - Protections and packing 6
4 - Storing 6
5 - Installation 7
5.1 - General 7
5.2 - Fitting of components to shaft ends 8
5.3 - Shaft mounting 8
5.4 - Hollow low speed shaft 8
5.5 - Backstop device 9
5.6 - Shrink disc 9
6 - Lubrication 12
6.1 - General 12
6.2 - Lubrication table 10
6.3 - Extruder support lubrication 12
7 -Cooling system 12
7.1 - Cooling by fan 12
7.2 - Water cooling by coil 13
7.3 - Independent cooling unit 13
8 - Commissioning 13
9 - Maintenance 13
9.1 - General 13
9.2 - Coil 14
9.3 - Seal rings 14
9.4 - IEC motor mounting and dismounting 14
9.5 - Servomotor mounting and dismounting 17
9.6 - Bearings 17
9.7 - Metal filler plug with filter and valve 17
10 - Sound levels 18
Painting table 18
Table of tightening torques for axial fastening
bolts and shrink disc
18
Table of tightening torques for fastening bots (foot,
flange, hub clamps and flexible half-coupling bolts)
19
Table of tightening torques for plugs 19
Gear reducer troubles: causes and corrective actions 20

Operating instructions − UTD.045.09-2021.00_EN
4
1 - General safety information
This document provides information about handling, installation and maintenance of helical and bevel helical gear
reducers and gearmotors (G series).
All the people involved in these activities will carefully read and follow all present instructions.
Information and data contained in this document correspond to the technical level reached at the moment the ca-
talog is printed. Rossi reserves the right to introduce, without notice, the necessary changes to improve e󰀩 ciency
and safety of its products.
1.1 - Disposal and recycling
Keep in mind the instructions in force concerning exhaust disposal and recycling:
– elements of gear reducer housing, gear pairs, shafts and bearings must be transformed into steel scraps along
with all other cast iron components, excluding specific cases;
–for all other non-metallic components (seal rings, caps, etc.) follow the instructions in force;
– all exhaust oils must be recycled and treated as per regulations in force.
1.2 - Safety
The paragraphs marked with symbols shown below contain dispositions to be strictly respected in order to assure
personal safety and to avoid any heavy damages to the machine or to the system.
(Electric or mechanical) danger, such as:
– live parts;
– temperature higher than 50 °C;
– components rotating during operation;
– suspended loads (lifting and transport);
– eventual high sound level ( 85 dB(A)).
IMPORTANT: gear reducers and gearmotors supplied by Rossi are partly completed machinery to be incorpo-
rated into machinery and should not be commissioned before the machinery in which the components have
been incorporated conforms to:
– Machinery directive 2006/42/EC and subsequent updatings; in particular, possible safety guards for
shaft ends not being used for eventually accessible fan cover passages (or other) are the Buyer's re-
sponsibility;
– «Electromagnetic compatibility (EMC)» 2004/108/EC and subsequent updatings.
Attention! It is recommended to pay attention to all instructions of present handbook, all standards con-
cerning correct installation and all existing safety laws. Whenever personal injury or property damage
may occur, foresee adequate supplementary protection devices against:
− release or breakage of fastening screws;
– rotation or unthreading of the gear reducer from shaft end of driven machine following to accidental
breakage of the reaction arrangement;
– accidental breakage of shaft end of driven machine.
If deviations from normal operation occur (temperature increase, unusual noise, etc.) immediately switch
off the machine.
Installation
An incorrect installation, an improper use, the removing or disconnection of protection devices, the lack of inspec-
tions and maintenance, improper connections may cause severe personal injury or property damage. Therefore
the component must be moved, installed, commissioned, handled, controlled, serviced and re-paired exclusively
by responsible quali ed personnel.
The quali ed personnel must be speci cally instructed and have the experience necessary to recognize and
prevent dangers (see table 1.2.1 - Residual dangers) connected to present products avoiding all possibile emer-
gencies.
Gear reducers and gearmotors of present handbook are normally suitable for installations in industrial areas:
additional protection measures, if necessary, must be adopted and assured by the personnel responsible for the
installation.
Attention! Components in non-standard design or with special executions or with constructive variations may dif-
fer in the details from the ones described here following and may require additional information.
Attention! For the installation, use and maintenance of the electric motor (standard, brake of non-standard motor)
or of the eventual motor variator and/or electric supply device (frequency converter, soft-start etc.), and/or optional
electric devices (e.g.: independent cooling unit, etc.), consult the attached speci c documentation. If necessary,
require it.
Maintenance
When operating on gear reducer or on components connected to it the machine must be at rest and cold: discon-
nect motor (including auxiliary equipments) from power supply, gear reducer from load, be sure that safety systems
are on against any accidental starting and, if necessary, pre-arrange mechanical locking devices (to be removed
before commissioning).
Attention! During the running the gear reducers could have hot surfaces; always wait that the gear reducer or the
gearmotor to cool before carrying out any operations.
Please download further technical documentation (e.g.: catalogs) from our website www.rossi-group.com or con-
tact Rossi. For any clari cation and/or additional information consult Rossi and specify all name plate data.
Lifting instructions.

Operating instructions − UTD.045.09-2021.00_EN 5
Tab. 1.2.1 - Residual risks
The products supplied by Rossi S.p.A. have been designed and manufactured according to the es-
sential health and safety requirements provided for by the Machine Directive 2006/42/EC - Annex I.
The following table lists the residual risks that the user must deal with in compliance with the instructions contained
in this document and in those eventually attached to the shipment.
Nature/Cause of Risk Countermeasures
Installation and maintenance
operations The component must be handled, installed, commissioned, operated, inspected, maintained, and repaired only by qualied, responsible
personnel who must carefully read and strictly follow all instructions in
this document, including any instructions enclosed with the shipment.
They shall also be specically instructed and have the necessary ex-
perience to recognize the hazards and potential hazards (electrical or
mechanical) associated with these products, such as, but not limited to:
- presence of electrical voltage;
- presence of temperature higher than 50 °C;
- presence of moving parts during operation;
- presence of suspended loads;
- presence of possible high sound level (> 85 dB (A).
It must be equipped with appropriate personal protective equipment
(PPE) and be familiar with and comply with all applicable regulations
regarding proper installation and current safety laws in order to ensure
the safety of persons and avoid signicant damage to the machine or sy-
stem.
Falling or projecting objects For gearboxes equipped with a backstop, provide a protection system
against the projection of objects resulting from the breaking of the backstop.
For gearboxes tted with a coupling (fast and/or slow shaft), provide
protection against the projection of objects resulting from breakage of the
coupling itself.
For shaft-mounted gear units, provide appropriate safety devices against
- Loosening or breaking of the mounting screws;
- Rotation or loosening of the gear unit from the machine pin due to acciden-
tal breakage of the reaction constraint;
- accidental breakage of the machine pin.
Movable elements Provide safety guards for unused shaft ends and accessible fan cover pas-
sages (or other).
Any work on the gearbox or gearmotor must be carried out with the machine
stopped and disconnected from the power supply and the gearbox or gear-
motor cold.
Extreme Temperatures During operation, the gearboxes may have hot surfaces (> 50 °C); befo-
re starting any operation, always wait for the gearbox or gearmotor to cool
down (wait about 1 to 3 hours depending on the size); if necessary, carry
out a temperature measurement on the surface of the gearbox or gearmotor
near the fast shaft. The same applies to the hydraulic coupling, if present.
After a period of operation, the gearbox is subjected to a slight internal over-
pressure that can result in the leakage of burning uid.
Therefore, before loosening the caps (of any kind) wait for the gearbox to
cool down; otherwise, use appropriate protection (PPE) against burns resul-
ting from accidental contact with hot oil.
In any case, always proceed with the utmost caution.
Noise Depending on the size, gear ratio, gearbox, type of service, and mounting
system of the gearbox or gearmotor, the noise emission level may exceed 85
dB(A). Perform eld measurements and, if necessary, equip the personnel
concerned with appropriate personal protective equipment (PPE).
Changes that may a󰀨ect the
safety of the equipment Do not make any structural modication to the products supplied by Rossi (reducers, gearmotors, control group, etc.) without prior approval by Rossi
S.p.A.
Use of substitute components
with characteristics not suita-
ble for the application
Spare parts must be those authorized by Rossi S.p.A.

Operating instructions − UTD.045.09-2021.00_EN
6
2 - Operating instructions
Gear reducers are designed for industrial applications according to name plate data, at ambient temperatu-
re 0  +40 °C (with peaks at -10 °C and +50 °C), maximum altitude 1 000 m.
Not allowed running conditions: application in aggressive environments having explosion danger, etc.
Ambient conditions must comply with specifications stated on name plate.
3 - How supplied
3.1 - Receipt
At receipt verify that the unit corresponds to the one ordered and has not been damaged during the transport,
in case of damages, report them immediately to the courier.
Avoid commissioning gear reducers and gearmotors, that are even if slightly damaged.
3.2 - Name plate
Every gear reducer presents a name plate in anodised aluminium containing main technical information
relevant to operating and constructive specifications and defining, according to contractual agreements, the
application limits (see fig. 1); the name plate must not be removed and must be kept integral and readable.
All name plate data must be specified on eventual spare part order .
3.3 - Painting
Products are painted according to the painting table shown on page 24.
Before adding further coats of paint (use dual-compound paints only), properly protect the seal rings (which must
neither be damaged nor painted), degrease and sand the gear reducer (or gearmotor) surfaces.
3.4 - Protections and packing
Overhanging free shaft ends and hollow shafts are treated with protective anti-rust long life oil and protected with
a plastic (polyethylene) cap (only up to D  48 mm for overhanging shafts, D 110 mm for hollow shafts). All
internal parts are protected with protective anti-rust oil.
Unless otherwise agreed in the order, products are adequately packed: on pallet, protected with a polyethyle-
ne film, wound with adhesive tape and strap (bigger sizes); in carton pallet, wound with adhesive tape and
strap (smaller sizes); in carton boxes wound with tape (for small dimensions and quantities). If necessary,
gear reducers are conveniently separated by means of anti-shock foam cells or of filling cardboard.
Do not stock packed products on top of each other.
4 - Storing
Surroundings should be sufficiently clean, dry and free from ex-cessive vibrations ( v
eff
 0,2 mm/s) to avoid
damage to bearings (excessive vibration should also be guarded during transit, even if within wider range) and
ambient storage temperature should be 0  +40 °C: peaks of 10 °C above and below are acceptable.
The gear reducers filled with oil must be positioned according to the mounting position mentioned on the order during
transport and storage.
Every six months rotate the shafts (some revolutions are sufficient) to prevent damage to bearings and seal
rings.
Assuming normal surroundings and the provision of adequate protection during transit, the unit is protected
for storage up to 1 year.
For a 2 year storing period in normal surroundings it is necessary to pay attention also to following instruc-
tions:
Fig. 1 (for more information, see Rossi technical catalogs; consult us).
Note: Starting from 04/05/2010 the company name ROSSI MOTORIDUTTORI S.p.A. has been changed into Rossi S.p.A., and the nameplates have been updated accordingly.
Series: A, AS, E, ES, G GX, P, L Series: H Series: SR
1 Designation (see table)
2 Mountig position
3 Date of manufacture
4 Transmission ratio
5 Serial number
6 Code
7 Motor power
8 Gear reducer nominal power
9 Gear reducer nominal output torque
10 Input speed
11 Service factor
12 Input side coupling dimension
13 Angular backlash on low speed shaft
14 Max low speed accelerating torque
Designation
Product
Machine Train of gears Size Design
R, MR V, IV, 2IV 32 ... 250 UO ... Worm
R, MR 2I, 3I 32 ... 180 FC ..., PC ..., UC ... Coaxial
R, MR I, 2I, 3I, 4I 40 ... 8001 UP ... Parallel shafts
R, MR CI, ICI, C2I, C3I 40 ... 8001 UO ...
Helical
R C 80 ... 320 PO ..., FO ... Bevel helical
R 2I 85 ... 250 OP Shaft mounted
A, AS, SR
E, ES, SR
G, GX, H, SR
G, H, SR
L
P
Series

Operating instructions − UTD.045.09-2021.00_EN 7
– generously grease the sealings, the shafts and the unpainted machined surfaces, if any, and periodically
control conservation state of the protective anti-rust oil;
– for gear reducers and gearmotors supplied without oil: completely fill the gear reducers with lubrication oil
and verify the specified level before commissioning.
For storages longer than 2 years or in aggressive surroundings or outdoors, consult Rossi
.
5 - Installation
5.1 - General
Before the installation, verify that:
– there were no damages during the storing or the transport;
– design is suitable to the environment (temperature, atmosphere, etc.);
– electrical connection (power supply, etc.) corresponds to motor name plate data;
– used mounting position corresponds to the one stated in name plate.
Attention! When lifting and transporting the gear reducer or gearmotor use through holes or tapped holes
of the gear reducer housing; be sure that load is properly balanced and provide lifting systems, and cables
of adequate section. If necessary, gear reducer and gearmotor masses are stated in Rossi technical cata-
logs.
Be sure that the structure on which gear reducer or gearmotor is fitted is plane, levelled and sufficiently
dimensioned in order to assure fitting stability and vibration absence (vibration speed
v
eff
 3,5 mm/s for PN
 15 kW and v
eff
 4,5 mm/s for PN > 15 kW are acceptable), keeping in mind all transmitted forces due to
the masses, to the torque, to the radial and axial loads.
For the dimensions of fixing screws of gear reducer feet and the depth of tapped holes consult the Rossi
technical catalogues.
Carefully select the length of fastening bolts when using tapped holes for gear reducer fitting, in order to
assure a sufficient meshing thread length for the correct gear reducer fitting to the machine without breaking
down the threading seat.
Attention! Bearing life and good shaft and coupling running depend on alignment precision
between the shafts. Carefully align the gear reducer with the motor and the driven machine (with the aid
of shims if need be, for gear reducers size  400 use level tapped holes), interposing flexible couplings
whenever possible.
Incorrect alignment may cause breakdown of shafts and/or bearings (which may cause overheatings)
which may represent heavy danger for people.
Do not use motor eyebolts when lifting the gearmotors.
Position the gear reducer or gearmotor so as to allow a free passage of air for cooling both gear reducer and
motor (especially at their fan side).
Avoid: any obstruction to the air flow; heat sources near the gear reducer that might affect the temperature of
cooling air and of gear reducer (for radiation); insufficient air recycle and applications hindering the steady dis-
sipation of heat.
Mount the gear reducer or gearmotor so as not to receive vibrations
.
Place the supplied adhesive pictogram identifying the risk associated with hot surfaces on the surfa-
ce of the gear unit in a position visible to personnel involved in machine operation and maintenance.
Mating surfaces (of gear reducer and machine) must be clean and su󰀩ciently rough to provide a good friction
coe󰀩cient (indicatively Ra 3,2 ÷ 6,3 µm). Remove by a scraper or solvent the eventual paint of gear reducer
coupling surfaces
When external loads are present use pins or locking blocks, if necessary.
When tting gear reducer and machine and/or gear reducer and eventual ange B5 it is recommended to use
locking adhesives such on the fastening screws (also on ange mating surfaces).
For accessories not suplied by Rossi, pay attention to their dimensioning; consult us, if need be.
Before wiring-up the gearmotor make sure that motor voltage corresponds to input voltage. If direction of
rotation is not as desired, invert two phases at the terminals.
Y-∆ starting should be adopted for no-load starting (or with a very small load) and for smooth starts, low star-
ting current or other similar devices should be tted.
If overloads are imposed for long periods or if shocks or danger of jamming are envisaged, then motor-
protection, electronic torque limiters, uid couplings, safety couplings, control units or other similar devices
should be tted.
Usually protect the motor with a thermal cut-out however, where duty cycles involve a high number of on-
load starts, it is necessari to utilise thermal probes for motor protection (tted on the wiring); magnetothermic
breaker is unsuitable since its threshold must be set higher than the motor nominal current of rating.
Connect thermal probes, if any, to auxiliary safety circuits.
Use varistors and/or RC lters to limit voltage peaks due to contactors.
For gear reducers equipped with backstop device (see ch. 5.12), foresee a protection system where a
backstop device breaking could cause personal injury or property damage.
Whenever a leakage of lubricant could cause heavy damages, increase the frequency of inspections and/or
envisage appropriate control devices (e.g.: remote level gauge, etc.).
In polluting surroundings, take suitable precautions against lubricant contamination through seal rings or
other.

Operating instructions − UTD.045.09-2021.00_EN
8
For outdoor installation or in a hostile environment (corrosivity class C3 according to ISO 12944-2) protect
the gear reducer or gearmotor with a proper anti-corrosion paint (see ch. 3.4), using water-repellent grease
(especially around the rotary seating of seal rings and the accessible zones of shaft end).
Gear reducers and gearmotors should be protected whenever possibile and by appropriate means from solar
radiation and extremis of weather; weather protection becomes essential when high or low speed shafts are
vertically disposed or when the motor is installed vertical with fan uppermost.
For ambient temperature greater than +40 °C or less than 0 °C, consult Rossi.
When gear reducer or gearmotor is supplied with water cooling by coil or independent cooling unit, see ch. 7.
5.2 - Fitting of components to shaft ends
It is recommended that the holes of parts keyed onto shaft ends should be machined to H7 tolerance; for
high speed shaft ends having D  55 mm, tolerance G7 is permissible provided that the load is uniform and
light; for low speed shaft end having D  180 mm, tolerance must be K7 if load is not uniform and light.
Before mounting, thoroughly clean mating surfaces and lubricate against seizure and fretting corrosion.
Attention! Installing and removal operations should be carried out with the aid of jacking screws and pull-
ers using the tapped hole at the shaft butt-end (see table in fig. 2) taking care to avoid impacts and shocks
which may irremediably damage the bearings, the circlips or other parts, for H7/m6 and K7/j6 fits it is
advisable that the part to be keyed is preheated to a temperature of 80  100 °C.
D d
Ø Ø
11
 00 M 5
14
 19 M 6
24
 28 M 8
30
 38 M 10
42
 55 M 12
60
 75 M 16
80
 95 M 20
100
 110 M 24
125
 140 M 30
160
 210 M 36
240
 320 M 45
Shaft ends
Fig. 2
UT.C 886
The couplings having a tip speed on external diameter
up to 20 m/s must be statically balanced; for higher tip speeds they must be dynamically balanced.
Where the transmission link between gear reducer and machine or motor generates shaft end loads, (see
fig. 3), ensure that:
– loads do not rise above catalog values;
– transmission overhang is kept to a minimum;
– gear-type transmissions must guarantee a minimum of backlash on all mating flanks;
– drive-chains should not be tensioned (if necessary – alternating loads and/or motion – foresee suitable
chain tighteners);
– drive-belts should not be over-tensioned.
5.3 - Shaft mounting
When shaft mounted, the gear reducer must be supported both axially and radially (also for mounting positions
B3 ... B8) by the machine shaft end, as well as anchored against rotation only, by means of a reaction having
freedom of axial movement and sufficient clearance in its couplings to permit minor oscillations always in
evidence without provoking dangerous overloading on the gear reducer.
Lubricate with proper products the hinges and the parts subject to sliding; when mounting the screws it is
recommended to apply locking adhesives.
For the mounting of the “kit using reaction disc springs” (sizes 125 helical gear units) use the tapped butt
end hole on the shaft end of the driven machine and the flat machined chamfered surface for compressing
and fitting the disc springs into the reaction recess.
Concerning the reaction system, follow the project indications sta-ted in the technical catalogs Rossi. When-
ever personal injury or property damage may occur, foresee
adequate supplementary protection devic-
es against:
– rotation or unthreading of the gear reducer from shaft end of driven machine following to accidental breakage
of the reaction arrangement;
– accidental breakage of shaft end of driven machine.
5.4 - Hollow low speed shaft
For machine shaft ends onto which the hollow shafts of gear reducers are to be keyed, h6, j6, and k6 toler-
ances are recommended, according to requirements.
Important! The shoulder diameter of the shaft end of the driven machine abutting with the gear reducer
must be at least 1,18  1,25 times the internal diameter of hollow shaft. For other data on machine shaft
end, in case of standard hollow low speed shaft, stepped shaft, with locking rings or bush, with shrink disc
see Rossi technical catalogs .
Attention! For vertical ceiling-type mounting and only for gear reducers equipped with locking rings or
bush, gear reducer support is due only to friction, for this reason it is advisable to provide it with a fastening
system.
Fig. 3
False Correct False Correct
UT.C 666

Operating instructions − UTD.045.09-2021.00_EN 9
When installing and removing gear reducers and gearmotors with hollow low speed shaft incorporating a
circlip groove – whether with keyway or shrink disc – proceed as per fig. 4a and 4b, respectively, on page
14.
Warning. Even if low speed shafts are principally machined within H7 tolerance, a check using a plug could
detect two areas with slightly smaller diameters (see Fig. 5a): this reduction is intentional and does not
affect the quality of keying - which in fact will be improved in terms of duration and precision - and it
does not represent an obstacle to the assembly of a machine shaft end executed according to the usual
methods, such as to the one shown on Fig. 4a.
Fig. 5a
In order to remove the hollow low speed shaft of
the helical and bevel helical gear reducers (this is
the first operation to perform when disassembling
the gear reducer) turn the shaft until the keyway is
facing the intermediate shaft as indicated in fig. 5b
and push the shaft from the reference groove side
(circumferencial keyway on shaft shoulder).
The system shown in fig. 4c and 4d, page 14, is good for axial fastening; when the shaft end of the driven machine has
no shoulder (as in the lower half of the drawing) a spacer may be located between the circlip and the shaft end itself.
Parts in contact with the circlip must have sharp edges.
The use of locking rings (fig. 4e, page 14) or locking bush (fig. 4f page 14) will permit easier and more accurate install-
ing and removing and eliminate backlash between the key and keyway.
The locking rings or bush are fitted after mounting and after having carefully degreased the coupling surfaces. Do not
use molybdenum bisulphide or equivalent lubricant for the lubrication of the parts in contact. When tightening the bolt,
we recommend the use of a locking adhesive.
Respect the tightening torques stated in the table on page 24.
In case of axial fastening with locking rings or bush – especially when having heavy duty cycles, with frequent reversals
– verify, after some hours of running, the bolt tightening torque and eventually apply the locking adhesive again.
When fitting with shrink disc (fig. 4g, page 14) proceed as follows:
– carefully degrease the surfaces of hollow shaft and shaft end of driven machine to
be fitted;
– mount the gear reducer onto the shaft end of driven machine following the method
indicated in fig. 4a, page 14;
– gradually and uniformly tighten the screws of shrink disc by a continuous sequence
(not crossing) and during several phases up to a torque stated in the table on page
24;
– at operation end verify the screw tightening torque by means of a dynamometric key
(flat, when it is mounted onto machine end).
5.5 - Backstop device
The presence on gear reducer of backstop device is stated by the arrow near the low speed shaft,
indicating the free rotation, excluding the shaft mounted gear reducers for which B or C design is stated
(see Rossi technical catalogs).
Provide a protection system where a backstop device breaking could cause personal injury or property damage.
Check - before starting - that there is correspondence between free rotation and the direction of rotation
of the machine to be driven and of the motor.
Attention! One or more startings in the false direction, even if short, could irremediably damage the backstop
device, the coupling seats and/or the electric motor.
5.6 Shrink disc
Installation
– Carefully degrease the surfaces of hollow shaft and shaft end of driven machine to be t;
– mount the shrink disc on gear reducer hollow shaft by lubricating rst only the external surface of hollow
shaft;
– slightly tighten a rst grouop of three screws positioned at about 120º;
– mount the gear reducer on machine shaft end;
– gradually and uniformly tighten, by means of dynamometric wrench, the screws of shrink disc at torque
value 5% higher than the one shown in the table at page 24, by a continuous sequence (not crossing)
using approximately 1/4 turns for each pass until 1/4 turn can no longer be achieved;
– continue to apply overtorque by means of dynamometric wrench for 1 or 2 more passes and at the end
verify that the tightening torque stated in the table has been achieved;
– when having heavy duty cycles, with frequent reversals, verify again after some hours of running, the bolt
tightening torque.
Removal
– Prior to initiating the removal procedure, check that no torque or thrust loads are acting on the shrink disc,
shaft or any mounted components;
– clean o󰀨 any rusty areas;
– loosen the fastening screws one after the other only by using approx. 1/2 turn at a time and by a continuous
sequence (not crossing), until shrink disc can be moved on hollow shaft;
– do not completely remove fastening screws before locking rings are disengaged: risk of serious injury!
– remove the gear reducer from the machine shaft.
groove side 
opposite side to groove
Fig. 5b
UT.C 322

Operating instructions − UTD.045.09-2021.00_EN
10
6.2 - Lubrication table
Independently-lubricated bearings, motor-bearings, backstop device fitted to motor:
lubrication is «for life» (except some cases of motors in which relubrication device is adopted). Should there be either a possibility of the grease
becoming contaminated, or a very heavy type of duty-cycle, it is good policy to check on the state of the grease (between one change and the next,
or every year or 2 years) and remove and replace grease in independently-lubricated bearings (every change or every other change, or every 2
or
4 years). Bearings should be filled with SHELL Gadus S2 V100 bearing-grease for ball bearings, KLÜBER STABURAGS NBU 8 EP for roller
bearings; lubricate the backstop device with SHELL Alvania RL2.
Product How supplied* and plugs Directions for first filling
Worm
sizes 32 ... 81
Worm
sizes 100 ... 250
Coaxial
sizes 32 ... 41
Right angle shaft
(cat. L)
sizes 80 ... 125
Coaxial
sizes 50 ... 81
Helical
and
bevel helical
sizes 40 ... 81
Coaxial
sizes 100 ... 180
Helical
and
bevel helical
sizes 100 ... 8001
Right angle shaft
(cat. L)
sizes 160 ... 320
Shaft mounted
FILLED WITH
SYNTHETIC OIL
AGIP Blasia S 320, KLÜBER
Klübersynth GH 6-320,
MOBIL Glygoyle HE 320,
SHELL Omala S4 WE 320
Worm speed  280 min
-1
KLÜBER Klübersynth GH6-680
MOBIL Glygoyle HE 680
SHELL Omala S4 WE 680
Filler plug
1 filler plug sizes 32 ... 64
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
WITHOUT OIL
(except different statement on
lubrication name plate)
Filler plug with valve,
drain and level plug
Before putting into
service, fill to speci
-
fied level with synthe -
tic oil (AGIP Blasia
S, ARAL Degol GS,
BP-Energol SG-XP,
MOBIL Glygoyle,
SHELL Omala S4
WE ... , KLÜBER
Klübersynth GH6...)
having the ISO visco
-
sity grade given in
the table.
FILLED WITH
SYNTHETIC GREASE
SHELL Gadus S5 V142W00
IP Telesia Compound A
MOBIL Glygoyle Grease 00
Filler/drain plug
(only for coaxial)
FILLED WITH
SYNTHETIC OIL
KLÜBER Klübersynth GH 6-220
MOBIL Glygoyle 30
SHELL Omala S4 WE 220
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
WITHOUT OIL**
(except different statement
on lubrication name plate)
Filler plug with valve
(with breathing for shaft
mounted gear reducers),
drain and level plugs
Before putting into servi-
ce, fill to specified level
with mineral oil (AGIP
Blasia, ARAL Degol
BG, BP-En ergol
GR-XP, IP Mellana oil,
MOBIL Mobilgear 600
XP, SHELL Omala S2
G, TEXACO Meropa,
TOTAL Carter EP) or
polyglycol** synthetic
oil (KLÜBER Klüber-
synth GH6 ..., MOBIL
Glygoyle, SHELL Omala
S4 WE) or polyalphaolefines** synthetic oil (AGIP Blasia SX, CASTROL Alphasyn EP,
ELF Reductelf SYNTHESE, SHELL Omala S4 GX, KLÜBER Klübersynth GEM4, MOBIL SHC
Gear) having the ISO viscosity grade given in the table.
ISO viscosity grade [cSt]
Ambient temperature 0  +40 °C2)
Worm speed Gear reducer size
min-1
100 125 ... 161 200, 250
B3
1)
, V5, V6 B6, B7, B8 B3
1)
, V5, V6 B6, B7, B8
2 800 1 400
3)
320 320 220 220
1 400 710
3)
320 320 320 220
710 355
3)
460 460 460 320
355 180
3)
680 680 460 460
< 180 680 680 680
1) Not stated on the name plate.
2) Peaks of 10 °C above and 10 °C (20 °C for 460 cSt) below the ambient tem-
perature range are acceptable.
3) For these speeds we advise to replace oil after running-in.
Speed n2
min-1
Ambient temperature1) [°C]
mineral
oil
synthetic
oil
Right angle 2) 2)
Shafts (L) Others -20 ÷ 0 0 ÷ 20 20 ÷ 40 -20 ÷ 0 0 ÷ 40
> 710 > 224 150 150 150 150 150
710 ÷ 280 224 ÷
22,4 150 150 220 150 220
280 ÷
90 22,4 ÷ 5,6 150 220 320 220 320
< 90 < 90 220 320 460 320 460
1) Peaks of 10 °C (20 °C) below and 10 °C above the ambient temperature
range are acceptable.
2) For size
 4001 only.
Mean kinematic viscosity [cSt] at 40 °C.

Operating instructions − UTD.045.09-2021.00_EN 11
Oil-change interval and lubricant quantity
Oil quantity [l] for worm gear reducers sizes 32 ... 81
For the other sizes the quantity is given by the level stated by the proper plug.
R V, MR V R IV, MR IV MR 2IV
Size B31), V5, B6, B7 B81) B31), V5, B6, B7 B81) B31) B6, B7 B81) V5, V6
V6 V6
32 0,16 0,2 0,16 0,2 0,25 0,2 – – – –
40 0,26 0,35 0,26 0,32 0,4 0,32 0,42 0,5 0,42 0,42
50 0,4 0,6 0,4 0,5 0,7 0,5 0,6 0,8 0,6 0,6
63, 64 0,8 1,15 0,8 1 1,3 1 1,2 1,55 1,2 1,2
80, 81 1,3 2,2 1,7 1,5 2,5 2 1,7 2,8 2,3 1,8
1) Not stated on name plate (B8, only sizes 32 ... 64).
Ambient temperature 0
 +40 °C with peaks up to –20 °C and +50 °C.
An overall guide to oil-change interval is given in the table, and assumes pollution-free
surroundings. Where heavy overloads are present, halve the values.
Apart from running hours, replace or regenerate the oil each 5  8 years according to size,
running and environmental conditions.
Lubrication «
for life » (assuming external pollution-free environment).
Lubrication «
for life » (assuming external pollution-free environment). Oil quantity [l] for sizes 50 ... 81
Oil Oil-change
temperature [°C] interval [h]

65 18 000
65  80 12 500
80  95 9 000
95  110 6 300
Oil Oil-change interval [h]
temperature [°C] mineral oil synthetic oil
 65
1)
8 000 25 000
65  80
1)
4 000 18 000
80  95
1)
2 000 12 500
95  110
1)
– 9 000
Grease quantity [kg] for coaxial gear reducers
R 2I MR 2I, 3I
Size B31), B6, B7, B8 V5, V6 B51) V1, V3
32 0,14 0,25 0,1 0,18
40, 41 0,26 0,47 0,19 0,35
1) Non stated on name plate
Ambient temperature 0
 +40 °C with peaks up to –20 °C and +50 °C.
1) Values admissible only for parallel, bevel helical and right angle shaft gear
reducers (cat. G and L) an for non-continuous duties.
1) Not stated on name plate.
2) Values valid for R 2I; for MR 2I the values are
respectively: 0,8; 1,2; 2,3.
3) The first reduction stage (the first two for 4I) is
lubricated with grease for life.
Ambient temperature 0
 +40 °C with peaks up to
–20 °C and +50 °C.
R 2I, 3I MR 2I, 3I
Coaxial B6, B7,
size
B3
1)
B8, V6 V5
50, 51
0,8 1,1 1,4
63, 64 1,6 2,2 2,8
80, 81 3,1 4,3 5,5
An overall guide to oil-change interval is given in the table, and assumes
pollution-free surroundings. Where heavy overloads are present, halve the
values.
Apart from running hours:
— replace mineral oil each 3 years;
— replace or regenerate synthetic oil each 5 8 years according to gear
reducer size, running and environmental conditions.
The oil quantity is given by the level stated by the proper plug.
**Identification through specific lubrication name plate.
** Lubrication with synthetic oil (polyglycol basis must be with special internal painting; polyalphaolefines basis is advisable for sizes 200 and obligatory for sizes 400). It is always
recommended, particularly for: high speed gear reducers, increase of oil-change interval («long life»), increase of the ambient temperature range, increase of the thermal power or
decrease of oil temperature.
R I R 2I, MR 2I R 3I, MR 3I MR 4I
Parallel B3
1)
, B7 B6, B3
1)
, B6
2)
B7, B3
1)
, B6 B7, B3
1)
, B6 B7,
V5
3)
size B8
1)
,V5, V6 B8
1)
,V5, V6 B8
1)
,V5
3)
, V6 B8
1)
,V6,
40, 00
– – – 0,4 0,9 0,55 0,47 0,7 0,6 – – – –
50, 00 – – – 0,6 0,9 0,80 0,70 1,05 0,9 – – – –
63, 64 0,7 0,8 1,0 0,9 1,4 1,201,00 1,50 1,3 1,1 1,8 1,4 1,3
80, 81 1,2 1,5 1,9 1,5 2,7 2,30 1,70 2,90 2,5 1,9 3,2 2,7 2,5
Right R CI, MR CI R ICI, MR ICI MR C3I
angle B3
1)
, B8 V5, B3
1)
, B6 B8 V5, B3
1)
, B6 B8 V5,
size B6, B7 V6,B7
1)
,V6,B7
1)
,V6,
40, 00 0,26 0,35 0,3 0,31 0,5 0,40 0,35
– – – –
50, 00 0,4 0,60 0,45 0,45 0,8 0,65 0,50 0,5 0,9 0,7 0,55
63, 64 0,8 1,00 0,95 1,00 1,6 1,20 1,15 1,2 1,8 1,4 1,35
80, 81 1,3 2,00 1,80 1,60 2,7 2,202,00 1,9 3,0 2,5 2,30

Operating instructions − UTD.045.09-2021.00_EN
12
6 - Lubrification
6.1 - General
Depending on type and size, gear reducers and gearmotors may be grease-lubricated and supplied FILLED
WITH GREASE, or (synthetic or mineral) oil-lubricated and supplied FlLLED WlTH OlL or WlTHOUT OIL
depending on type and size (see ch. 6.2). When supplying WITHOUT OIL, the filling up to specified level
(normally stated by means of transparent level plug) is Buyer’s responsibility.
Every gear reducer has a
lubrication plate.
Concerning lubricant type and quantity, gear reducer type, how supplied, plugs, filling instructions, oil-chan-
ge interval, etc. see lubrication table (6.2).
Be sure that the gear reducer has been mounted in the mounting position foreseen in the order - including
inclined mounting positions (e.g.: B3 38° V5) - as stated on the nameplate; when it is not stated, the gear
reducer must be mounted in horizontal mounting position B3 or B5 (B3, B8, worm gear reducers size  64),
vertical V1 (for bevel helical gear reducer design with flange FO1...). For oscillatory mounting positions, the
gear reducers are equipped with auxiliary nameplate with statement of mounting position and oil quantity to
be filled with as well as level check to be executed during the periodical maintenance.
Be sure that for gear reducers and gearmotors size  100, the filler plug is provided with a valve (symbol
); otherwise, replace it with the one normally supplied with.
When gear reducer or gearmotor is provided with a
spilway plug (red colour) fill after unscrewing a.m. plug
in order to check the obtained level by oil outlet.
When gear reducer or gearmotor is provided with a
level plug with rod , fill with oil up to specified level on
rod.
When gear reducer or gearmotor is supplied with a level plug (size 100), the necessary lubricant quantity
is that which reaches a.m. Ievel in center line of plug (gear reducer at rest) and not the approximate
quantity given on the catalog.
Usually bearings are automatically and continuously lubricated (bathed, splashed, through pipes or by a
pump) utilising the main gear reducer lubricant. The same applies for backstop devices, when fitted to gear
reducers.
In certain gear reducers in vertical mounting positions V1, V3, V5 and V6, and bevel helical gear reducers
in horizontal positions B3, B6 and B51 (though not gearmotors in this case, for which the above indications
hold good) upper bearings are independently lubricated with a special grease «for life», assuming pollution-
free surroundings. The same applies for motor bearings (except some cases in which relubrication device is
adopted) and backstop devices when fitted to motors.
Combined gear reducer units. Lubrication remains independent, thus data relative to each single gear
reducer hold good.
6.3 - Extruder support lubrication (helical and bevel helical)
The lubrication of extruder support is separate from the gear reducer, except:
– for designs HA ... HC;
– in presence of the independent cooling unit, if applied to lubricate
both the gear reducer and the support.
The separate lubrication of extruder support sensibly improves the reliability and real life of the axial bea-
ring; the separation between gear reducer and support is granted by a seal ring.
With separate lubrication, for the
extruder support, use polyalphaolephines based synthetic oil (MOBIL SHC
Gear, CASTROL Alphasyn EP) with ISO 680 cSt viscosity grade.
With common lubrication (designs HA ... HC in presence of independent cooling unit , if applied to lubri-
cate both the gear reducer and the support), lubricant ISO viscosity grade must be according to the instruc-
tions given in ch. 6.2 «lubrication table» and oil must be polyalphaolephine based synthetic type.
For the filling up of oil of extruder support, see the table below.
For the lubrication of gear reducer refer to ch. 6.2, lubrication table.
Gear reducer Lubrication of extruder support
size Separate lubrication1)
Joint lubrication2)
125 ... 451
Filling up Filling up
to the level (of support) to the level (of gear red.)
1) Support with metal filler plug with filter and valve, level and draining plug.
2) The level is the one of gear reducer housing..
7 - Cooling system
7.1 - Cooling by fan
aria If there is fan on the gear reducer verify that there is sufficient space allowing for
adequate circulation of cooling air also after fitting coupling protection. If a cou-
pling protection is fitted (drilled case or wire netting), smooth, the coupling hub, if
necessary.

Operating instructions − UTD.045.09-2021.00_EN 13
7.2 - Water cooling by coil
The presence of coil is given by water inlets (pipes DIN 2353) protruding from the casing as shown in the
following figure.
size. d A
1)
spanner
Ø ≈
125 ... 180 12 140 22
200 ... 280 12 150 22
320 ... 360 16 160 30
400 ... 6301 16 200 30
A
1) These values for some mounting
positions and designs can vary.
Attention: Do not tamper with the eventual stop plate in order to keep the pipes them locked; in particular keep
the pipe locked while tightening the nut of connection pipe. Water fed into the system must:
– be not too hard;
– be at max temperature +20 °C;
– flow at 10 20 dm3/min;
– have a pressure 0,2  0,4 MPa (2 4 bar).
Where ambient temperature may be less than 0 °C, make provision for water drain and compressed air inlet,
so as to be able to empty out the coil completely and avoid freezing up.
When risking high input pressure peaks, install a safety valve set to a proper operating threshold.
7.3 - Independent cooling unit
See specific documentation supplied together with the unit.
8 - Commissioning
Carry out an overall check, making particularly sure that the gear reducer is filled with lubricant.
Where star-delta starting is being used, input voltage must match the motor lower voltage (connection).
For asynchronous three-phase motor, if the direction of rotation is not as desired, invert two phases at the
terminals.
Before running gear reducers fitted with backstop device, see ch. 5.5.
A running-in period is advisable:
– of approx. 400 1 600 h for gear reducers with worm gear pairs in order to reach maximum efficiency;
– of approx. 200 400 h for gear reducers with bevel and/or cylindrical gear pairs in order to reach maximum
functionality.
The temperature of both gear reducer and lubricant may well rise beyond normal values during running-in.
After the running-in period it may be necessary to verify the gear reducer fastening bolt tightness.
Note: worm gear reducer efficiency is lower in the first running hours (about 50) and at every cold starting
(efficiency will be better with oil temperature increasing). For further information consult Rossi technical
catalogs.
9 - Maintenance
9.1 - General
At machine rest, verify at regular intervals (more or less frequently according to environment and use):
a) all external surfaces are clean and air passages to the gear reducer or gearmotors are free, in order
that cooling remains fully effective;
b) oil level and deterioration degree (check with cold gear reducer at rest);
c) the correct fastening screws tightening.
During the operation check:
– noise level;
– vibrations;
– seals;
– etc.
Attention! After a running period, gear reducer is subject to a light internal overpressure which may cause
burning liquid discharge. Therefore, before loosening whichever plug wait until gear reducer has become
cold; if not possible, take the necessary protection measures against burning due to warm oil contact. ln all
cases, always proceed with great care.
Maximum oil temperatures indicated in lubrication table (see ch.6.2) do not represent a hindrance to the gear
reducer regular running.
Oil change. Execute this operation at machine rest and cold gear reducer.
Prearrange a proper drain oil collection, unscrew both the drain plug and the filler plug in order to facilitate
oil draining; dispose the exhaust lubricant in compliance with the laws in force.
Wash the inside part of gear reducer housing using the same oil type suitable for the running; the oil used
for this wash can be applied for further washings after proper filtering by 25 μm of filtration standard.
Fill in the gear reducer again up to level.
It is always recommended to replace the seal rings (see ch. 9.3)
When dismounting the cap (whenever gear reducers are provided with), reset the sealing with adhesive on
cleaned and degreased mating surfaces.

Operating instructions − UTD.045.09-2021.00_EN
14
9.2 - Coil
In case of long non-running periods at ambient temperatures lower than 0 °C, the coil should be emptied out
using compressed air to blast out all the coolant, so as to avoid freezing-up which would cause the coil to break.
9.3 - Seal rings
It is always recommended that the seal rings are replaced with new ones when they are removed or during
periodic checks of gear reducer; in this case, the new ring should be generously greased and positioned so
that the seal line does not work on the same point of sliding contact as the previous ring.
Oil seals must be protected against heat radiation, also during the shrink fitting of parts, if applicable.
Durating depends on several factor such as dragging speed, temperature, ambient conditions, ect.; as a
rough guide it can vary from 3 150 to 25 000h.
9.4 - IEC motor mounting and dismounting
Gearmotors with motor keyed on hollow high speed shaft of gear reducer:
– Worm gearmotors MR V
– Helical gearmotors MR 2I, MR 3I 140 ... 360
– Bevel helical gearmotors MR CI, MR C2I
– be sure that the mating surfaces are machined under accuracy rating (IEC 60072-1);
– clean surfaces to be fit thoroughly;
– check that the fit-tolerance (push-fit) between hole and shaft end is G7/j6 for D  28 mm, F7/k6 for D 
38 mm;
– lubricate surfaces to be fitted against fretting corrosion.
– when a lowered key is needed, replace the motor key with the one supplied together with the servo gear
reducer; if necessary, adjust it accordingly to the motor shaft keyway length; check that there is a clearan-
ce of 0,1  0,2 mm between the top and the bottom of the keyway of the hole. If shaft keyway is without
shoulder, lock the key with a pin.
In case of hub clamp (helical gearmotors 2I, 3I with motor size  200) assemble as follows:
– rotate the hub clamp so that the tightening screw head is aligned with one of the input holes present on
gear reducer flange, removing first the relevant plugs;
– do not modify the factory setting of hub clamp axial position as this is the best solution in order to reach
the maximum tightening effect;
– introduce the motor from the top down to shoulder;
– lock the motor fitting screws of bolts to the gear reducer flange;
– lock the hub clamp screw by means of torque wrench until the tightening torque stated in the tightening
torque table (see page 24) is reached (also during this operation it is advisable not to modify the hub clamp
axial position);
– screw the hole plugs of gear reducer flange;
For the disassembly please proceed as follows:
– acting on rear motor shaft end, if possibile, or disconnecting the gear reducer from machine and acting on
gear reducer low speed shaft (with brake motor please keep the brake released) alligning the key hole with
the locking screw of hub clamp;
– align the key through hole with the tightening screw of the hub clamp, (trying not to modify the axial position
of hub clamp);
– loosen the motor fastening bolts or nuts from gear reducer flange;
– disassemble the motor.
Gearmotors with cylindrical pinion keyed directly into the motor shaft end:
– Worm gearmotors MR IV, MR 2IV
– Helical gearmotors MR 3I 40 ... 125, MR 4I
– Bevel helical gearmotors MR ICI, MR C3I
– Coaxial gearmotors
– be sure that the motor mating surfaces are machined under accuracy rating (IEC 60072-1);
– clean surfaces to be fitted thoroughly;
– check that the fit-tolerance (standard locking) between hole and shaft end is K6/j6 for D  28 mm, and
J6/k6 for D 38 mm;
– when a lowered key is needed, replace the motor key with the one supplied together with the servo gear
reducer; if necessary, adjust it accordingly to the motor shaft keyway length; check that there is a clearan-
ce of 0,1  0,2 mm between the top and the bottom of the keyway of the hole. If shaft keyway is without
shoulder, lock the key with a pin.
– make sure that the motors have bearing location and overhang (distance S) as shown in the table;

Operating instructions − UTD.045.09-2021.00_EN 15
Motor size Min dynamic load capacity Max dimension
'S' mm
daN
Front Rear
63 450 335 16
71 630 475 18
80 900 670 20
90 1 320 1 000 22,5
100 2 000 1 500 25
112 2 500 1 900 28
132 3 550 2 650 33,5
160 4 750 3 350 37,5
180 6 300 4 500 40
200 8 000 5 600 45
225 10 000 7 100 47,5
250 12 500 9 000 53
280 16 000 11 200 56
– mount onto the motor shaft as follows:
– the spacer pre-heated at 65° C treating the relevant motor shaft area with adhesive type LOXEAL 58-14 and
checking that between keyway and motor shaft shoulder there is a cylindrical part ground by 1,5 mm at least;
pay attention not to damage the external surface of spacer;
– the key in the keyway, making sure that a contact length of at least 0,9 times the pinion width is present;
– the pinion pre-heated at 80 ÷ 100 °C;
– the axial fastening system when foreseen (self locking screw on motor shaft butt-end with washer and spacer
or hub clamp with 1 or more dowels, fig. a); for the cases foreseen without axial fastening (fig. b), apply adhe-
sive type LOXEAL 58-14 also on the motor shaft part laying under the pinion;
– in case of axial fastening system with hub clamp and dowels, make sure that they do not overhung from spacer
external surface: screw the dowels completely and, if necessary, imprint the motor shaft with a point;
–grease (with grease type KLÜBER Petamo GHY 133N) the pinion teeth, the seal ring rotary seating and the ring
itself, and assemble carefully, taking care not to damage seal ring lip in case of accidental shock with pinion
toothing.

Operating instructions − UTD.045.09-2021.00_EN
16
9.5 - Servo motor mounting and dismounting
Attention! Excessive long and heavy motors may cause critical conditions
for bending torque and, during running, abnormal vibrations. In these
cases, it is advisable to adopt an adequate auxiliary motor mounting system.
Servo gear reducer type MR (servo motor coupling of direct type):
– Worm servo gear reducer MR V
– Helical servo gear reducer MR 2I
– Bevel-helical servo gear reducer MR CI
The servo gear reducer input face has a servo motor mounting flange, including
bolts, a hollow high speed shaft provided with axial slots and hub clamp.
This kind of fitting can be even suitable for mounting servo motors with
keyless shaft end.
Prior to installation, throughly clean and lubricate the mating surfaces to avoid
the risk of seizing and fretting corrosion (see fig. 1).
For the servomotor mounting proceed as follows:
– when a lowered key is needed, replace the key on the servomotor shaft end
with the one supplied together with the servo gear reducer; if necessary, adjust i t
accordingly to the servo motor shaft keyway length;
– position the gear reducer vertically with motor mounting flange upwards (see
fig. 2);
– rotate the hub clamp so that the tightening screw head is aligned with one
of the input holes present on gear reducer flange, removing first the relevant
plugs (see fig. 2);
– do not modify the factory setting of hub clamp axial position as this is the
best solution in order to reach the maximum tightening effect;
– introduce the motor from the top down to shoulder (see fig. 3);
– lock the servomotor fasetning bolts or nuts to the servo gear reducer flange;
– lock the hub clamp screw by means of torque wrench until the tightening
torque stated in the tightening torque table (at page 24) is reached (also
during this operation it is advisable not to modify the hub clamp axial position,
see fig. 4);
– screw the hole plugs of gear reducer flange.
Before any motor dismounting be sure that the hub clamp tightening
screw has been unloosed, if present.
Servo gear reducer type MR
(servo motor coupling of direct type)
– Worm servo gear reducer MR IV
– Coaxial servo gear reducer MR 2I, MR 3I
– Helical servo gear reducer MR 3I
– Bevel-helical servo gear reducer MR ICI
The servo gear reducer input face has a flange (bolts included) for servo motor
mounting and a helical pinion gear to be fitted onto the servo motor shaft end.
Assembly not possible for servomotors with shaft end without key.
Prior to installation, thoroughly clean and lubricate the mating surfaces to
avoid the risk of seizing and fretting corrosion.
For the servo motor mounting proceed as follows:
– check that the fit-tolerance (standard locking) between hole and shaft
end is K6/j6 for D ≤ 28 mm, J6/k6 for D ≥38 mm; the length of the
parallel key is to be at least 0,9 times the pinion face width;
– mount onto the servo motor shaft end, in the following order:
– the spacer pre-heated at 65 °C treating the relevant motor shaft area
with adhesive type LOXEAL 58-14 and checking that between keyway
and motor shaft shoulder there is a cylindrical part ground by 1,5 mm
at least; pay attention not to damage the external surface of spacer;
– the key in the keyway, making sure that a contact length of at least 0,9
times the pinion width is present;
– the pinion pre-heated at 80 ÷ 100 °C;
– the axial fastening system when foreseen (self locking screw on
motor shaft butt-end with washer and spacer or hub clamp with 1 or
more dowels, fig. a); for the cases foreseen without axial fastening
(fig. b), apply adhesive type LOXEAL 58-14 also on the motor shaft
part laying under the pinion;
– in case of axial fastening system with hub clamp and dowels, make
sure that they do not overhung from spacer external surface: screw
the dowels completely and, if necessary, imprint the motor shaft with
a point;
g. 3
g. 4
g. 1
g. 2

Operating instructions − UTD.045.09-2021.00_EN 17
– grease (with grease type KLÜBER Petamo GHY 133N) the pinion teeth, the seal ring rotary seating
and the ring itself, and assemble carefully, paying particular attention not to damage the seal ring
lip due to an accidental impact with the pinion toothing.
Servo gear reducer type R
(servo motor coupling with bell and torsionally stiff coupling)
– Worm servo gear reducer R V, R IV
– Helical servo gear reducer R 2I, R 3I
– Bevel-helical servo gear reducer R CI, R ICI
The servo gear reducer type R input face has a flange (bolts not included)
for servo motor mounting and a torsionally stiff coupling.
A half-coupling hub is to be fitted onto the servo motor keyless shaft end (if
present, remove it; see fig. 1). In case of high starts/hour and heavy loads, it
is necessary to request the non-standard design «Coupling with keyway».
All mounting surfaces (shafts, bores, keys and keyways), must be clean and
free of burrs, nicks and dents.
Check the servo motor shaft diameter, coupling bore diameter, key and keyway dimensions and
tolerances.
All coupling bores are machined to tolerance H7.
Assembling clearance between the servo motor shaft diameter and half-coupling hub diameter has to be
maintained within 0,01 and 0,05 mm.
A light coating of oil is recommended to ease the mounting process and will not affect the clamping force
of the hub.
Do not use molybdenum disulphide or equivalent lubricants.
Insert the half-coupling onto the servo motor shaft, as shown in fig. 1, abutting with elastomer
ring seat.
Tighten the clamp screw E, using a dynamometric wrench, to the appropriate
torque stated in the table1) (see page 24).
Clean the elastomer ring and the seats into the coupling hubs and apply a
light film of oil to facilitate the assembly process, see fig. 2 (use polyurethane
compatible lubricants such as e.g. vaseline).
Insert the elastomer ring (fig. 2) and assemble the servo motor on the servo
gear reducer, tightening the screws (fig. 3) on the servo motor flange.
The achievement of the zero angular backlash is ensured by the squeezing
of the elastomer ring interposed between the two parts of the coupling.
1) In some cases, a spacer to be interposed between the half-coupling and the servo motor shaft
shoulder is provided
9.6 - Bearings
Since there are many different types of bearings in a gear reducer (roller, tape-
red roller, straight roller, etc.) and each bearing works with different loads and speeds depending on the
input speed, the nature of the load of the driven machine, the transmission ratio, etc., and with different
lubricants (oil bath, oil splash, grease, oil circulation, etc.), it is not possible to define any periodical
maintenance and replacement of bearings in advance.
If a precautionally maintenance is required, undertake periodical checks to verify noise level and
vibration with the help of appropiate diagniostic equipment and instruments. If the measured
values worsen even slightly it is necessary to stop gear reducer or gear motor and after having inspected
inside the unit replace the bearings which are subject to breakdown.
9.7 - Metal filler plug with filter and valve
When the gear reducer or gearmotor (size  100) is equipped with metal filler plug with filter and valve
(see fig. beside), in order to clean it, it is necessary to unscrew it from the gear reducer (preventing any
debris or other foreign items from entering the reducer, disassemble the cover, wash it
with solvent, dry with compressed air and reassemble it).
This operation is to be made according to environment conditions.
g. 1
g. 2
g. 3

Operating instructions − UTD.045.09-2021.00_EN
18
Painting table
1) For worm gear reducers UNI 5931-84.
2) The bolts of shrink disc must be gradually and uniformly tightened, with continuous sequence (not diagonally!) and in several phases up to the reaching of maximum tightening torque stated on table.
1) For servo gear reducers (cat. SR) the final colors is matt black RAL 9005.
2) Integrated low backlash planetary servogearmotors.
3) Before adding further coats of paint, properly protect the seal rings and carefully degrease and sand the gear reducer surfaces.
Product Size Internal painting External painting Notes
Final color
Blue RAL 5010 Features
Worm 32 … 81
Epoxy powder
(prepainted) Epoxy powder (prepainted)
Resistant to atmospheric
and aggressive agents
(atmospheric corrosivity category C3
according to ISO 12944-2)
Suitable for further coats of
dual-compound paints only3)
Machined parts remain
unpainted and are protect-
ed with an easily removable
anti-rust oil (before painting
remove the protective oil)
Helical and
bevel helical
40 … 81
Coaxial type 32 … 41
Worm 100 … 250
Single-compound
ester epoxy or phe-
nolic resin basis
primer
(prepainted)
Single-compound ester
epoxy or phenolic resin
basis primer
(prepainted)
+
Water-soluble
polyacrylic
dual-compound enamel
Resistant to atmospheric
and aggressive agents
(atmospheric corrosivity category C3
according to ISO 12944-2).
Suitable for further coats of
dual-compound paints only3)
Machined parts are painted
wih water-soluble polyacrylic
dual-compound enamel
The internal painting
does not resist polyglycol
synthetic oils (polyalpha-
olefines synthetic oils are
suitable).
Remove by a scraper or
solvent the possible paint
of gear reducer coupling
surfaces
Coaxial type 50 … 81
Helical and
bevel helical
100 … 8001
Coaxial type 100 … 180
Right angle
(cat. L) 160 … 320
Right angle
(cat. L) 80 … 125
–Water-soluble
polyacrylic
dual-compound enamel
Remove by a scraper or
solvent the possible paint
of gear reducer coupling
surfaces
Shaft mounted
Coaxial2) 56 … 142
–
Dual-compound epoxy
polyamide primer
+
Water-soluble dual-com-
pound polyacrylic enamel
(matt black RAL 9005)
Resistant to atmospheric
and aggressive agents
(atmospheric corrosivity category C3
according to ISO 12944-2).
Suitable for further coats of
dual-compound paints only3)
Machined parts remain
unpainted and are protect-
ed with an easily removable
anti-rust oil (before painting
remove the protective oil)
Bevel helical 2) 85 … 142
Table of tightening torques for axial fastening bolts and shrink disc2)
Worm gear
reducer size
32 40 50 – 63,
64 –80,
81 100 125,
126 160 161 – 200 – 250 – – – – – – – – – –
Helical and
bevel
helical size
40 50 – 63 64 80 81 100 125 140 – 160 180 200 225 250 280 320,
321 360
400,
401
4000,
4001
4500,
4501
5000,
5001
5600,
5601
6300,
6301
7101,
8001
Bolts for axial
fastening
UNI 5737-88
class 10.9
M81) M81) M101) M10 M10 M10 M10 M12 M14 M16 M16 M20 M20 M24 M24 M30 M30 M36 M36 M30 M30 M36 M36 M36 M45
Ms [N m]
for rings or bush
29 35 43 43 43 51 53 92 170 210 210 340 430 660 830 1350 1660 2570 3150 – – – – – –
Bolts for
shrink disc
UNI 5737-88
class 10.9
– M5 – M6 M6 M6 – M8 M8 M8 – M10 M10 M12 M12 M16 M16 M16 M16 M20 M20 M20 M20 M24 M27
Ms [N m]
for shrink disc
– 04 – 12 12 12 – 30 30 30 – 60 60 100 100 250 250 250 250 490 490 490 490 840 125
10 - Sound levels
Most of the Rossi product range is characterised by sound pressure
levels L
¯pA
(mean value of mea-surement, assuming nominal load and
input speed n1= 1 400 min -1, at 1 m from external profile of gear reducer
standing in free field on a reflecting surface, according to draft proposal
ISO/CD 8579) lower or equal to 85 dB(A).
The table indicates the pro ducts which can exceed a.m. threshold. For
further information about sound levels of every single product see Rossi
technical catalogs.
Machine/Train of gears iNSize
Helical R I  3,15 160
4 200
R 2I all 320
R 3I all 400
R 4I 160 5000
200 6300
Bevel helical R CI all 320
R C2I 63 400
71 5000
R C3I all 6300
Right angle R C 1 250

Operating instructions − UTD.045.09-2021.00_EN 19
Note
- Class 8.8 is usually sufficient.
-
Before tightening the bolt be sure that the eventual centering of flanges are inserted properly
- The bolts are to be diagonally tightened with the maximum tightening torque.
Table of tightening torques fastening bolts (foot,
flange, hub clamps and flexible half-coupling bolts)
Table of tightening torques for plugs
Bolt Ms [N m]
UNI 5737-88, UNI 5931-84
cl. 8.8 cl. 10.9 cl. 12.9
M4 2,9 4 –
M5 68,5 10
M6 11 15 20
M8 25 35 40
M10 50 70 85
M12 85 120 145
M14 135 190 230
M16 205 290 350
M18 280 400 480
M20 400 560 680
M22 550 770 930
M24 710 1000 1200
M27 1000 1400 1700
M30 1380 1950 2350
M33 2000 2800 3400
M36 2500 3550 4200
M39 2950 4200 5000
M42 4100 5800 6900
M45 5000 7000 8400
M48 6100 8600 10300
M56 9800 13800 16500
Thread
dimension
Ms [N m]
G 1/4’’ 7
16 MB 14
G 1/2’’ 14
G 3/4’’ 14
G 1’’ 25
Attention! Before tightening, carefully degrease the bolts.
For strong vibrations, heavy duties, frequent motion
reversals apply a thread-braking seal type Loxeal 23-18 or
equivalent.

Operating instructions − UTD.045.09-2021.00_EN
20
Motor: see specific documentation.
NOTE
When consulting Rossi state:
– all data of gear reducer or gearmotor name plate;
– nature and duration of failure;
– when and under which conditions the failure occured;
– during the warranty period, in order not to loose validity, do not disassemble nor tamper the gear reducer or gearmotor without approval by
Rossi.
Trouble Possible causes Corrective actions
Gear reducer troubles: causes and corrective actions
Excessive oil temperature
Damaged raceway surface (scoring, rust, dent, etc.)
Position the gear reducer correctly
Clean/replace filler plug with vent valve
Low speed shaft not rotating
even with high speed shaft/
motor running
Consult Rossi
Consult Rossi
Vibrations Check the fastening and the bearings
Lubricant leaking
from seal rings
Seal ring with worn, bakelized, damaged or false
mounted seal lip
Replace seal ring (see ch. 9.3)
Restore the raceway
Mounting position differs from the one stated on the
name plate
Inadequate lubrication:
– excessive or insufficient oil quantity;
– unsuitable lubricant (diffe rent type, too viscous,
ex hausted, etc.)
wrong mounting position
Too tightened taper roller bearings
Worm gear reducer with excessive load during
running-in
Excessive ambient temperature
Check:
– oil level (gear reducer at rest) or quantity
–lubricant type and/or state (see ch. 6.2 lubrication
table); replace if necessary
Change mounting position
Consult Rossi
Reduce the load
Increase the cooling or correct the ambient temperature
Inefficiency of auxiliary bearing lubrication
system
Check the pump and the pipes
Inefficient or out of service oil cooling system:
obstructed filter, insufficient oil (exchanger) or water
(coil) flow rate, pump out of service, water temperature
20 °C, etc.
Oil leaking from filler plug Too much oil Check oil level/quantity
Incorrect mounting position Check mounting position
Check pump, pipes, oil filter and safety devices effi-
ciency (pressure switchs, thermostats, flow indicators,
etc.)
Anomalous noise
Inefficient vent valve
One or more teeth with:
–dents or spallings
–excessive flanks roughness
Consult RossiWorn, faulty or badly lubricated bearings
Broken key
Completely worn gear pair Consult Rossi
Lubricant leaking from
joints (covers or
half-casing joints)
Defective oil seals Consult Rossi
Taper roller bearings with ex cessive clearance
Worn, faulty or badly lubricated bearings Consult Rossi
Obstructed passage of air Eliminate obstructive material
Slow or missing air recycle Arrange auxiliary ventilation
Radiance Screen gear reducer and motor properly
Consult Rossi
Water in the oil Defective cooling coil or heat exchanger