Habasit Rossi IFIT Series User manual

Operating instructions
Series
UT.D 208-2021.12-EN

2UT.D 208-2021.12-EN

1General safety information 5
1.1 Recycling 5
1.2 Safety 5
1.2.1 Residual risks 7
2Application conditions and use limits 8
3How supplied and product designation 8
3.1 Receipt 8
3.2 Name plate 8
3.3 Lubrication 9
3.4 Painting 9
3.5 Protections and packing 9
3.6 Designation 10
4Lifting, handling and storing 12
4.1 Lifting and handling 12
4.2 Storage 13
5Installation of gear reducer 14
5.1 General 14
5.2 Tightening torques for fastening bolts (feet, fl ange, accessories) and for plugs 15
5.3 Flange mounting 16
5.4 Foot mounting 16
5.5 Fitting of components to shaft ends 17
6Lubrication 19
6.1 General 19
6.2 Lubrication table 20
6.3 Oil level (quantity) 22
6.4 Mounting positions and plug position 23
Contents
3
UT.D 208-2021.12-EN

7Motor assembly and disassembly 25
7.1 General 25
7.2 Procedures for assembling the cylindrical pinion keyed onto motor shaft 25
7.3 Assembling the IEC and NEMA motor to adapter 26
8Commissioning 27
8.1 General 27
8.2 Running-in 27
9Maintenance 28
9.1 General 28
9.2 Oil change 28
9.3 Seal ring 29
9.4 Bearings 29
9.5 Metal fi ller plug with fi lter and valve 29
9.6 Sound levels LWA and LpA 29
9.7 Spare part tables 30
10 Gear reducer troubles: causes and corrective actions 32
11 Index of revisions 33
Contents
4UT.D 208-2021.12-EN

This document provides information about handling, installation and maintenance of helical and bevel helical gear reducers and
gearmotors (iFIT series).
All the people handling with these activities must carefully read all the following instructions and apply them rigorously.
Information and data contained in this document correspond to the technical level reached at the moment the catalog is printed.
Rossi reserves the right to introduce, without notice, the necessary changes to improve effi ciency and safety of its products.
General safety information 1
1.1
Recycling
IMPORTANT: gear reducers and gearmotors supplied by Rossi S.p.A. are "partly completed machinery" and as such they
must be incorporated in fi nished appliances or systems and should not be commissioned before the machinery in which the
component has been incorporated conforms to:
• Machinery directive 2006/42/EC and subsequent updatings; in particular, possible safety guards for shaft ends not
being used and for eventually accessible fan cover passages (or other) are the Buyer's responsibility;
• «Electromagnetic compatibility (EMC)» 2004/108/EC and subsequent updatings.
Attention!
Observe the established legislation concerning waste treatment and recycling of exhaust material:
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:
• – the elements of housing, gear pairs, shafts and bearings of gear reducer must be transformed into steel
scraps as well as cast iron elements, subject to other specifi c requirements;
• for other non-metallic components (seal rings, covers, etc.) comply with applicable regulations;
• waste oils must be recovered and treated in accordance with applicable legal requirements.
• live parts;
• temperature higher than 50 °C;
• components rotating during operation;
• suspended loads (lifting and transport);
• eventual high sound level ( > 85 dB(A));
• lifting instructions.
All instructions in this manual, all applicable installation regulations, as well as all applicable
safety regulations must be duly followed.
Whenever personal injury or property damage, due to falling or projecting parts of gear reducer or of its
parts, 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.
5
UT.D 208-2021.12-EN

General safety information 1
Safety during installation
An incorrect installation, an improper use, the removing or disconnection of protection devices, the lack of inspections and
maintenance, improper connections may cause severe personal injury or property damage. Therefore the component must be
moved, installed, commissioned, handled, controlled, serviced and repaired exclusively by responsible qualifi ed personnel.
Qualifi ed personnel must be specifi cally trained and have the necessary experience to recognize any risks (see section 1.2.1
- Residual risks) related to these products, avoiding possible emergency situations.
Gear reducers and gearmotors in this manual are normally intended for installations in industrial areas : additional protection
measures that may be necessary must be adopted and ensured by the personnel responsible for the installation.
Attention!
Motors in non-standard design or with constructive variations may diff er 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, or non-standard motor) or the
possible motor-variator and/or the electric supply device (frequency converter, soft-start, etc.), and/or any optional
electric devices (e.g.: independent cooling unit, etc.), consult the specifi c attached documentation. Request it if
necessary.
Maintenance safety
When operating on a gear reducer or components connected to it, the machine must be at rest, disconnected from the power
supply, and cold : disconnect the motor (including auxiliary equipment) from the power supply, gear reducer from the 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.
Further technical documentation (e.g. catalogs) can be downloaded from our website www.rossi.com or can be
directly required to Rossi S.p.A. For any clarifi cation and/or information, please contact Rossi S.p.A. specifying all
data found on the name plate.
6UT.D 208-2021.12-EN

The products supplied by Rossi S.p.A. have been designed and manufactured according to the essential health and
safety requirements provided for by Machine Directive 2006/42/EC - Annex I.
The following table lists the residual risks that the user is required to handle in accordance with the instructions
contained in this document and in those, if any, enclosed with the shipment.
General safety information 1
Residual risks
Nature/Cause of risk Countermeasures
Installation and maintenance
operations
The component must be handled, installed, commissioned, operated, inspected,
maintained, and repaired only by qualifi 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 specifi cally instructed
and have the necessary experience 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 signifi cant
damage to the machine or system.
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 equipped with a coupling (high or low speed shaft), provide protections
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 accidental breakage of
the reaction constraint;
- accidental breakage of the machine pin.
Movable elements Provide safety guards for unused shaft ends and accessible fan cover passages (or
others).
Any operation on the gear reducer or gearmotor must be carried out with the machine
stopped and disconnected from the power supply, after the gear reducer or gearmotor have
cooled down.
Extreme temperatures During operation, the gear reducers may have hot surfaces (> 50 °C); before 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 high speed shaft. The same applies to the hydraulic
coupling, if present.
After a period of operation, the gear reducer will undergo a slight internal overpressure that
can result in the leakage of burning fl uid.
Therefore, wait until the gear reducer has cooled down before loosening the caps (of
any kind); alternatively, use appropriate protections (PPE) against burns resulting from
accidental contact with hot oil.
In all cases, always proceed with great care.
Noise Depending on the size, gear ratio, transmission ratio, duty cycle type, and mounting system
of the gear reducer or gearmotor, the noise emission level may exceed 85 dB(A). Perform
fi eld measurements and, if necessary, equip the personnel concerned with appropriate
personal protective equipment (PPE).
Changes that may aff ect the
safety of the equipment
Do not make any structural modifi cation to the products supplied by Rossi (reducers,
gearmotors, control group, etc.) without prior approval by Rossi S.p.A.
Use of replacement
components with
characteristics unsuitable for
the application
Spare parts must be those authorized by Rossi S.p.A.
Table 1.2.1 Residual risks
7
UT.D 208-2021.12-EN

Application conditions and use limits 2
Gear reducers are designed for industrial applications according to catalog data, ambient temperature 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 specifi cations stated on name plate.
How supplied and product designation 3
3.1
Receipt
Upon receipt check that the goods correspond to the order specifi cations and that they have not suff ered damage during
transport; in this event, immediately contest such damage to the carrier.
Do not commission gear reducers and gearmotors that are even slightly damaged.
Report any non-compliance to Rossi
3.2
Name plate
Each gear reducer is provided with a name plate in anodized aluminium containing main informations necessary for a correct
identifi cation of the product (see ch. 3.6); the name plate must not be removed and must be kept integral and readable.
All name plate data must be specifi ed on eventual spare part orders.
Rossi S.p.A.
41123 Modena (MO) - Italy
Made in Italy - www.rossi.com
Via Emilia Ovest, 915/A
i
S.N.
M.P.
Date
WA
Type
Code
ITEM
(1) Gear reducer type
(2) Transmission ratio
(3) Production date
(4) Gear reducer mounting
position
(5) Product code
(6) Serial number
(7) Production batch
(8) Customer code (1)
(1) On request
8UT.D 208-2021.12-EN

How supplied and product designation 3
Unless otherwise stated, the gear reducers are supplied complete with synthetic oil for long-life lubrication.
For V6 mounting position, the upper bearing and metal shield are lubricated with grease. In detail, see page 19.
Standard paint unless otherwise indicated.
For special paintings, please request additional information.
(1) Before overpainting, suitably protect the seal rings and degrease and sand the gear reducer surfaces (as an alternative
to sanding, a coat of solvent-based primer can be applied).
Frame size
gear
reducer
Painting
Internal
External painting
Notes
Final color
Blue RAL 5010 Features
2...9 Epoxy powder
(prepainted)
Epoxy powder
(prepainted)
Resistant to atmospheric
and aggressive agents.
(corrosivity class C3
according to ISO 12944-2)
Overpaintable only with
dual-compound products 1)
Machined parts remain
unpainted; they are protected
with an easily removable
antitrust oil
(before painting remove
the protective oil).
Overhanging free shaft ends and hollow shafts are treated with protective anti-rust long-life oil and protected with a a plastic
(polyethylene) cap. 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 polyethylene fi lm, 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 fi lling cardboard.
Do not stock packed products on top of each other.
Table 3.4.1 Standard painting
3.3
Lubrication
3.4
Painting
3.5
Protections and packing
9
UT.D 208-2021.12-EN

How supplied and product designation 3
Gearmotor designation
iC 4 7 3 J E -34.73 -B3 -F416 -
Series
Frame size
gear
reducer
Model Train of
gears
Performance
gear reducer
Low speed
shaft design -
Transmission
ratio
-
Gear
reducer
mounting
position
-Output
fl ange -
Mounting position
compact motor
Motor adapter code
2
3
4
5
iC
Gear
reducers
Coaxial
i-FIT
6
7
8
9
7
P
Performance
foot mounting
J
Performance
with fl ange E
Metric 3.37
4.00
...
...
B3
B6
B7
B8
V5
V6
F212
F214
...
... B12B
...
B30M
gear reducer
AB12BI063
...
B16D
AB16BI063
confi guration with adapter and standard IEC motor
confi guration with compact motor
IEC
AB12BN056
...
NEMA
2
Stages
reduction
3
Stages
reduction
AB12CN143
AB30MN324
AB12BI071
AB30MI200
UT.C 2381
UT.C 2382
3.6
Designation
10 UT.D 208-2021.12-EN

How supplied and product designation 3
Motor designation
(TB0) TB3
TB2
TB1
(TB0)
TB3
TB2
TB1
Motor terminal block position
HB 3 Z 90S -4 230,400 50 -B16D -TB2(1)
Series
Class
energy
Brake
Integrated
Motor size -N.
poles Voltage supply Frequency supply -
Motor mounting position
-Position terminal
block
compact IEC
HB
2
effi ciency
IE2
3
effi ciency
IE3
63A
63B
71B
...
2
4
6
50
60
-
Z
TB1
TB2
TB3
230,400
400
...
B12B
...
B30C
B5
Drive end (D) Non-drive end (N)
UT.C 2383
The designation is to be completed with the statement of motor terminal box position if diff ering from the standard one TB0.
The release lever (for brake motor) follows the position of the terminal box.
The cable entry is the responsibility of the Buyer: the terminal box is integral with housing with knockout cable openings on
both sides (one for power cable and one for auxiliary equipment).
(1) For standard terminal box position TB0, no indication in motor designation is necessary.
11
UT.D 208-2021.12-EN

Lifting, handling and storing 4
Make sure that the lifting equipment (e.g.: crane, hook, eye bolt, straps, etc.) are suitable for the weight and size of the gear
reducer (consult Rossi technical catalog for dimensions and weight).
For the lifting and transport of gear reducer (or gearmotor) use through holes or threads on the gear reducer housing feet as
stated in the fi gures below.
Avoid unbalanced lifting (during the movement, inclination must not exceed max ±15° as to mounting position) and, if necessary,
use additional belts to balance the weight.
Do not use any shaft ends.
Do not use motor eyebolts.
Do not use front threads of shaft ends or eventual external pipes.
Do not add supplementary loads to the gear reducer or gearmotor mass.
Attention!
During the lifting and handling:
• do not stand under the suspended loads;
• do not damage the gear reducer with an inadequate transport;
• keep the gear reducers fi lled with oil in the mounting position foreseen in the order.
Gear reducers
Size ≤ iC 57...
Size ≥ iC 67...
UT.C 2427 UT.C 2428 UT.C 2429
UT.C 2430 UT.C 2431 UT.C 2432
UT.C 2433
UT.C 2434
Gearmotors
Belt to be used exclusively to ensure the motor, when directly mounted, against
oscillations due to transport; not to be used for the lifting of entire gearmotor group.
Lifting point
4.1
Lifting and handling
12 UT.D 208-2021.12-EN

Lifting, handling and storing 4
Surroundings should be suffi ciently clean, dry (relative humidity < 50%), free from excessive vibrations (ve ff ≤ 0,2 mm/s) not
to damage the bearings (vibrations must be limited, although within a wider range, also during transport) and must have a
temperature of 0 ÷ +40 °C: peaks of 10 °C above or below this temperature range are allowed.
The gear reducers fi lled with oil must be positioned according to the mounting position stated on name plate during transport and
storage.
Do not stack units.
Every six months rotate the shafts (some revolutions are suffi cient) 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.
Do not, under any circumstances, loosen the closed plugs or activate the drain plug before commissioning.
In the event of "Long germ storage" option, for a storage period from 12 to 24 months in normal environments, the following is
envisaged:
• gear reducer delivered without oil fi lling;
• internal volume of the gear reducer protected by VI lubricant coating;
• application of a layer of special anti-corrosive oil to all unpainted external parts (shafts, feet, fl anges), including galvanized
components (screws, nuts, washers, eyebolts, etc.);
• application of an adhesive label indicating the type of protection used;
• single packaging with sealed VCI bag.
The following instructions must be followed:
• abundantly grease the seals, shafts and unpainted machined surfaces, even if they are protected with anti-rust oil, periodically
checking the grease condition;
• completely fi ll the gear reducer with lubrication oil, topping it up to the indicated level before startup
For longer periods please contact Rossi S.p.A.
4.2
Storage
13
UT.D 208-2021.12-EN

Installation of gear reducer 5
Before installing, check that:
• the shafts and contact surfaces are not damaged;
• gear reducer specifi cations are suitable for ambient conditions (temperature, atmosphere, etc.);
• the structure on which the gear reducer is secured is fl at, levelled and suffi ciently dimensioned to ensure installation stability
and absence of vibrations, (vibration speed veff≤ 3,5 mm/s for PN< 15 kW and veff< 4,5 mm/s for PN> 15 kW are acceptable),
taking into account all transmitted forces due to masses, torque, radial and axial loads;
• the mounting position intended use corresponds to that indicated on name plate.
Attention!
Take the greatest care when aligning the gearmotor with the machine to be driven (use shims if necessary).
Incorrect alignment may cause breakdown of shafts and/or bearings (which may cause overheatings) which
may represent heavy danger for people.
Position the gear reducer 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 fl ow; heat sources near the gear reducer that might aff ect the temperature of cooling air and of
gear reducer (for radiation); insuffi cient air recycle and applications hindering the steady dissipation of heat;
Verify that the gear reducer housing is dust-free in order to achieve an effi cient heat dispersal.
Place the supplied adhesive pictogram identifying the risk associated with hot surfaces on the surface of the
gearbox in a position visible to personnel involved in the operation and maintenance of the machine (taken
from UTD189).
Mating surfaces (of gear reducer and machine) must be clean and suffi ciently rough to provide a good friction coeffi 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 fi tting gear reducer and machine and/or gear reducer and eventual fl ange B5 it is recommended to use locking adhesives
such as LOCTITE on the fastening screws (also on fl ange mating surfaces).
For accessories not supplied 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 starting current or other
similar devices should be fi tted.
If overloads are imposed for long periods or if shocks or danger of jamming are envisaged, then motor-protection, electronic torque
limiters, fl uid couplings, safety couplings, control units or other similar devices should be fi 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 (fi 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 fi lters to limit voltage peaks due to contactors.
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.
For outdoor installations or aggressive environments, paint the gear reducer or gearmotor with a suitable anti-corrosive paint (see
ch. 3.4), protecting it with water-repellent grease (especially in position with the rotating seats of the seal rings and the access
areas on the shaft ends).
Gearmotors should be protected wherever possible, and by whatever appropriate means, from solar radiation and extremes of
weather; weather protection becomes essential for V5 and V6 mounting positions.
For ambient temperature greater than +40 °C or less than 0 °C, consult Rossi.
5.1
General
14 UT.D 208-2021.12-EN

Installation of gear reducer 5
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.
Further technical documentation can be downloaded from our website www.rossi.com.
Fitting of components to shaft ends
It is recommended that the bore of parts keyed to low speed shaft ends is machined to K7 tolerance (H7 when load is uniform
and light).
Before mounting, thoroughly clean mating surfaces with proper antirust products, and lubricate against seizure and fretting
corrosion.
Installing and removal operations should be carried out with pullers and jacking screws using the tapped hole at the shaft butt-end.
Tightening torques for fastening bolts (feet, fl ange, accessories) and for plugs
Unless otherwise specifi ed, it is normally suffi cient to use class 8.8 screws; the following cases are an exception, for which
screws with strength class 10.9 must be used:
• iC 372 - iC 373 FE with fl ange F312
• iC 472 - iC 473 FE with fl ange F414
• iC 572 - iC 573 FE with fl ange F516
Before tightening, carefully degrease the screws; in the event of heavy vibrations, heavy duties, frequent drive inversions apply
a thread-braking seal type LOCTITE or similar.
Fastening
bolts
Tightening torque Ms
for bolts for foot and fl ange fastening
N m
cl. 8.8 cl. 10.9
M4 2.9 4
M5 68.5
M6 11 15
M8 25 35
M10 50 70
M12 85 120
M14 135 190
M16 205 290
M18 280 400
M20 400 560
M22 550 770
M24 710 1000
Frame size
gear reducer
Tightening torque Ms
for oil drain and breather plugs
Plug threading
dimension
Ms
N m
iC 27 ... iC 67 M10 x 1 8
iC 77, iC 87 M12 x 1,5 14
iC 97 M22 x 1,5 45
Table 5.2.2 Tightening torques for oil drain and fi ller plugsTable 5.2.1 Tightening torque for fastening bolts
5.2
15
UT.D 208-2021.12-EN

Installation of gear reducer 5
If through-holes ( flange B5) are used for fastening, carefully select the length of the fastening screws, which must be long enough
to ensure a sufficiently extended clamping section to ensure correct fastening of the gearbox to the machine.
Before tightening the bolt be sure that the eventual centering of fl anges is inserted properly
Screws must be tightened diagonally with the maximum torque indicated in Table 5.2.1.
In the fastening screws and in the fl ange mating surfaces use locking adhesives.
Frame size
gear reducer
Dimensions
B5 fl ange
mm
Tightening torque
Ms ± 10%
Strength class 10.9
N m
Ø P Ø F S
iC 27, iC 37 120 M6 8 15
iC 27 140 M8 935
iC 37, iC 47 140 M8 10 35
iC 27 ... iC 57 160 M8 10 35
iC 37 ... iC 67 200 M10 12 70
iC 57 ... iC 77 250 M12 15 120
iC 77 300 M12 15 120
iC 87 300 M12 16 120
iC 87 350 M12 15 120
iC 97 350 M16 18 290
iC 97 450 M16 22 338
UT.C. 2435
Frame size
gear reducer
Foot mounting screw
UNI5737
(minimum length in mm)
iC 27, iC 37 M8 x 18
iC 47, iC 57 M12 x 24
iC 67 M12 x 30
iC 77 M16 x 30
iC 87 M16 x 45
iC 97 M20 x 55
Table 5.3.1 B5 fl ange hole dimensions
Table 5.4.1 Foot mounting screw dimensions
Attention!
Thoroughly degrease the screws before tightening.
In the event of strong vibrations, heavy-duty cycles, frequent motion reversals, it is always advisable to apply a
suitable threadlocker adhesive such as LOXAEL 23-18 or equivalent on the tnread.
Housing for 4 screws or nuts
(minimum length indicated in the table)
5.3
Flange mounting
5.4
Foot mounting
16 UT.D 208-2021.12-EN
F
S
P

Installation of gear reducer 5
Fitting of components to shaft ends
Gear reducer shaft end Machine shaft
Shaft end
mm
Key
mm
Key
mm
Ø D
k6 E Ø d S L
b x h x l
h9 h11
b
H9 hub
N9 shaft
t
shaft
t1
hub
25 50 M10 7.6 18.4 8 x 7 x 40 8 4 28.3
30 60 M10 7.6 18.4 8 x 7 x 50 8 4 33.3
35 70 M12 9.5 22.5 10 x 8 x 56 10 5 38.3
40 80 M16 12.7 27.3 12 x 8 x 70 12 5 43.3
50 100 M16 12.7 27.3 14 x 9 x 80 14 5.5 53.8
60 120 M20 16 34 18 x 11 x 110 18 7 64.4
Shaft end
at
(mm)
Key
at
(mm)
Key
at
(mm)
Ø D E Ø d S
(mm) L b h l b t shaft
t1
hub
1
(25,4)
1.93
(50)
3/8-16
(7,9) 7.5 14.5 (22,9)
0.25
(6,35)
0.25
(6,35)
1.313
(33,34)
0.25
(6,35)
0.141
(3,58)
1.114
(28,3)
1,25
(31,75)
2.36
(60)
1/2-13
(10,7) 10 18.5 (29,5)
0.25
(6,35)
0.25
(6,35)
1,688
(42,86)
0.25
(6,35)
0.141
(3,58)
1.367
(34,72)
1,375
(34,93)
2.76
(70)
1/2-13
(10,7) 10 18.5 (29,5)
0.313
(7,94)
0.313
(7,94)
1.813
(46,04)
0.313
(7,94)
0.174
(4,42)
1.518
(38,56)
1,625
(41,28)
3.15
(80)
5/3-11
(13,5) 50 23 (36,8)
0.375
(9,52)
0.375
(9,52)
2.25
(57,15)
0.375
(9,52)
0.209
(5,31)
1.796
(45,62)
2,125
(53,93)
3.94
(100)
3/4-10
(16,5) 15 26 (42,2)
0.50
(12,7)
0.50
(12,7)
2.625
(66,68)
0.50
(12,7)
0.28
(7,11)
2.35
(59,69)
2,375
(60,33)
4.72
(120)
3/4-10
(16,5) 15 26 (42,2)
0.625
(15,88)
0.625
(15,88)
3.625
(92,08)
0.625
(15,88)
0.354
(8,99)
2.651
(67,34)
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.000
- 0,002
+0.002
- 0,000
+0.002
- 0,000
+0.002
- 0,000
+0.002
- 0,000
+0.002
- 0,000
+0.002
- 0,000
Table 5.5.1 Shafts in metres
Table 5.5.2 Shaft in inches
5.5
17
UT.D 208-2021.12-EN

Installation of gear reducer 5
Incorrect
Correct
UT.C. 2437
Generally, it is recommended to machine the hole of parts keyed onto shaft end, tolerance H7.
For low speed shaft ends, provided that load is not uniform and light, tolerance must be K7.
Before mounting, thoroughly clean mating surfaces with proper antirust products, and lubricate against seizure and fretting
corrosion.
Attention!
Assemble and disassemble with the aid of jacking screws and pullers using tapped holes at shaft butt-end, taking
care to avoid impacts and shocks which may irremediably damage the bearings, the circlips or other parts.
For couplings H7/m6 and K7/j6 it is advisable that the part to be keyed is preheated to a temperature of 80 ÷ 100 °C.
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, ensure that: loads do not
rise above catalog values:
• loads do not rise above catalog values;
• transmission overhang is kept to a minimum;
• drive-chains should not be tensioned (if necessary – alternating loads and/or motion – foresee suitable chain tighteners);
• in the gear transmission systems there is a proper backlash (≈ 0,03 ÷ 0,04 mm) between pinion and rack;
• drive-belts should not be over-tensioned.
18 UT.D 208-2021.12-EN

Lubrication 6
The gear pairs and the bearings are oil bathed, splashed or lubricated «for life» with grease (with or without NILOS ring).
Unless otherwise stated, gearmotors are supplied FILLED WITH POLYGLYCOL BASIS SYNTHETIC OIL (KLÜBER Klübersynth
GH 6-220, MOBIL Glygoyle 220, SHELL Omala S4 WE 220), providing lubrication – assuming pollution-free surroundings – “for
life”.
We recommend that you check the oil level; each gear reducer is equipped with a lubrication plate.
For lubricant type, gear reducer delivery condition, plugs, fi lling instructions, lubrication intervals, etc., see ch. 6.2 and 6.3.
Attention!
Ensure that the gear reducer is complete with oil and (metal) breather plug mounted in the correct position as per
required mounting position; for BX mounting positions, it is supplied loose and must be mounted in the position
corresponding to the desired mounting position.
The breather plug must be activated prior to commissioning by removing the tab provided (see fi g. 6.1.1).
It is necessary to keep the breather free from dirt that could compromise its functionality.
If this is not possible, please contact Rossi S.p.A. to fi nd a diff erent solution
The lubricant quantity to add shall be the one that will allow you to reach the required level, shown in the middle of the plug,
with the gear reducer not running, and not the indicative quantity mentioned in the catalog.
Fig. 6.1.1 Activating the breather
The bearings are normally automatically and continuously lubricated (oil bath, splash method) by the gear reducer lubricant or by
"lifetime" grease with or without a metal shield.
For gear reducers in vertical V6 mounting position, the upper bearings are independently lubricated with special grease for
"lifetime" lubrication, if no external pollution is present
(the outer bearing on the low speed shaft is always grease lubricated).
Make sure that the gear reducer is fi tted according to the mounting position specifi ed in the order - including inclined
mounting positions (e.g. B3 38° V5) - as indicated on the name plate (see ch. 3.2).
For mounting positions, oil quantity and plug position, see ch. 6.3 and 6.4.
General
6.1
19
UT.D 208-2021.12-EN

Lubrication 6
Using synthetic oil is always recommended, especially if you want to increase the lubrication interval, ambient temperature
range and/or reduce the oil temperature.
Important:
Inappropriate lubricants can cause damage to the gear reducer.
Viscosity and type of lubricating oil used for fi lling are indicated on the gear reducer name plate.
Rossi S.p.A. declines any responsibility for damages deriving from the use of other lubricants or from the use outside the expected
ambient temperature range. The indications on lubricants do not bind Rossi S.p.A. on the quality of the lubricant supplied by each
individual manufacturer. Do not mix diff erent lubricating oils; do not mix synthetic oils with mineral oils.
Manufacturer Oil
synthetic PAO
Oil
synthetic PAG
Oil
mineral
AGIP Blasia SX Blasia S Blasia
ARAL Degol PAS Degol GS Degol BG
BP Enersyn EPX Enersyn SG-XP Energol GR-XP
CASTROL Alphasyn EP Optifl ex A Alpha SP
FUCHS Renolin Unisys Renolin PG Renolin CLP
Manufacturer Oil
synthetic PAO
Oil
synthetic PAG
Oil
mineral
KLÜBER Klübersynth GEM4 Klübersynth GH6 Klübersynth GEM1
MOBIL Mobil SHC Gear Mobil Glygoyle Mobilgear 600 XP
SHELL Omala S4 GX Omala S4 WE Omala S2 G
TEXACO Pinnacle Synlube CLP Meropa
TOTAL Carter SH Carter SY Carter EP
ISO viscosity grade
Unless otherwise specifi ed, the gearmotors are supplied complete with synthetic oil of viscosity grade ISO VG 220 suitable
for most applications in normal industrial environments. For diff erent application conditions or specifi c needs, please contact
Rossi S.p.A.
The following table provides a general guideline for lubricant viscosity selection (average cSt value of kinematic viscosity at 40
°C).
Speed
n2[min-1]
Ambient temperature Tamb [C°]
Mineral Oil Synthetic oil
0 ÷ 20 10 ÷ 40 0 ÷ 40
> 224 150 150 150
224 ÷ 22,4 150 220 220
22,4 ÷ 5,6 220 320 320
< 5,6 320 460 460
Ambient temperature peaks of ± 10 °C for mineral oils and ± 20 °C for synthetic oils are permissible with respect to the
conditions given in the table.
6.2
Lubricant table
20 UT.D 208-2021.12-EN