Motovario TXF Series User guide

MAINTENANCE AND USE INSTRUCTIONS OF
MOTORVARIATORS SERIES:
TXF
TXF-UM 98/01 rev. 0 English version

2
Motovariators series TX
WAREHOUSE STORAGE
When moving the unit, care should be taken to protect external parts from breakage
or damage due to accidental knocks or falls.
If the unit is to be stored in a hostile atmosphere or for a long time (2/4 months), it is
important to apply protective and waterproofing products to avoid deterioration of shafts
and rubber parts.
Before starting up the unit, carry out the following checks:
Check the data shown on the name plate of the variator and/or the electric motor;
Check for any leaks of lubricant
If possible, remove any traces of dirt from the shaft and from the areas around the oil
seal.
If the oil seal is not immersed in the lubricant inside the assembly during particularly
long storage periods (4/6 months) it is recommended that it should be replaced as
the rubber might stick to the shaft or even have lost the elasticity it needs to work
properly.
INSTALLATION
Particular care must be taken when installing drives, and is often the source of
damage and of down time. Careful choice of the type of drive and mounting position
can often avoid the need for protection of sensitive areas, particularly underneath the
unit from oil leaks, however limited they may be.
The machine must be firmly fastened in place in order to prevent any vibrations
Whenever possible, protect the variator from direct sunlight and bad weather,
especially when it is mounted on its vertical axis
Make sure the air intake on the fan side is unobstructed in order to ensure that the
motor is correctly cooled
In the case of temperatures of < -10 °C or > +50 °C, contact Technical Assistance
If the motor is to be started up very often under load, the use of a heat probe inserted
into the motor is recommended
The various machine members (pulleys, gear wheels, couplings, etc.) must be
mounted on the shafts using special threaded holes or other systems that ensure
correct operation without risk of causing damage to the bearings or the external parts
of the assemblies (fig. 1)
Lubricate the surfaces that come into contact in order to prevent oxidation or seizure.

3
Motovariators series TX
Fig.2
Correct (A) and incorrect (B) examples of pulleys mounted on the output shaft of a
variator
Correct (A) and incorrect (B-C) examples of coupling connections on the output shaft
of a variator
Example of a winch mounted correctly on the output shaft of a variator.
N.B. avoid using improper tools
Fig.1
AB
Fig.3
( A ) ( B ) ( C )

4
Motovariators series TX
COUPLING NOTES
The pulley must be mounted on the output shaft as close as possible to the stop so
that it does not cause excessive radial load on the bearings (fig. 2).Great care must
be taken when connecting the couplings to ensure that they are well aligned, so as not
to cause excessive radial load on the bearings (fig.3).When it is applied, paint must
never be used on rubber parts: oil seal, etc. It must never be applied to any breather
holes in plugs if they are mounted on the unit.In the case of assemblies with oil plugs,
remove the closed cap used for transport and fit it with the breather plug that is
supplied with the variator.When the assembly is supplied without a motor, the
following precautions must be followed in order to ensure that connections are
properly made.
Mounting the motor on the pam B5 flange
Check that the tolerance of the shaft and the motor flange comply with at least one
normal class of quality. Carefully clean off any trace of dirt or paint from the shaft, the
centering and the face of the flange. Carry out mounting operations making sure not to
use force. If this is not possible, check the tolerance of the motor key and ensure that it
is correctly positioned. Apply assembly grease to the shaft in order to prevent oxidation
or seizure caused by contact.
Good quality motors should be used in order to ensure that the unit works correctly,
without vibrations or noise.
Use the oil window, if present, to check that the lubricant reaches the correct level
required for the mounting position used.
STARTING UP
The unit should be started up gradually: do not immediately apply the maximum load
the machine is able to take ; look for and correct any malfunction that may be caused by
incorrect mounting.
Running-in is essential for the variator to run properly since, notwithstanding the
modern construction techniques for the gears and castings, the extreme cleanliness
of the internal parts, and the excellent qualities of the lubricants used, the variator is a
drive operating by friction therefore it is necessary a certain adaptation of the internal
parts during the first running phases.

5
Motovariators series TX
SERVICING
The high degree of finish of the internal parts ensures that the unit will work correctly
with only a minimum amount of servicing.
Generally speaking, the following rules should be followed: periodically check that the
exterior of the assembly is clean, especially in the cooling areas; periodically check to
see if there are any leaks, especially in the areas around the oil seals.
Assemblies that are lubricated for life and thus do not have any oil plugs do not require
any special maintenance except as stated above.
For the other assemblies, low maintenance is required with an oil change at 1000 hours
of use, and the following changes have to be done at 8000 hours of use. The change of
oil naturally depends on the type of environment and service.
Apart from the normal maintenance rules given above, make sure the breather hole in
the plug is clean and, using the oil window, periodically check that there is sufficient
lubricant.
Should it be necessary to top up with lubricant, use the same type that is already in the
variator or one that is compatible with it.
In case of doubtful incompatibility between lubricants, we recommend you empty out
the oil from the variator completely and, before refilling with new oil, wash out the unit to
remove any residue.
When changing the oil, follow the previous instructions.
TROUBLESHOOTING
If any problems should arise when starting up the unit or during its first few hours of
operation, contact the after sales service unit of Motovario.
The table shows a series of problems with a description of possible remedies.
It should be borne in mind however that the information given is for reference only as all
the drives manufactured by Motovario are thoroughly tested and checked before they
leave the factory.
Please note that tampering with the assembly without prior authorization from
Motovario immediately invalidates the warranty and often makes it impossible to
ascertain the causes of a defect or bad function.

6
Motovariators series TX
352%/(06 &$86(6 $&7,21 $&7,21
The motor does not start. Problems with power supply. Defective motor.
Wrong motor size. Check power supply. Replace electric motor.
Current absorbed by the
motor is higher than shown
on the data plate. Wrong motor size. Check the application. Replace the electric motor
and, if necessary, the
variator.
Very high temperature of
the motor housing. Defective motor. Wrong motor size. Check the application. Replace the electric motor
and, if necessary, the
variator.
Very high temperature of
the variator housing.
Wrong variator size.
Mounting position does not
comply with the order. Check the application.
Correct the working
conditions: mounting
position and/or lubricant
level.
Oil leakages from oil seal. Defective oil seal. Oil seal damaged during shipment.
Defective motor shaft seat.
Replace the oil seal.
Repair motor shaft seat (if
possible).
Replace the part or return
the unit to Motovario.
Oil leakages from joint. Flat gasket or O-ring
dama
g
ed. Replace damaged gasket or O-rin
g
.Return the unit to Motovario.
The output shaft rotates in
the wrong way. Incorrect connection of the electric motor. Reverse two phases of the power supply of the motor.
Intermittent noise from the
gears. Dents in the internal components.
No practical problem if the
noise has no effect on the
application.
Return the unit to Motovario
if there is significant noise
in the application.
No intermittent noise from
the gears. Dirty inside the variator. No practical problem if the
noise has no effect on the
application.
Return the unit to Motovario
if there is significant noise
in the application.
Electric motor vibrates. Geometrical error on the
coupling.
Check geometric
tolerances of electric motor
flange. Check tolerances
and geometry of key on
motor shaft.
Replace the electric motor.

7
Motovariators series TX
B5 B8 V1 V3
B6 B7
MOUNTING POSITION AND LUBRICATION
Quantity of lubricant in litres
TXF
B5-B6 -B7
V1-V3-B8
002
0,1 0,25
005
0,13 0,4
010
0,33 0,75
TXF - TXC
Minerale
(-25) ÷ (+ 40)
ISO
VG32
IP TRANSMISSION
V.E.
SHELL A.T.F.
DEXRON
AGIP A.T.F.
DEXRON
ESSO A.T.F.
DEXRON
MOBIL MOBIL
ATF 220
CAST ROL TQDEXRONII
BP AUTRAN DX
TXF variators size 002-005-010 come pre-filled with
lubricant for life and they do not need any
maintenance.The above mentioned sizes are
supplied without oil plugs.
All the variators come pre-filled with IP
TRANSMISSION V.E., a mineral oil.
All the sizes, if not specified in the order, are
supplied with the oil quantity as per B3-B5 mounting
positions.
Mineral

Motovariators series TX
8

Motovariators series TX
9
TAV 001
Size 002 ÷ 010
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1 Screw DIN 912 M6x20 6 M6x20 6 M6x20 6 M6x20 8 M6x20 8
1 Nut UNI 5587 M6 6M66M66M68M68
1 Pin UNI 6364 4x10 24x1024x1024x1024x102
(11) A 4x4x15 1 (14) A 5x5x20 1 (14) A 5x5x20 1 (19) A 6x6x30 1 (19) A 6x6x30 1
(14) A 5x5x20 1 (19) A 6x6x30 1 (19) A 6x6x30 1 (24) A 8x7x35 1 (24) A 8x7x35 1
1 Seeger ring DIN 471 E 12 1 E 15 1 E 15 1 E 17 1 E 17 1
1 Seeger ring DIN 983 E18-K 1 E25-K 1 E30-K 1 E30-K 1 E45-K 1
1 Seeger ring DIN 472 I 28 1 I 35 1 I 35 1 I 40 1 I 40 1
1 Bearing 6001 1 6202 1 6202 1 6203 1 6203 1
1 Bearing 6001-2RS1 1 6202-2RS1 1 6202-2RS1 1 6203-2RS1 1 6203-2RS1 1
1 Oil seal DIN 3760 TC 15-24-7 1 TC 20-30-7 1 TC 20-30-7 1 TC 25-35-7 1 TC 25-35-7 1
1 Oil seal DIN 3760 SC 18-30-7 1 SC 25-40-7 1 SC 30-47-7 1 SC 30-62-7 1 SC 45-62-8 1
1 Cap RCA 22-4 1 RCA 22-4 1 RCA 28-4 1 RCA 28-4 1 RCA 35-7 1
 Variator casing 6.002.01 6.005.01 6.005.01 6.010.01 6.010.01
 Input flange 6.002.03 6.010.03 6.010.03
 Fixed sun race 6.002.17 6.005.17 6.010.17 6.010.17 1.020.17
 Adjustable sun race 6.002.18 6.005.18 6.010.18 6.010.18 1.020.18
 Annulus race 6.002.19 6.005.19 6.005.19 6.010.19 6.010.19
 Cam ring 6.002.20 6.005.20 6.005.20 6.010.20 6.010.20
 Planet disk (3) 6.002.22 (3) 6.005.22 (3) 6.005.22 (3) 6.010.22 (3) 6.010.22
 Friction bearing - planet disk (3) 6.002.23 (3) 6.002.23 (3) 6.002.23 (3) 6.010.23 (3) 6.010.23
 Planet carrier 6.002.24 6.005.24 6.005.24 6.010.24 6.010.24
 Output shaft 6.002.27 6.005.27 6.005.27 6.010.27 6.010.27
 Stop ring belleville springs 6.002.35 6.005.35 6.010.35 6.010.35
 Bearings spacer 6.002.37 6.005.37 6.005.37 6.010.37 6.010.37
 Centrifugal oil seal 6.002.51
 Guide ring 6.010.60
 Special key 6.010.77
 Belleville spring assembly
 Ball ring
 Coil spring
 Flange gasket
1 Key DIN 6885
(3) 1.002.99.40
6.002.99.51
6.002.99.37
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6.010.51.090

6.010.35.090
(3) 1.002.99.36 6.010.77
6.005.51.071
6.005.03.160 6.005.03.200
6.005.51.080 6.005.51.080
6.005.99.51
(4) 1.002.99.40
6.005.99.37
(3) 1.005.99.36
6.005.99.51
(4) 1.002.99.40
6.005.99.37
(5) 1.010.99.36
6.010.99.51
(4) 6.010.99.40
6.010.99.37
(5) 1.010.99.36
6.010.99.51
(4) 6.010.99.40
6.010.99.37
(3) 1.020.99.36

10
Motovariators series TX
TAV 002
Size 002 ÷ 010
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1 Screw SFS torx TN912/8.8 M5x14 6 M5x14 6 M5x14 6 M5x14 6 M5x14 6
1 Nut UNI 5589 M12x1.5 4 M12x1.5 4 M12x1.5 4 M14x2 4 M14x2 4
1 Pin UNI 6873 4x24 1 4x24 1 4x24 1 4x24 1 4x24 1
1 O-Ring OR 106 1 OR 106 1 OR 106 1 OR 108 1 OR 108 1
1 O-Ring OR 108 1 OR 108 1 OR 108 1 OR 2043 1 OR 2043 1
 Cover-control screw
 Control screw
 Control block
 Stop plate
 Handwheel
 Handwheel cover
 Cover gasket
   
6.002.06
6.002.99.53
6.002.99.43
6.002.99.42
(2) 6.002.99.33

6.002.99.53
6.002.99.43
6.002.99.42
(2) 6.002.99.33
6.002.34
6.002.33
6.002.34
6.002.33
6.002.06 6.002.06
6.002.33
6.002.34
(2) 6.002.99.33
6.002.99.42
6.002.99.43
6.002.99.53
6.010.06
6.010.33
6.010.34
(2) 6.010.99.33
6.010.99.42
6.002.99.43
6.010.99.53
6.010.34
6.010.33
6.010.06
6.010.99.53
6.002.99.43
6.010.99.42
(2) 6.010.99.33

11
ISO 9001 - Cert. n°0129
Via Giardini, 45 - 41040 SPEZZANO (MO) ITALY
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INTERNET (e-mail) [e-mail]
(Home page) www.motovario.it
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