Motovario CH Series Operation instructions

MAINTENANCE AND USE
INSTRUCTIONS FOR GEAR AND
GEARMOTORS SERIES:
CH - IH - H
GB

2
Warehouse storage Installation
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 period of 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 reduction unit 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.
Installation
Example of a pulley mounted correctly on the slow shaft of a reduction unit
Correct and incorrect examples of pulleys mounted on the main shaft of a reduction unit.
AB
Fig.1
Fig.2
Particular care must be taken when installing drives, as this is often the source of damage
and 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 reduction unit 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 < -5 °C or > +40 °C, contact Technical Assistance.
- If the motor is to be started 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
(A) (C)(B)
Installation
Correct and incorrect examples of coupling connections
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 not essential for the reduction unit to run properly since modern construction
techniques for the gears and castings, the extreme cleanliness of the internal parts, and the
excellent qualities of the lubricants used, ensure that the internal parts receive a high degree
of protection even during the first moments.
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 other assemblies, low maintenance is required with an oil change at 8/10,000 hours of
use. The change of oil naturally depends on the type of environment and use to which the unit
is put.
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 reducer
or one that is compatible with it.
In case of doubtful incompatibility between lubricants, we recommend you empty out the oil
from the gearbox 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 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 kept 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 malfunction.
Fig.3
The pulley must be mounted on the main shaft as close as possible to the shoulder so that is
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 reduction unit.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/B14 flange
Check that the tolerance of the motor 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
diameter 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
fitted. 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.
Before mounting the unit on the machine, check that the principal shaft of the reduction unit
rotates in the right direction.
Use the oil window, if present, to check that the lubricant reaches the correct level required for
the mounting position used.

4
Troubleshooting Troubleshooting
PROBLEMS CAUSES ACTION (1) ACTION (2)
The motor does not
start.
Problems with power
supply. Defective motor.
Wrong size of motor. Check power supply. Replace electric motor.
Current absorbed by
the motor is greater
than shown on the
data plate.
Wrong size of motor. Check the application. Replace the electric motor and, if necessary,
the reduction unit.
Temperature of the
motor housing is very
high.
Defective motor. Wrong
size of motor. Incorrect
mounting of motor Check the application. Replace the electric
motor and, if necessary,
the reduction unit.
Temperature of the
reduction unit housing
is very high.
Wrong size of reduction
unit. Mounting position
does not comply with the
order. Incorrect mounting
of motor
Check the application.
Correct the working
conditions: mounting
position and/or lubricant
level.
Incorrect rotation
speed of the main
reducer unit shaft.
Incorrect reduction ratio.
Incorrect polarity of motor. Check reduction ratio. Check polarity of motor. Replace reduction unit and/or electric motor.
Oil leak from oil seal. Defective oil seal. Oil seal damaged during shipment.
Defective motor shaft.
Replace the oil seal.
Repair motor shaft (if
possible).
Replace the part or return
the assembly to
Motovario.
Oil leak from joint. Flat gasket or O-ring
damaged. Replace damaged gasket or O-ring. Return the assembly to Motovario.
The main shaft rotates
the wrong way. Incorrect connection of the electric motor. Swap two phases of the motor supply.
Intermittent noise from
the gears. Dents in the gear wheels. No practical problem if
the noise has no effect on
the application.
Return the assembly to
Motovario if there is
significant noise when
laaded.
PROBLEMS CAUSES ACTION (1) ACTION (2)
No intermittent noise
from the gears. Dirty inside the gearbox. No practical problem if
the noise has no effect on
the application.
Return the assembly to
Motovario if there is
significant noise when
laaded.
Noise (whine) from the
drive assembly.
Bearings incorrectly
adjusted. Gears with mesh
errors. Insufficient
lubricant.
Check correct quantity of
lubricant. Return the assembly to Motovario.
Electric motor vibrates. Measurement of the
assembly coupling.
Check geometric
tolerance of flange on
electric motor. Check
tolerance and geometry
of key on motor shaft.
Replace electric motor.

5
Lubrication H
- I riduttori di media/grossa taglia vengono for
niti privi di olio e completi dei tappi necessari a
garantire tutte le posizoni di piazzamento.I
sudetti riduttori vengono contraddistinti dal
l’applicazione della relativa targhetta.
Lubrication H
Attenzione: riduttore privo di lubrificante,riempire
a livello prima dell’avviamento.
Achtung : Getriebe ohne Schmierstoff, bitte vor
Inbetriebnahme füllen.
Attention : groupe sans lubrifiant, remplir au niveau
avant le démarrage.
Atención: grupo sin lubricante, llenar hasta el nivel
antes de la puesta en marcha.
D
F
E
I
Attention: gearbox unit without lubricant,fill it up to
the level before starting.
GB
- Motovario dispone la lubrificazione dei gruppi come indicato in tabella.
-
- non esiste - lubrificato
- non lubrificato
T°C
ISO VG... (-5) ÷ (+40) ISO VG220 (-15) ÷ (+25) ISO VG150
AGIP BLASIA
220 BLASIA 150
SHELL OMALA
OIL220 OMALA OIL150
ESSO SPARTAN
EP220 SPARTAN EP150
MOBIL MOBILGEAR
630 MOBILGEAR 629
CASTROL
A
LPHA MAX
220
A
LPHA MAX
150
BP ENERGOL
GR-XP220 ENERGOL GR-XP150
Mineraloil
In cases of ambient temperatures not envisaged in the table, call our Technical Service.
In the case of temperatures under -30°C or over 60°C it is necessary to use oil seals with special
properties.
For operating ranges with temperatures under 0°C it is necessary to consider the following:
1-The motors need to be suitable for operation at the envisaged ambient temperature.
2-The power of the electric motor needs to be adequate for exceeding the higher starting torques
required.
3-In the case of reduction units with a cast-iron case, pay attention to impact loads since cast iron may
have problems of ragility at temperatures under -15°C.
4-During the early stages of service, problems of lubrication may arise due to the high level of viscosity
taken on by the oil and so it is wise to have a few minutes of rotation under no load.
The oil needs to be changed after approximately 10,000 hours. This period depends on the type of service
and the environment where the reduction unit works.
For units supplied without oil plugs, lubrication is permanent and so they need no servicing.
- Quantity of oil in litres
H - CH 032/..3 042/..3 052/..3 062/..3 082/..3 102/..3 122/..3 142/..3
B3-B5 0,7 1,1 1,2 2,4 4,6 8 23 25
B8 0,7 1,1 1,2 2,5 4,7 8,2 23,5 26
B6-B7 0,7 1,1 1,2 2,6 5 8,6 25 27
V5-V1 1,4 1,7 1,9 3,9 7 12,5 33 36
V6-V3 1,2 1,5 1,7 3,6 6,5 14,3 31 34
H - CH 041 051 061 081 101 121
B3-B5 0,6 0,8 1 1,8 2,6 3,5
B8 0,6 0,8 1 1,8 2,6 3,5
B6-B7 0,6 0,8 1 1,8 2,6 3,5
V5-V1 0,8 1,1 1,3 2,5 3,2 4,3
V6-V3 0,6 0,8 1 1,8 2,6 3,5
030 040 050 060 080 100 125 140
H















041 051 061 081 101 121
H







6
V5
B3
B8 B7
V6
B6
041÷120Mounting position
V6
B3
B8 B7
V5
B6 V1B5
V3
Oil level plug
Oil drain plug
Oil fill / breather plug

7
V6B3
B8 B7
V5
B6
025÷150Mounting position
Oil level plug
Oil drain plug
Oil fill / breather plug

8
Critical applications
A- Application not recommended
B- Check the application and/or call our technical service
H 030 040 050 060 080 100 125 140
V5 - V1: 1500 < n1 < 3000 ------BB
n1 > 3000 BBBBBBAA
V3 - V6 BBBBBBBB
The performance given in the catalogue correspond to mounting position B3 or similar, ie. when the first
stage is not entirely immersed in oil. For other mounting positions and/or particular input speeds, refer to
the tables that highlight different critical situations for each size of reduction unit.
It is also necessary to take due consideration of and carefully assess the following applications by calling
our Technical Service:
- As a speed increasing.
- Use in services that could be hazardous for people if the reduction unit fails.
- Applications with especially high inertia.
- Use as a lifting winch.
- Applications with high dynamic strain on the case of the reductionunit.
- In places with T° under -5°C or over 40°C.
- Use in chemically aggressive environments.
- Use in a salty environment.
- Monting positions not envisaged in the catalogue.
- Use in radioactive environments.
- Use in environments pressures other than atmospheric pressure.
Avoid applications where even partial immersion of the reduction unit is required.
The maximum torque (*) that the gear reducer can support must not exceed two times the nominal torque
(f.s.=1) stated in the performance tables. (*) intended for momentary overloads due to starting at full load,
braking, shocks or other causes, particularly those that are dynamic.

9
Spare parts tables 030÷140 Spare parts tables 041÷121
004
P= Project of pertinence
T= Reference table
C= Part number
002
003
009
001
008
010
009
008
010
005
006
007

10
TAV 001 032÷142MOTOVARIO

11
TAV 001 032÷142MOTOVARIO
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3$ 3$ 3$ 3$3' 3' 3' 3$
.$"%)%' &$''" &&'" .%&%'4)+ + + +
+ + + ++ + ."&%"%4) +
&$''" &'" ."%%'4) 3*'"3''" .*(%'(%" .))%*)%" 3$'"
3&'! 3'! 3")'! 3*'!3''! 3*'! 3)'! 3$'!
3&"$ 3"$ 3")"$ 3*"$3'"$ 3*"$ &("$ 3$"$
3&") 3") 3")") 3*")3'") 3'") 3)") 3$")
3&"* 3"* 3")"* 3*"*3'"* 3'"* 3)"* 3$"*
3&&) 3&$ 3")&( 3*&!3'&") 3*&' 3)&') 3$&*
3&( 3( 3")( 3*(3'( 3'( 3)( 3$(
3& 3 3") 3*3' 3* 3) 3$
      

12
TAV 002 032÷142MOTOVARIO

13
TAV 002 032÷142MOTOVARIO
  

   
   
   55.
   55
   55
   
   
   
   
   
   
   
   
   
   
   
   

   
    !" #&%" ) #&%" ) #&%") ) #%' ( #"%') ( #*%* ( #*%* ( #$%*) (
    !" #$%" $ #$%" $ #$%" $ #$%"  #$%"  #$%"  #$%" " #&%$ "
            '"$  ''(  ''&  ''! 
            '"(%  '"&  '""  '"" 
    '"$%  '"(%  '"&%  '"!  '"  '"'  '"&%  '"" 
    '"'  '")%  '"$%  '"&%  '"%  '""  '""'  '"$ 
    *(" ')  *"  )"  $"  $"  &  !   
    *(" *  *(  ))  $&  &    "  * 
    *( )  )   + "&  + + '&  + + + +
    *( )  )  "  "&  '"  '&  *)  ) 
   ,- $&&) )%)%"  )%)%"  $%$%*  &%(%&  %&%")  %&%' + *%!%* + *%!%*) +
   ,- $&&) &%(%"  %&%")  $%%'  &%%'*  "%"%*  ")%*%)  "&%$%$  &$'& 
   ,- $&&) .&%(%')  .&%(%)  .%&%)  ."%&%$  .*%!%&  .&%%  ."%"%  .")%*%* 
    + + + + + + '/&0 " '/&0 " /"0 " /"0 " /"0 "
    + + + + + + '/&0 " '/&0 " /"0 " /"0 " /"0 "
   1 + + + + + + '/&0 * '/&0 * /"0 * /"0 * /"0 *
    ('** $%$ " $%$ " $%$ " &%"* " %' " "%'$ " "%'$ " *%* "
    '($ .'+*(+(  .')+)"+(  .*+$"+&  .*)+("+&  .))+&+&  .$)++  .!+"+"  .+'+" 
    2.')+)  2.*"+(  2.)"+(  2.$"+(  2.$"+(  2.&+  2.!+  2.+ 
+ 3$' + 3*$*3'$* 3'$* + +
3&$' 3$') 3")$* 3*$*)3'$$ 3'$$ 3)$" 3$$")
3&" 3" 3")" 3*"3'" 3*" 3)" 3$"
     
3) 3")) 3*)3') 3*) 3$) 3&)3))
+ + +3'$" 3'$" 3$$' 3&$')3)$")
3( 3")( 3*(3'( 3'( 3$( 3&(3)(
3&$ 3")&( 3*&!3'&") 3*&' 3$&* 3&&)3)&')
3"* 3")"* 3*"*3'"* 3'"* 3$"* 3&"*3)"*
3") 3")") 3*")3'") 3'") 3$") 3&")3)")
3"$ 3")"$ 3*"$3'"$ 3*"$ 3$"$ 3&"$&("$
3'! 3")'! 3*'!3''! 3*'! 3$'! 3&'!3)'!
&'" ."%%'4) 3*'"3''" .*(%'(%" 3$'" &$''".))%*)%"
+ + ++ + + +."&%"%4)
&$''" &&'" .%&%'4)+ + + .$"%)%'+
3$ 3$ 3$3' 3' 3$ 3$3'
!*!! !*!! !*!!!*!! !*!! !*!! !*!!!*!!
     

14
TAV 003 033÷143MOTOVARIO

15
TAV 003 1/2 033÷143MOTOVARIO
  

   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   
   

   
    !"# $%&# % $%&# % $%&# % $%&#  $%&#  $%&#  $%&# # $'&% #
    !"( ) ) ) ) ) ) $*&%  $'&#  $#&(  $#&(*  $%&+ 
            (#%  ((,  (('  ((" 
            (#%  ((,  (('  ((" 
    %#  %#  %##  %#(      %#,  (#'& 
    %##  %##  %#(  %#+  %%  %#,  %#'  (#& 
    (#%&  (#,&  (#'&  (#"  (#  (#(  (#'&  (## 
    (#(  (#*&  (#%&  (#'&  (#&  (##  (##(  (#% 
    !+,# (*  +#  *# %#  %#  '  "   
    !+,# ) ) ) ) ) ) +  +,  *#  ) ) ) )
    !+,# (*  (*  + +,  **  ,#  '  ' 
    !+,# +  +,  ** %'  '    #  + 
    !+, ) ) ) ) ) ) #  ) ) (*  ) ) ) )
    !+, +  +  ) ) ) ) #'  (#  ('  ) )
    !+, +  +  +  ) ) ) ) ) ) ) ) ) )
       
-( -+ -* -% -' - -#* -+
-(, -(, -*, -%, -', -, -#*, -+,
-('#* -+'( -*'(* -%'+ -''* -'% -#*', -+'"
-(#+ -(#+ -*#+ -%#+ -'#+ -#+ -#*#+ -+#+
-(#' -(#' ',#* -%#' -'#' -#' -#*#' -+#'
-(#% -+#% ',#% -%#% -'#% -#% -#*#% -+#%
-(#,* -(#,* -*#,% -%#, -'#,* -#,* -#*#,* -+#,*
-(#"%* -(#"%* -(#"%* -*#+%, -%#+%, -'#+,% -#+'* -#*#+,,
-((" -+(" -*(" -%(" -'(" -(" -#*(" -+("
-((# .+,&(,&# .**&+*&# -%(# '%((# '(# .#&&(/* -+(#
) ) ) -%(' ) ) ) '%((#
) ) -*+ ) ) ) ) )
) ) .#'&#&/* ) ) ) ) )
) ) ) ) .%#&*&( '%((# ''(# .&'&(/*
-( -( -( -% -% -% -% -%
) ) ) #'#, '(+ '#*(+ '#*(+ %(+
"+""( "+""( "+""( "+""( "+""( "+""( "+""( "+""(
       

16
TAV 003 2/2 033÷143MOTOVARIO
   
   01 !%''* *&*&#  *&*&#  %&%&+  '&,&'  &'&#*  &'&( ) +&"&+ ) +&"&+* 
   01 !%''* *&*&#  *&*&#  *&*&#  %&%&#  '&,&'  &'&##  &'&(  +&"&+ 
   01 !%''* '&,&#  &'&#*  %&&(  '&&(+  #&#&+  #*&+&*  #'&%&%  '%(' 
   01 !%''* .'&,&(*  .'&,&*  .&'&*  .#&'&%  .+&"&'  .'&&  .#&#&  .#*&+&+ 
    ) ) ) ) ) ) (2'3 # (2'3 # 2#3 # 2#3 # 2#3 #
    ) ) ) ) ) ) (2'3 # (2'3 # 2#3 # 2#3 # 2#3 #
   4 ) ) ) ) ) ) (2'3 + (2'3 + 2#3 + 2#3 + 2#3 +
    !(,% .()+,),  .(*)*#),  .+)%#)'  .+*),#)'  .**)')'  .%*))  .")#)#  .)()# 
    .(*)*  .+#),  .*#),  .%#),  .%#),  .')  .")  .) 
       

17
TAV 004 1/2 033÷143MOTOVARIO

18
TAV 004 1/2 033÷143MOTOVARIO
  

   
   
   55.
   55
   55
   
   
   
   
   
   
   
   
   
   
   
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   
   
   
   

   
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19
TAV 004 2/2 033÷143MOTOVARIO
P T C Commercial
H 004 16/N CirclipDIN471 141141141----------
H 004 17/N Key DIN 6885 B 5x5x12 1 B 5x5x12 1 B 6x6x14 1 B 8x7x18 1 B 10x8x25 1 B 10x8x30 - B 14x9x40 - B 14x9x45 1
H 004 18/N Key DIN 6885 B 5x5x12 1 B 5x5x12 1 B 5x5x12 1 B 6x6x12 1 B 8x7x18 1 B 10x8x22 1 B 10x8x30 1 B 14x9x40 1
H 004 19/N Key DIN 6885 B 8x7x20 1 B 10x8x25 1 B16x10x30 1 B 18x11x34 1 B 20x12x40 1 B 25x14x50 1 B 28x16x60 1 816038 1
H 004 20/N Key DIN 6885 A 8x7x35 1 A 8x7x50 1 A 10x8x50 1 A 12x8x60 1 A 14x9x80 1 A 18x11x100 1 A 20x12x110 1 A 25x14x140 1
H 004 21/N Closing plug - - - - - - 3/8" gas 2 3/8" gas 2 1/2" gas 2 1/2" gas 2 1/2" gas 2
H 004 22/N Oil level plug - - - - - - 3/8" gas 2 3/8" gas 2 1/2" gas 2 1/2" gas 2 1/2" gas 2
H 004 23/N Gasket - - - - - - 3/8" gas 4 3/8" gas 4 1/2" gas 4 1/2" gas 4 1/2" gas 4
H 004 24/N Dowel pin DIN 7344 6x16 2 6x16 2 6x16 2 8x24 2 10x30 2 12x36 2 12x36 2 14x40 2
H 004 25/N Oil Seal DIN 3760 AS 30-47-7 1 AS 35-52-7 1 AS 40-62-8 1 AS 45-72-8 1 AS 55-80-8 1 AS 65-100-10 1 AS 90-120-12 1 AS 100-130-12 1
H 004 26/N Cap RCA 35-5 1 RCA 42-7 1 RCA 52-7 1 RCA 62-7 1 RCA 62-7 1 RCA 80-10 1 RCA 90-10 1 RCA 100-10 1
033 043 053 063 083 103 123 143

20
TAV 005 041÷121MOTOVARIO