Rossi G Series User manual

G series
Operating instructions
Helical and bevel helical
gear reducers and gearmotors

2Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series

3
UTD.187.2019.09.00_EN Operating instructions G series
Contents
1 - General information and safety instructions ..............................................................................................4
1.1 - Recycling ............................................................................................................................................................. 4
1.2 - Safety................................................................................................................................................................... 4
2 – Application conditions and use limits ........................................................................................................5
3 – How supplied .............................................................................................................................................5
3.1 - Receipt................................................................................................................................................................. 5
3.2 - Name plate .......................................................................................................................................................... 5
3.3 - Lubricant.............................................................................................................................................................. 5
3.4 - Painting................................................................................................................................................................ 5
3.5 - Protections and packing...................................................................................................................................... 5
4 – Lifting, handling and storing......................................................................................................................6
4.1 - Lifting and handling............................................................................................................................................. 6
4.2 - Storing ................................................................................................................................................................. 7
5 – Installation of gear reducer ........................................................................................................................8
5.1 - General ................................................................................................................................................................ 8
5.2 - Tightening torque for fastening screws (feet, flange, accessories) and for plugs............................................... 9
5.3 - Flange mounting.................................................................................................................................................. 9
5.4 - Foot mounting ..................................................................................................................................................... 10
5.5 - Shaft mounting.................................................................................................................................................... 10
5.6 - Hollow low speed shaft mounting....................................................................................................................... 12
5.7 - Installing and removing of gear reducer ............................................................................................................. 12
5.8 - Gear reducer axial fastening................................................................................................................................ 13
5.9 - Gear reducer fitting with key and locking bushing.............................................................................................. 13
5.10 - Mounting of hollow low speed shaft with shrink disc....................................................................................... 14
5.11 - Fitting of components to low and high speed shaft ends................................................................................. 16
5.12 - Backstop device ................................................................................................................................................ 17
6 – Lubrication .................................................................................................................................................18
6.1 - General ................................................................................................................................................................ 18
6.2 - Lubrication table.................................................................................................................................................. 19
6.3 - Oil levels (quality) for sizes 40 ... 81 supplied FILLED with OIL........................................................................... 20
6.4 - Mounting positions and position of plugs for sizes 100 ... 360 supplied WITHOUT OIL................................... 22
7 – Motor assembly and disassembly..............................................................................................................28
7.1 - General ................................................................................................................................................................ 28
7.2 - Gearmotors with motor keyed onto hollow high speed shaft of gear reducer ................................................... 28
7.3 - Gearmotors with helical pinion keyed directly on motor shaft end..................................................................... 28
7.4 - Maximum flange bending moment MR .............................................................................................................. 30
8 - Cooling system ...........................................................................................................................................31
8.1 - Fan cooling .......................................................................................................................................................... 31
8.2 - Cooling by coil or internal exchanger.................................................................................................................. 31
8.3 - Independent cooling unit..................................................................................................................................... 32
9 - Accessories ................................................................................................................................................34
9.1 - Heater.................................................................................................................................................................. 34
9.2 - Oil temperature probe ......................................................................................................................................... 35
9.3 - Oil temperature probe with terminal box and amperometric transducer............................................................ 35
9.4 - Bearing temperature probe ................................................................................................................................. 36
9.5 - Bearing temperature probe with terminal box and amperometroc transducer .................................................. 37
9.6 - Bi-metal type thermostat..................................................................................................................................... 37
9.7 - Oil level switch and float ..................................................................................................................................... 37
9.8 - Oil optical probe .................................................................................................................................................. 38
10 - Commissioning.........................................................................................................................................38
10.1 - General .............................................................................................................................................................. 38
10.2 - Running-in ......................................................................................................................................................... 38
11 - Maintenance.............................................................................................................................................39
11.1 - General .............................................................................................................................................................. 39
11.2 - Oil change.......................................................................................................................................................... 39
11.3 - Coil and internal heat exchanger....................................................................................................................... 39
11.4 - Seal rings........................................................................................................................................................... 39
11.5 - Bearings............................................................................................................................................................. 40
11.6 - Metal filler plug with filter and valve ................................................................................................................. 40
11.7 - Hollow low speed shaft..................................................................................................................................... 40
11.8 - Sound levels LWA and LpA .................................................................................................................................. 40
12 - Gear reducer troubles: causes and corrective actions..............................................................................41
Index of revisions ............................................................................................................................................42

4Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
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 catalog is printed. Rossi reserves the right to introduce, without notice, the necessary changes to improve
efficiency and safety of its products.
1.1 - 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 components to be incorporated 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 responsibility;
– «Electromagnetic compatibility (EMC)» 2004/108/EC and subsequent updatings.
Attention! It is recommended to pay attention to all instructions of present handbook, all standards
concerning 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 o the machine.
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 re-paired
exclusively by responsible qualified personnel.
The qualified personnel must be specifically instructed and have the experience necessary to recognize and
prevent dangers connected to present products avoiding all possibile emergencies.
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
differ 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 specific documentation. If
necessary, require it.
Maintenance
When operating on gear reducer or on components connected to it the machine must be at rest: disconnect
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
contact Rossi. For any clarification and/or additional information consult Rossi and specify all name plate data.
Lifting instructions.

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UTD.187.2019.09.00_EN Operating instructions G series
2 – Application conditions and limits
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 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.
Do not commission gear reducers and gearmotors that are even slightly damaged.
Report any non-compliance to Rossi.
3.2 - Name plate
Every gear reducer is provided with a name plate in anodized aluminium containing main technical information
relevant to identification; 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 orders.
Product assembled by Rossi Italy
1) Before adding further coats of paint, properly protect the seal rings and carefully degrease and sand the gear reducer surfaces (instead
of sanding, it is possible to apply a coat of water-soluble primer).
Size
gear reducer
Internal painting External painting Notes
Final color
blue RAL 5010
Features
40 … 81 Epoxy powder (pre-
painted)
Epoxy powder
(prepainted)
Resistant to atmospheric
and aggressive agents.
(corrosivity class C3
according to ISO 12944-2)
Suitable for further coats of
dual-compound paints1)
Machined parts remain
unpainted and are protected
with an easily removable antitrust oil
(before painting remove the protective
oil).
100 … 360
Single
compound
ester epoxy or
phenolic resin basis
primer
(prepainted)
Single
compound exter epoxy
or phenolic resin basis
primer
(pre-painted)
+
Water-soluble polyure-
than dual-compound
enamel
Resistant to atmospheric
and aggressive agents.
(corrosivity class C3
according to ISO 12944-2)
Suitable for further coats of dual-
compound paints only 1).
Machined parts are painted with
water-soluble
polyurethan dual-compound enamel
The internal painting does not
resist polyglycol synthetic oils
(polyalphaolefines synthetic oils are
suitable).
Remove by a scraper or solvent, if
present, the eventual paint of gear
reducer coupling surfaces
3.3 - Lubricant
Unless otherwise stated, the gear reducers sizes 40 ... 81 are supplied complete with synthetic oil whereas
for sizes 100 ... 360 gear reducers are supplied without lubricant.
3.4 - Painting
3.5 - 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 polyethylene
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.
Product assembled by Rossi ACs
assembled by Rossi North America
Transmission
ratio
Gear reducer
type
Product code
Mounting
position
Date
Serial
number
www.rossi.com www.rossi.com

6Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
4 – Lifting, handling and storing
4.1 - Lifting and handling
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 figures 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 filled with oil in the mounting position foreseen in the order.
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
Gear reducers
Gearmotors
R I, R 2I, R 3I
R CI, R C2I
R ICI
MR 2I, MR 3I, MR 4I

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UTD.187.2019.09.00_EN Operating instructions G series
4.2 - Storing
Surroundings should be sufficiently clean, dry (relative humidity < 50%), free from excessive vibrations
(ve ff 0,2 mm/s) not to damage the bearings (excessive vibration should als be guarded during transit, even
if within wider range) and at a temperature of 0 ÷ +40 °C: peaks of 10 °C above and belowe are acceptable.
The gear reducers filled with oil must be positioned according to the mounting position stated on name plate
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 instructions:
– generously grease the seal rings, the shafts and the unpainted machined surfaces, if any, and periodically
check the conservation state of the protective anti-rust oil;
– completely fill the gear reducers with lubrication oil and the specified level before commissioning.
For storages longer than 2 years or in aggressive surroundings or outdoors, consult Rossi.
MR CI, MR C2I
MR ICI

8Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
5 Installation of gear reducer
5.1 - General
Before the installation, verify that:
– There are no damages on shafts and on mating surfaces;
– gear reducer specifications are adequate to ambient conditions (temperature, atmosphere, etc.);
– the structure on which gear reducer is fitted is plane, levelled and sufficiently dimensioned in order to assure
fitting stability and vibration absence (vibration speed veff < 3,5 mm/s for PN< 15 kW and veff < 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;
– Used mounting position corresponds to the one stated on name plate;
Attention! Bearing life, 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).
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 or gearmotor so as to allow a free passage of air for cooling both gear reducer and
motor (especially at motor fan sides).
– 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
dissipation of heat;
Verify that the gear reducer housing is dust-free in order to achieve an efficient heat dispersal.
Mating surfaces (of gear reducer and machine) must be clean and sufficiently rough to provide a good friction
coefficient (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 fitting gear reducer and machine and/or gear reducer and eventual flange B5 it is recommended to use
locking adhesives such on the fastening screws (also on flange 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
starting current or other similar devices should be fitted.
If overloads are imposed for long periods or if shocks or danger of jamming are envisaged, then motor-
protection, electronic torque limiters, fluid couplings, safety couplings, control units or other similar devices
should be fitted.
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 (fitted 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 filters 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.
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. 8.

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UTD.187.2019.09.00_EN Operating instructions G series
Tab. 5.2.1. Tightening torque Ms for feet and flange fastening bolts
Screw Ms [N m]
NI 5737-88, UNI 5931-84
cl. 8.8 cl. 10.9 cl. 12.9
M4 2.9 4 –
M5 6 8.5 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
5.2 - Tightening torques for fastening bolts (foot, flange, accessories) and for plugs
Unless otherwise stated, usually it is sufficient to use screws in class 8.8;
- 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 (see table 5.2.1).
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.
1) With B5 flange type B: 14 n.4 (M12).
Fig. 5.3.2. B14 Flange
5.3 - Flange mounting
Carefully select the length of fixing screws when using tapped holes (B14 flange) 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.
For the mounting of sizes 140, 200 and 250 including B14 flange it is necessary that the tapped holes of
counterflange (driven machine) are realized with the same diameter (equal to Ø15, Ø21 and Ø25 respectively)
ase the 2 tapped holes of lower diameter are not exactly in position 22° 30'.
In the fastening screws and in the flange mating surfaces use locking adhesives.
Sizes 140, 200 Size 250
Gear red. size Dimension
of threading
Ms
[N m]
40, 50 G 1/4’’ 7
63 ... 81 M16 ×1,5 14
100 ... 140 G 1/2’’ 14
160 ... 280 G 3/4’’ 14
320 ... 360 G 1’’ 25
Tab. 5.2.2. Tightening torques for plugs
Tab. 5.3.1. Dimension and flange hole numbers B5 and B14
B5 Flange
B5 Flange (type B)
Fig. 5.3.1.
Fig. 5.3.3. Drilling B14 for sizes 140, 200 and 250.
Gear red. size Flange B14
d
Flange B5
ØF S
40 M5 n. 4 9,5 n. 4 (M8) 11
50 M6 n. 4 9,5 n. 4 (M8) 12
63, 64 M8 n. 4 11,51) n. 41) (M101)) 14
80,81 M10 n. 4 14 n. 4 (M12) 16
100 M12 n. 4 14 n. 4 (M12) 18
125 M14 n. 7 18 n. 4 (M16) 20
140 M14 n. 6 + M12 n. 2 18 n. 4 (M16) 22
160, 180 M16 n. 8 18 n. 8 (M16) 22
200 M20 n. 6 + M16 n. 2 18 n. 8 (M16) 25
225 M20 n. 8 22 n. 8 (M20) 25
250 M24 n. 6 + M20 n. 2 27 n. 8 (M24) 30
280 M24 n. 8 27 n. 8 (M24) 30
320 ... 360 M30 n. 8 33 n. 8 (M30) 37

10 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
Nut seating
Bolt or nut seating
(maximum length stated in the table)
Bolt or nut seating
(maximum length stated in the table)
•
•
•
•
•
•
•
•
•
•
5.4 - Foot mounting
5.5 - Shaft mounting
Important! When shaft mounted, the gear reducer must be supported both axially and radially (also
for mounting position 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.
Important! Concerning the reaction system, follow the project indications stated in the technical
catalogs Rossi. 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:
– 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.
System kit using reaction disc springs (reaction recess).
For the mounting of the kit, use the tapped butt end
hole on the shaft end of the driven machine and the
flat machined chamfered surface for compressine and
fitting the disc springs into the reaction recess.
(50 ... 81, 125) (100)
Fig. 5.4.1. Bolts for foot fastening
UT.C 2119
Gear red.
size
Screw
UNI 5737-88
(l max)
40 M6 × 22
50 M8 × 30
63, 64 M10 × 35
80, 81 M12 × 40
100 M14 × 50
125, 140 M16 × 55
160, 180 M20 × 70
200, 225 M24 × 90
250, 280 M30 × 110
320 ... 360 M36 × 130

11
UTD.187.2019.09.00_EN Operating instructions G series
Reaction bolt using disc spring
For sizes 140 ... 360 C2I, 2I, 3I, in B3 or B8 mounting position, ensure that the housing oscillation, during
the running, does not overtake – towards the top – the horizontal position.
Rigid or flexible torque arm using bracket
If the direction of rotation is opposite to that given in the fig. rotate the torque arm by 180° (operation not
necessary in case of flexible torque arm).
System with torque arm
According to dimensions, some ounting positions of motor flange torque arm could not be possible.
Before mounting the torque arm, carefully clean the torque arm, all coupling surfaces and apply locking
adhesives on the screws and on mating surfaces. Tighten the screws by a dynamometric wrench at values
shown in the table 5.2.1 «Tightening torques».
UT.C 2121
UT.C 2122

12 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
* Recommended length.
1) Values not to standard.
5.6 - Mounting of hollow low speed shaft
For machine shaft ends onto which the hollow shafts of gear reducers are to be keyed, h6, j6, and k6 tolerances
are recommended, according to requirements.
Important! the shoulder diameter of the driven machine shaft end abutting with the gear reducer must be at least
1,18 ÷ 1,25 time the hollow shaft internal diameter. For other data on machine shaft end (in case of standard
hollow low speed shaft, stepped shaft, with locking rings or bushings) see Rossi technical catalogs.
Attention! For vertical ceiling-type mounting and only for gear reducers equipped with locking rings
or bushing, gear reducer support is due only to friction, for this reason it is advisable to provide it with
a fastening system.
Attention! Even if the hollow low speed shafts machined in tollerance H7, a check through bott could reveal
two areras with a slightly underdimensioned diameter (see Fig. 1): this und underdimensioning is intentional
and not affecting the keying quality – which is improved in terms of duration and precision – and is not
hindering the assembly of machine shaft end according to usual methodes, such as the one shown at fig. a).
Attention! In order to facilitate the mounting of gear reducer onto machine shaft end, diameter D (**, see
Fig. 2) is slightly overdimensioned as to nominal dimension, at hollow shaft input (standard, stepped, with
shrink disc): this will not affect realiability.
5.7 - Gear reducer installing and removing
In order to have an easier installing and removing of gear reducers and gearmotors with retaining ring groove
(sizes 64 ... 360) – both with keyway and shrink disc – proceed as shown at fig. 5.7.1 and 5.7.2 (excluding MR
3I 100 with motor sizes 112 and 3I 125 with motor size 132; consult us).
For MR 3I 64 ... 81, first insert the washer with screw and the retaining ring into the gear reducer hollow shaft
(on motor opposite side); then mount on machine shaft end.
Gear reducer Machine shaft
Fig. 5.6.1
Fig. 5.6.2
Fig. 5.7.1 Fig. 5.7.2
Hollow low speed shaft
Hole Parallel key Keyway
Dbhl* b t t1
Ø H7 h9 h11 H9 hub
N9 shaft shaft hub
19 6 × 6 × 50 6 3,5 21,8
24 8 × 7 × 63 8 4 27,3
30 8 × 7 × 63 8 4,51) 32,71)
32 10 × 8 × 70 10 5 35,3
38 10 × 8 × 90 10 5,51) 40,71)
40 12 × 8 × 90 12 51) 43,3
48 14 × 9 × 110 14 5 51,8
60 18 × 11 × 140 18 7 64,4
70 20 × 12 × 180 20 81) 74,31)
80 22 × 14 × 200 22 9 85,4
90 25 × 14 × 200 25 9 95,4
100 28 × 16 × 250 28 10 106,4
110 28 × 16 × 250 28 10 116,4
125 32 × 18 × 320 32 11 132,4
140 36 × 20 × 320 36 12 148,4
160 40 × 22 × 400 40 141) 168,31)
180 45 × 25 × 400 45 15 190,4

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UTD.187.2019.09.00_EN Operating instructions G series
5.8 - Axial fastening of gear reducer
For the axial fastening it is possible to adopt the system as per fig. 5.8.1 and 5.8.2. For sizes 64 ... 360, when
shaft end of driven machine has no shoulder, a spacer may be located between the retaining ring and the shaft
end (as in the lower half on fig. 5.8.2). Parts in contact with the retaining ring must have sharp edges.
5.9 - Gear reducer fitting with key and locking rings or bushing
1) UNI 5931-84 cl. 8.8 (excluding MR 3I).
2) UNI 5737-88 cl. 10.9.
3) UNI 5931-84 cl. 10.9.
Tab. 5.9.1 Tightening torques for axial fastening bolts with locking rings or bushing
Using locking rings (sizes 40 ... 63, fig. 5.9.1) or locking bushing (sizes 64 ... 360, fig. 5.9.2) will allow to
have easier and more accurate installing and removing and to eliminate backlash between key and keyway,
friction system complying with ATEX.
The locking rings or the locking bushing are fitted after mounting (for MR 3I 64 ... 81 insert the bushing onto
machine shaft end or into hollow shaft before mounting; pay attention when positioning the keyway). 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 locking adhesives type Loctite or equivalent. For vertical ceiling-type
mounting, contact us.
In case of axial fastening with locking rings or bushing – 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.
Respect the tightening torques stated in table 5.9.1.
Attention! In applications with travelling lifts, the locking bushing is not sufficient to guarantee a stable
fitting of hollow low speed shaft with the machine shaft end, also when the axial fastening bolt is fastened
with locking adhesive. In these cases, it is necessary to fit with hollow shaft and shrink disc. This is valid, in
general, also when there is a high frequency of starting and brakings with motion reversal and when the ratio
of inertia J/J0is very high ( 5).
Helical and bevel helical
size 40, 50
Helical and bevel helical
size 63
Helical and bevel helical
size 64 ... 160
Helical and bevel helical
size 180 ... 360
Parallel shaft
MR 3I 40, 50
Parallel shaft
MR 3I 63
Fig. 5.9.1 Fig 5.9.2
Fig. 5.8.1a Fig. 5.8.1b Fig. 5.8.2
Gear red. size 40 50 63 64 80 81 100 125 140 160 180 200 225 250 280 320,
321 360
Bolts for axial fastening
UNI 5737-88 cl 8.8 M8
1)
M8
1)
M10
1)
M10 M10
2)
M10
2)
M12
2)
M14
2)
M16 M20 M20
2)
M24 M24
2)
M30 M30
2)
M36 M36
3)
Ms [N m]
for rings or bushing 29 35 43 43 51 53 92 170 210 340 430 660 830 1350 1660 2570 3150

14 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
5.10 - Mounting of Hollow low speed shaft with shrink disc
Shrink disc
machine opposite side
Shrink disc
machine side
Shrink disc
machine side
(sizes 40 ... 125)
Shrink disc
machine opposite side
(sizes 140 ... 360)
Shrink disc
machine side
(sizes 140 ... 360 )
Fig. 5.10.1 Fig. 5.10.2 Fig. 5.10.3
Tab. 5.10.1 - Hollow low speed shaft and machine shaft end with shrink disc 3)
Gear
reducer size
D D2d E E1E2FMSQ
Ø Ø UNI 5737-88
cl. 10.9 N m
H7 H7 1) 1) 2)
40 20 – 24 99,5 – 65 – 25 – M5 n. 6 4 –
50 25 – 30 116,5 – 77 – 30 – M5 n. 7 4 –
63 30 – 38 135,5 – 86 – 34 – M6 n. 5 12 –
64 35 – 44 140 – 86 – 36 – M6 n. 7 12 –
80, 81 40 – 50 166 – 103 – 39,5 – M6 n. 8 12 –
100 50 – 62 197 – 122 – 46,5 – M8 n. 6 30 –
125 65 – 80 239 – 148 – 55 – M8 n. 8 30 –
140 70 75 90 273 294,5 180 192,5 52 52 M8 n. 10 30 27,5
160 80 85 105 307 329 199 208 62 57 M10 n. 9 60 29
180 90 100 120 335 363 221 228 65 63 M10 n. 12 60 35
200 100 110 130 377 402 251 260 72 66 M12 n. 10 100 33,5
225 110 120 140 404 428 265 277 78 75 M12 n. 12 100 32,5
250 125 135 160 461 493 307 318 86 84 M16 n. 8 250 45
280 140 150 180 506 543 324 337 104 94 M16 n. 10 250 47
320, 321 160 170 200 567 607 375 388 104 107 M16 n. 12 250 50
360 180 195 230 621 668 400 414 124 116 M16 n. 15 250 57
1) Values valid for shrink disc on machine opposite side.
2) Bolt tightening torque.
3) For design with labyrinth seals at low speed shaft, the dimensions E, E1, E2 are changing: please consult us.

15
UTD.187.2019.09.00_EN Operating instructions G series
Attention! Verify that the machine shaft end has dimensions, tolerances and roughness as stated in fig.
5.10.1 ... 5.10.3 and tab. 5.10.1; following these instructions the correct running of shrink disc will be
granted.
Pre-arrange a proper protection of the shrink disc against accidental contacts.
Installing
Attention! Do not tighten the screws of shrink disc before mounting the gear reducer onto machine shaft in
order not to deform the hollow shaft. When keying the shrink disc follow these instructions:
– carefully degrease the surfaces of hollow shaft and shaft end of driven machine to be fitted;
– mount the shrink disc on the gear reducer hollow shaft taking care to lubricate the only external surface,
first; position the shrink disc axially to «Q» dimension (see tab. 5.10.1).
– slightly tighten a first group of three screws positioned at about 120° as shown for example in the figure
5.10.4;
– tighten through dynamometric wrench – balanced to a value aproximately higher than 5% compared to the
one foreseen in tab. 5.10.1 – the bolts of the shrink disc, by a continuous sequence (not crossing) see fig.
5.10.5 and during several phases (approx. 1/4 turn at a time) until no 1/4 turn is possible anymore;
– do again 1 or 2 passages with dynamometric wrench verifying that the tightening torque stated in tab.
5.10.1 has been realized;
– when having heavy duty cycles, with frequent reversals, verify again after some hours of running, the bolt
tightening torque.
– verify the tightening torque of screws at every maintenance interval (oil exchange) or in case of anomalous
vibrations.
Removing
Before starting the disassembling operation, be sure that no torque nor load is applied to shrink disc, shaft or
other connected elements.
Attention! Do not completely remove fastening screws before locking rings are disengaged. Risk
of serious injury!
Clean off any rusty areas.
Loosen the fastening screws one after the other only by using approx. ½ turn at a time and by a continuous
sequence (not crossing), until shrink disc can be moved on hollow shaft.
Remove the gear reducer from machine shaft end.
Fig. 5.10.4 Fig. 5.10.5

16 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
High speed shaft end Low speed shaft end Solid low speed shaft end
Gear reducer shaft end Machine shaft
5.11 - Mounting of components on high and low speed shaft ends
1) Values valid for high speed shaft end.
2) Values valid for standard low speed shaft end.
3) Values valid for solid low speed shaft end.
4) Maximum angular disalinement of keyways on double extension shafts.
5) For low speed shaft ends: E = 97 (E = 101 if double extension); value not to standanrd.
6) Value not to standard.
7) For MR 3I with low speed shaft end, E dimension increases by 1.
Shaft end Parallel key Keyway
D E d S L a/24) bhl b t t1
Ø Ø arc min h9 h11 H9 hub
1) 2) 3) 1) 2) 3) 1) 2) 3) 1) 2) 3) N9 shaft shaft hub
11 j 6 – – 23 –M 5 3,6 9,4 –– 4 418 –4 2,5 12,7
14 j 6 – – 30 –M 6 4,6 11,4 –– 5 525 –5 3 16,2
16 j 6 – – 30 –M 6 4,6 11,4 –– 5 525 –5 3 18,2
19 j 6 h7 –40 30 M 6 4,6 11,4 13,4 5,43 6 636 25 6 3,5 21,7
24 j 6 h7 –50 367) M 8 5,9 15,1 17,1 5,16 8 745 25 8 4 27,2
28 j 6 – – 60 –M 8 5,9 15,1 – – 8745 –8 4 31,2
30 –h7 –58 587) M 10 7,6 –20,4 4,13 8 745 45 8 4 33,2
32 k 6 h7 –80 587) M 10 7,6 18,4 20,4 3,87 10 870 50 10 5 35,3
38 k 6 h7 –80 58 M 10 7,6 18,4 20,4 3,27 10 870 50 10 5 41,3
40 –h7 – – 58 M 10 7,6 –20,4 3,7 12 850 50 12 5 43,3
42 k 6 – – 110 –M 12 9,5 22,5 – – 12 890 –12 5 45,3
45 k 6 – – 110 –M 12 9,5 22,5 – – 14 990 –14 5,5 48,8
48 k 6 h7 k6 110 82 M 12 9,5 22,5 26,5 3,08 14 990 70 14 5,5 51,8
55 m 6 –110 –M 12 9,5 22,5 – – 16 10 90 –16 6 59,3
60 m 6 h7 k6 140 1055) M 16 12,7 27,3 35,3 2,46 18 11 110 90 18 7 64,4
70 m 6 h7 k6 140 105 M 16 12,7 27,3 35,3 2,55 20 12 125 90 20 7,5 74,9
75 m 6 – – 140 –M 16 12,7 27,3 – – 20 12 125 –20 7,5 79,9
80 –h7 k6 –130 M 20 16 –44 2,23 22 14 –110 22 9 85,4
90 m 6 h7 k6 170 130 M 20 16 34 44 1,99 25 14 140 110 25 9 95,4
95 m 6 – – 170 –M 20 16 34 – – 25 14 140 –25 9 100,4
100 – j6 k6 –165 M 24 19 –41 1,79 28 16 180 140 28 10 106,4
110 m 6 j6 k6 210 165 M 24 19 41 41 1,63 28 16 180 140 28 10 116,4
125 – j6 k6 –2006) M 30 22 –45 1,71 32 18 –180 32 11 132,4
140 – j6 k6 –200 M 30 22 –45 1,52 36 20 –180 36 12 148,4
160 – j6 k6 –240 M 36 27 –54 1,33 40 22 –220 40 13 169,4
180 – j6 k6 –240 M 36 27 –54 1,18 45 25 –220 45 15 190,4

17
UTD.187.2019.09.00_EN Operating instructions G series
In general, it is recommended to machine the hole of the parts keyed onto shaft end to H7 tolerance.
For high speed shaft end with D 55 mm, provided that load is uniform and light, tolerance can be G7.
For low speed shaft ends, provided that load is not uniform and light, tolerance must be K7.
Before mounting, thoroughly clean mating surfaces 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;
– 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.
For splined couplings apply adequate antirust-products.
5.12 - Backstop device
The presence on gear reducer of backstop device is stated by the arrow near the low speed shaft, indicating
the free rotation.
Provide a protection system where a backstop device breaking could cause personal injury or property damage.
Make sure that the direction of rotation in machine, gear reducer and motor all correspond correctly.
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.
Incorrect
Correct

18 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
6 - Lubrication
6.1 - General
Gear reducers and gearmotors must be lubricated with polyglycol or polyalphaolephines based synthetic
oil depending on the series; they are supplied FILLED WITH OIL or WITHOUT OIL according to type
and size (see ch. 6.2 and 6.3). When supplying WITHOUT OIL, the filling up to specified level is
Buyer’s responsibility and has to be carried out with gear reducer at rest; normally stated by means of
transparent level plug (see ch. 6.4 or eventual SPT sketch attached to present instructions). Every gear reducer
is equipped with lubrication name plate.
Concerning lubricant type, how supplied status of gear reducers, plugs, filling instructions, oil-change interval,
etc. see lubrication table at ch. 6.2 and 6.3.
Be sure that, for gear reducers and gearmotors sizes 100, the filler plug is equipped with filter
and valve (symbol ; see fig. 6.1.1). When these gear reducers are required filled with oil (non-standard
design) the filler plug is not mounted but sent separately; The installer will take care of the assembly in the
right position (see ch. 6.4 or eventual SPT sketch attached) replacing the fitted plug.
If gear reducer or gearmotor is supplied with transparent oil level plug (size 100), the necessary lubricant
quantity is the one which reaches a.m. level at gear reducer at rest, in center line, and not the approximate
quantity given on the catalog.
When gear reducer or gearmotor is provided with a level plug with dipstick (see fig. 6.1.2), fill with oil up
to specified level on rod.
When gear reducer or gearmotor is provided with a plug for flowing over level (red colour, see fig. 6.1.3) fill
after unscrewing a.m. plug in order to check the obtained level by oil outlet.
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 V5 and V6, and bevel helical gear reducers in horizontal
positions B3, B6 (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.
Always be sure that the gear reducer is located as per the mounting position ordered - including
the inclined mounting positions (e.g. B3 38° V5) - which appears on the name plate (see ch. 3.2).
In case of oscillating mounting positions the gear reducers are equipped with auxiliary name plate with
statement of mounting position for the oil filling and the level check during maintenance.
For mounting positions, oil quantity and plug position see ch. 6.3 and 6.4.
Combined gear reducers. Lubrication remains independent, thus data relative to each single gear reducer hold
good.
Fig. 6.1.1
Filler plug with filter and valve
Fig. 6.1.2
Level plug with dipstick
Fig. 6.1.3
Spilway plug
2I, 3I, 4I (100, 125), m.p. V6
3I (125), m.p. V51)
ICI (100, 200), m.p. B61) C3I (100, 125), m.p. B61)
1) For high speed continuous duty an expansion tank is envisaged: consult us.
80
Spilway
plug
Filler plug Siplway
plug
Filler plug

19
UTD.187.2019.09.00_EN Operating instructions G series
6.2 - Lubrication table
Size 81 Size 100
How supplied
and plugs
(identification
also
through
specific
lubrication nameplate)
FILLED with SYNTHETIC OIL
(polyglycol based synthetic oil) WITHOUT OIL (except different statement on lubrication name plate)
AGIP Blasia S 220
KLÜBER Klübersynth GH 6-220
MOBIL Glygoyle 220
SHELL Omala S4 WE 220
1 filler plug for size 64
2 filler/drain plugs for sizes 80, 81
Filler plug with filter, valve,
drain and level plug
Standards
for
eventual
first filling
–
Before commissioning, fill to specified level, with synthetic oil type
and ISO viscosity grade as follows:
mineral oil:
AGIP Blasia
ARAL Degol BG
BP Energol GR XP
CASTROL Alpha SP
FUCHS Renolin CLP
KLÜBER Klüberoil GEM1
MOBIL Mobilgear 600 XP
SHELL Omala S2 G
TEXACO Meropa
TOTAL Carter EP
Polyalphaolephine based
synthetic oil
AGIP Blasia SX
ARAL Degol PAS
BP Enersys EPX
CASTROL Alphasys EP
FUCHS Renolin Unisys CLP
KLÜBER Klübersynth GEM4
MOBIL SHC Gear
SHELL Omala S4 GX
TEXACO Pinnacle
TOTAL Carter SH0
Lubrication
interval
and lubricant
quantity
Lubrication «for life»
(assuming external pollution-free
environment). 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 synthetic oil at least each 5
÷ 8
years according to gear reducer size and to operating and ambient conditions.
The oil quantity is given by the level stated by the proper plug or an
equivalent system (plug for flowing over level, plug with dipstick).
Grease-lubricated bearings:
lubrication is «for life» assuming uniform load and pollution-free environment. Otherwise replace the grease every
year with running up to 12 h/d and every 6 months with running of 12 ÷ 24 h/d; in these occasions, re-lubricate the
backstop device with grease SHELL Alvania RL2. Bearing should be filled with SHELL Gadus S2 V100 bearing-
grease for ball bearings, KLÜBER STABURAGS NBU 8 EP for roller bearings.
In case of labyrinth seal with greaser apply, unless otherwise stated, KLÜBER STABURAGS NBU 8 EP (see ch.
11.4).
Attention! Refer to ch. 6.4 for bearings requiring greasing and contact Rossi in case of doubt.
ISO viscosity grade [cSt]
Speed
n2
min-1
Ambient
temperature
0 ÷ 40 °C
1)
>224 150
224÷22.4 220
22.4÷5.6 320
<5.6 460
1) Peaks of 20 °C below and 10 °C above the
ambient temperature range are acceptable.
ISO viscosity grade [cSt]
Speed
n2
min-1
Ambient
temperature
0 ÷ 20 °C
1)
20 ÷ 40 °C
1)
>224 150 150
224 ÷22.4 150 220
22.4 ÷5.6 220 320
<5.6 320 460
1) Peaks of 10 °C below and 10 °C above the ambient
temperature range are acceptable.
Oil
temperature
°C
Lubrication
interval
h
65 25 000
65 ÷80 18 000
80 ÷ 95 12 500
95 ÷110
1)
9 000
1) Values valid for non continuous duties. 1) Values valid for non continuous duties.
Oil
temperature
°C
Lubrication
interval
h
65 8 000
65 ÷80 4 000
80 ÷ 95 2 000
95 ÷ 110
1)
−

20 Operating instructions G series UTD.187.2019.09.00_EN
UTD.187.2019.09.00_EN Operating instructions G series
6.3 - Oil level (quantity) for sizes 40 ... 81 supplied FILLED with OIL
Important! Verify mounting position keeping in mind that if gear reducer is installed in a mounting position
which differs from the one indicated on the name plate, it could require the addition of the difference between
the two quantities of lubricant corresponding to x dimension and stated in the following tables. Measure x
dimension in fig. 6.2.1 (helical) and 6.2.2 (bevel helical), after eliminating potential residual air in the oil, inside
the gear reducer.
1) Tolerance of dimension x: ± 5 mm for size 50; ± 10 for size 63.
2) For mounting positions V5 and V6 the upper bearings are greased.
3) The first reduction (the first 2 for 4I), mounting position V5, is lubricated with grease for life.
4) For design UO3D in mounting position B6 or B7 the bearings of upper bevel pinion are grease lubricated.
5) For C3I in mounting position B6, the bearing of the first gear pair (wheel side) is grease lubricated.
Fig. 6.2.1 - Position the helical gear reducer or gearmotor,
mounting position V6 for oil level (quantity)
measurement
Fig. 6.2.2 - Position the bevel helical gear reducer or gearmotor,
mounting position B7 for oil level (quantity)
measurement
Tab. 6.1.1 - Oil level (X measurement) and quantity for HELICAL gear reducers and gearmotors sizes 40 ... 81
Size
Train of gears
Mounting position
Oil level (x1) measurement) [mm] and quantity [l]
I 2I 3I 4I
B3, B8 B7 B6, V5,
V6
2)
B3, B8 B6 B7, V5,
V6
2)
B3, B8 B6 B7, V5, V6
2) 3)
B3, B8 B6 B7, V5,
V6
2) 3)
R MR
mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l
40 – – – – – – 45 0,4 – – 24 0,55 24 0,55 35 0,47 20,7 12 0,6 – – – – – –
50 – – – – – – 60 0,6 25 0,9 30 0,8 30 0,8 45 0,7 51,05 15 1– – – – – –
63, 64 80 0,7 65 0,8 46 160 0,9 42 1,4 48 1,2 48 1,2 58 140 1,5
B7: 50 1,3
V5: 50 1,4
V6: 50 1,3
58 1,1 40 1,8 50 1,4
80, 81 115 1,2 92 1,5 68 1,9 80 1,5 45 2,7 54 2,3 54 2,3 72 1,7 42 2,9
B7: 52 2,5
V5: 48 2,6
V6: 52 2,5
72 1,9 42 3,2 52 2,7
Tab. 6.1.2 - Oil level (X measurement) and quantity for BEVEL HELICAL gear reducers and gearmotors sizes 40 ... 81
Size
Train of gears
Mounting position
Oil level (x1) measurement) [mm] and quantity [l]
CI ICI C3I
B3, B6, B7
4)
B8 V5, V6
2)
B3 B6, B7
4)
B8 V5, V6
2)
B3, B7
4)
B6
5)
B8 V5, V6
2)
mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l mm l
40 48 0,26 30 0,35 41 0,3 31 0,31 15 0,5 30 0,4 50 0,35 ––––––––
50 48 0,4 30 0,6 50 0,45 50 0,45 15 0,8 30 0,65 54 0,5 50 0,5 15 0,9 30 0,7 54 0,55
63, 64 72 0,8 40 148 0,95 58 115 1,6 42 1,2 45 1,15 58 1,2 15 1,8 42 1,4 45 1,35
80, 81 90 1,3 50 256 1,8 90 1,6 25 2,7 48 2,2 56 290 1,9 25 348 2,5 56 2,3