TECO MOTOVARIO PBH Series Parts list manual

Instructions for installation,
use and maintenance
MHD reducers
EN
QL0336 ∕ REV.2

ENGLISH TRANSLATION OF
THE ORIGINAL ITALIAN VERSION
IMPORTANT! The data and information given in this document substitute those given in previous editions which
are thus to be considered obsolete; periodically consult the technical documentation available on Motovario web
site for up-to-date performance information and specifications. For the motor section relating to motorvariators
and geared motors, consult the motors manual available on Motovario web site.

1.1
2.1
2.2
2.3
2.4
3.1
4.1
4.2
5.1
6.1
6.2
6.3
7.1
INTENDED USE OF THE MANUAL
INTENDED USE OF THE MANUAL 4
GENERAL INFORMATION
PURPOSE 5
SYMBOLS 5
PRODUCT IDENTIFICATION 5
SERVICE 6
COMPLIANCE
COMPLIANCE 7
TECHNICAL INFORMATION
PRODUCT DESCRIPTION 8
CRITICAL APPLICATIONS 8
SAFETY INFORMATION
SAFETY INFORMATION 10
HANDLING AND STORAGE
RECEIPT 11
HANDLING 11
STORAGE 12
INSTALLATION
INSTALLATION 13
1.
2.
3.
4.
5.
6.
7.
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QL0336 ∕ REV.2
Instructions for installation, use and maintenance
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8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.2
8.2.1
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.4
8.4.1
8.4.2
9.1
10.1
10.1.1
10.1.2
10.1.3
10.1.4
11.1
SPECIFIC ASSEMBLING
OUTPUT SHAFT CONNECTIONS 15
Solid shaft 15
Hollow shaft with key series PBH 17
Hollow shaft with key series PBC 17
Hollow shaft with key series PBZ 18
Mounting with shrink disc series PBH, PBZ 19
INPUT SHAFT CONNECTIONS 21
Motor mounting flanges - PBH, PBZ 21
ACCESSORIES 22
Backstop device 22
Assembly of connecting parts 22
Shaft mounting with reaction bolt series PBH 23
Oil seals for input-output shafts 23
Other Accessories and Options 23
DEVICES 24
Cooling and heating systems 24
Lubrication and monitoring systems 26
STARTUP
STARTUP 28
MAINTENANCE
MAINTENANCE 30
Oil change procedure 31
Replacement procedure of external sealing rings 32
Bearings 32
Checks and maintenance table 33
PROBLEMS DURING OPERATION
PROBLEMS DURING OPERATION 34
8.
9.
10.
11.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
2

12.1
12.1.1
12.2
13.1
13.1.1
13.1.2
13.1.3
14.1
15.1
16.1
17.1
LUBRICATION
LUBRICATION 35
Lubricants 37
QUANTITY 38
MOUNTING POSITIONS
MOUNTING POSITIONS 42
PBZ 43
PBH 45
PBC 46
SPARE PARTS TABLES
SPARE PARTS TABLES 47
UNIT DISPOSAL
UNIT DISPOSAL 48
RESPONSIBILITY
RESPONSIBILITY 49
DECLARATION OF PARTLY COMPLETED MACHINERY
INCORPORATION
DECLARATION OF PARTLY COMPLETED MACHINERY INCORPORATION 50
12.
13.
14.
15.
16.
17.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
3

1. INTENDED USE OF THE MANUAL
INSTALLATION, USE AND MAINTENANCE INSTRUCTIONS FOR MOTOVARIO PBH, PBZ, PBC PRODUCTS:
STANDARDSTANDARD
"ORIGINAL VERSION IN ITALIAN"
IMPORTANT!
The data and updated information given in this technical catalogue substitute those given in previous editions, which
are thus to be considered obsolete; periodically consult the technical documentation available on Motovario website
for up-to-date performance information and specifications.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
4

CAUTION - DANGER
Indicates a serious personal health and safety hazard.
CAUTION - HOT PARTS
Indicates a serious thermal hazard which may endanger personal health and safety.
CAUTION - HIGH VOLTAGE
Indicates a serious personal health and safety hazard due to the presence of dangerous voltage.
IMPORTANT INFORMATION
Indicates important technical information.
2. GENERAL INFORMATION
2.1 PURPOSE
This manual has been provided by Motovario to give information to authorized persons regarding transport, handling,
installation, maintenance, repair, disassembly and scrapping of the unit.
Information regarding the electric motor can be found in the motor's "Use and maintenance instructions".
Failure to follow the instructions is a health and safety hazard and can result in economic damages.
The information must be kept carefully by the person charged with doing so and be available at all times for reference in
good condition.
In case of damage or loss, the documentation can be requested directly from Motovario.
2.2 SYMBOLS
2.3 PRODUCT IDENTIFICATION
In order to identify the product, the unit bears a label of the following model.
PBH, PBZ, PBC STANDARD LABEL
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
5

STANDARD
Information contained on the nameplate:
1. Type: Unit abbreviation.
2. Mounting position.
3. Serial number.
4. i: reduction ratio.
5. Pn1: input nominal power [kW].
6. n1: number of input revolutions [rpm].
7. Mn2: output nominal torque [Nm].
8. n2: Number of output revolutions [rpm];
9. Identification field (Production order-Job order progressive number).
10. Unit weight with no load.
11. Year of manufacture.
The nameplate must not be removed and must be kept intact and readable. In case you need a copy of it just contact
MOTOVARIO TECHNICAL SERVICE.
2.4 SERVICE
For any service request please contact the Motovario sales network directly indicating the data on the nameplate.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
6

3. COMPLIANCE
Gearmotors are designed in compliance with the safety requirements of the Machinery Directive 2006/42/EC and are
supplied with a Declaration of Incorporation. We recommend considering the Machinery Directive 2006/42/EC on the
entire system where the MOTOVARIO product is installed.
Motovario electric motors comply with the Low Voltage Directive 2014/35/EU and the Directive EMC 2014/30/EU
regarding the intrinsic characteristics concerning emissions and immunity levels.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
7

4. TECHNICAL INFORMATION
4.1 PRODUCT DESCRIPTION
The unit has been designed to be used in specific applications and, to satisfy particular requirements, it may be supplied
in several mounting arrangements and configurations, including accessories and optional variants.
The user is responsible for using it appropriately and in line with the warnings given in this manual and the instructions on
the product identification labels.
4.2 CRITICAL APPLICATIONS
The performance specified in the catalogue corresponds to position B3 or similar. For different mounting positions and/or
particular input speeds, refer to the tables that highlight any critical situations for each size of the unit. Also bear in mind
the following applications, and contact MOTOVARIO TECHNICAL SERVICE for further information:
Use in conditions which could lead to injury if the unit fails;
Applications with especially high inertia;
Applications with high dynamic loading of the unit casing;
Use in conditions with T° lower than -5°C or higher than 40°C;
Use in environment with presence of aggressive chemical agents;
Use in a salty environment;
Mounting positions not provided by the catalogue;
Use in a radioactive environment;
Use in ambient with pressure other than the atmospheric one;
Applications providing immersion, even partial, of the unit;
Use as multiplier.
Note: The maximum torque bearable by the unit can get twice the Mn2 stated on the label, but only intended for
momentary, non-repetitive overload due to starting at full load, braking, impacts and other dynamic causes.
The value of maximum input speed n 1 max shown in the table reflects continuous duty S1 (operation under steady loading
for a period long enough to achieve thermal balance) and B3 mounting position.
Continuous speeds above 1800 rpm are nevertheless not recommended since they could cause overheating and early
deterioration of seals, bearings and lubricant.
Mounting positions other than B3 could make it necessary to use dedicated pressure-fed lubrication systems, while the
transmission ratio could in some cases originate a further limitation of the permissible maximum input speed n1 max,
contact MOTOVARIO TECHNICAL SERVICE.
For intermittent duty, please contact MOTOVARIO TECHNICAL SERVICE.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
8

Table of MAXIMUM PERMISSIBLE INPUT SPEED n1 max
nn11 max [rpm] max [rpm]
PH - BH P1HP1H P2HP2H P3HP3H P4HP4H B2HB2H B3HB3H B4HB4H
180 2800 2800 2800 2800 2800 2800 2800
200 2400 2800 2800 2800 2400 2800 2800
225 2240 2800 2800 2800 2240 2800 2800
250 2000 2400 2800 2800 2000 2400 2800
280 1800 2240 2800 2800 1800 2000 2800
355 1400 1800 2400 2800 1400 1800 2400
nn11 max [rpm] max [rpm]
PZ - BZ P2ZP2Z P3ZP3Z P4ZP4Z B3ZB3Z B4ZB4Z
179 2800 2800 - 2800 -
199 2800 2800 - 2400 -
219 2800 2800 2800 2400 2800
249 2400 2800 2800 2240 2800
269 2240 2800 2800 2240 2800
279 2240 2800 2800 2000 2800
319 1800 2400 2800 2000 2400
349 1800 2400 2800 1800 2400
399 1800 2000 2400 1800 2240
409 1400 1800 2400 1400 2000
nn11 max [rpm] max [rpm]
PC - BC P1CP1C P2CP2C P3CP3C P4CP4C B2CB2C B3CB3C B4CB4C
176 2800 2800 2800 - 2800 2800 2800
196 - 2800 2800 - 2240 2400 2800
216 2240 2800 2800 2800 2240 2400 2800
246 - 2400 2800 2800 2000 2240 2800
266 1800 2240 2800 2800 1800 2240 2800
276 - 2240 2800 2800 1800 2000 2800
316 1800 1800 2400 2800 1800 2000 2400
346 - 1800 2400 2800 1400 1800 2400
396 1400 1800 2000 2400 1400 1800 2240
406 - 1400 1800 2400 1400 1400 2000
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
9

5. SAFETY INFORMATION
Carefully read the content of this manual and any instructions reported directly on the plates applied to the gear reducer.
The personnel working on the gear reducer must have specific technical expertise, experience and skills, as well both the
necessary work tools and PPE (in accordance with current applicable laws). Failure to comply with these requirements
may affect the health and safety of people.
Only use the gear reducer for the purposes permitted by Motovario. Incorrect use poses a risk to the health and safety of
people, as well economic damage. Always keep the gear reducer in good working order by carrying out the required
maintenance. The gear reducer is can become very hot. Avoid touching the surface with bare hands and ensure the
necessary safety protections are in place.
Ensure maintenance is carried out in safe conditions, with the help of protective clothing and/or equipment, in
accordance with current laws on safety in the workplace.
Only use original Motovario spare parts for replacements. Only use oils and greases recommended by Motovario. Do not
discard polluting material into the environment and ensure disposal is carried out in compliance with current applicable
laws. After replacing the lubricant, clean the surface of the gear reducer, as well as the area where the work was carried
out.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
10

Identify the gripping points on the gear reducer and go ahead with handling by using straps/slings.
Accessories such as flanges, pumps, driving motors can change the centre of gravity, in which case an
additional anchoring point may be required. Do not exceed 15° of oscillation for the load during the lifting
phases; should this happen, stop and repeat the operation.
Do not use piping, threads or protrusions of accessory or shaft ends as anchoring points and pay
attention to any lubrication and cooling systems.
Use the through or threaded holes in place on the fixing feet of the gear reducer’s case. These points are
designed to only withstand the weight of the gear reducer. Do not add more weight during the lifting and
handling phases.
6. HANDLING AND STORAGE
6.1 RECEIPT
Upon receipt, immediately check that the gear reducer matches the order and has not undergone any damage during
transport. Any discrepancy of the product from the specifications ordered must be reported to Motovario.
Always make sure the paintwork is intact. If it isn’t, contact Motovario to have it fixed.
Do not start gear reducers that have undergone damage, including minor damage, or that are not considered suitable for
their intended use: in these cases, contact Motovario.
Dispose of packaging material in accordance with current applicable standards.
6.2 HANDLING
Provide for the following to receive and unload the gear reducer:
1. A suitable and well-defined area with a flat bottom
2. Handling equipment, taking into account the overall dimensions, weight and gripping points, data on the gear reducer
to be handled (cranes, forklifts, eyebolts, ropes, slings, snap links, hooks, etc.) to avoid injury to people and/or
damage to property. The weight to be handled can be found on the related sales catalogue.
Those authorised to handle the gear reducer must ensure all the necessary safety conditions.
Carry out all handling operations with extreme caution. The precautions to be taken during handling are measures suitable
to ensure the safety of the operator and avoid failures or damage due to accidental shocks or falls.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
11

6.3 STORAGE
The units must be stored according to the following requirements:
Be placed as per specified mounting position of the label;
Be free from vibration and protected from accidental impacts;
Be kept at relative humidity <50%, with no intense temperature change, no ultraviolet light and no direct sunlight;
In case of low temperatures (Tamb < -5°C) take special care to avoid shocks and vibration that could damage the
structure.
In the event of storage for 6 months or more, or in environmental conditions other than those specified:
Fill up the gear reducer with oil. Restore the suitable level when commissioning the transmission;
Every six months, rotate the shafts by a few turns to avoid damage to the bearings and prevent the sealing rings from
being glued.
Apply plenty of grease or suitable protective and water-repellent products on the shafts and surfaces processed in
order to prevent metal oxidation or deterioration of rubber parts;
Caution! The formation of oxide on metal surfaces considerably reduces the energy required for the spark in the event of
a collision, thereby increasing the chances of ignition. Always make sure processed surfaces are free from oxide and
protected.
In case of units featuring a drywell or for other types of storage, contact MOTOVARIO TECHNICAL SERVICE.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
12

7. INSTALLATION
Before installing and setting up the gear reducer, proceed by following all the items of the following checklist:
Check the nameplate data of the gear reducer and, if needed, of the electric motor;
Make sure the equipment supplied corresponds to the equipment ordered;
Make sure that the category of the equipment is suitable for the environmental classification in which it will be
installed and subsequently operated;
The fastening of the machine to the structure must be stable and without any vibrations. The structure must not be
subject to torsional movements;
For the fastening use screws with a minimum resistance class of 8.8, without deforming the case due to incorrect
fastening (see the table with the TIGHTENING TORQUES FOR FIXING SCREWS). In threaded joints we recommend
using thread locking liquids to prevent loosening due to vibrations. Always check the correct tightening after the first
hours of operation.
Make sure the supporting surface is flat and large enough to fit the whole gear reducer;
Make sure the operating position matches the mounting position reported on the nameplate;
Check the position of the oil level plug, which must always be clearly visible for periodic inspections even after fitting
the gear reducer on the machine. Make sure the oil drain/filler plugs are accessible.
Make sure the gear reducer has been filled with the right amount of oil according to the required mounting position;
Replace the closing plug, if present, with the breather plug in the kit provided with the gear reducer;
Check for any lubricant leakages. If there are any, interrupt the installation, identify the leak and contact
MOTOVARIO’s TECHNICAL SERVICE;
Remove any traces of dirt or dust from the shafts and from the areas around the sealing rings;
Lubricate contact surfaces to prevent oxidation or seizure;
Check the static seals and the bolted joints;
Do not install the unit in an environment with fumes or abrasive and/or corrosive dust, or in environments with
ionising radiation;
Install all the protections designed for the rotary parts to ensure the system is safe, in accordance with current
regulations;
Check the correct direction of rotation of the output shaft of the unit;
In case of shaft mounting, it is recommended to use Motovario torque arms;
Ensure proper cooling of the motor through a good flow of air from the fan side;
Avoid solar radiation or irradiation from other heat sources. The cooling air temperature must never exceed 40°C or
drop below -20°C;
Check that the assembly of the various parts (pulleys, sprockets, couplings, etc.) on shafts is performed by using the
relevant threaded holes or any other system able to ensure a correct operation without damaging the bearings or the
outer parts of the gear reducer, see paragraph 8 for details. SPECIFIC ASSEMBLIES.
Ensure an equipotential bond (earthing) of the gear reducer case by using one of the free holes previously cleaned to
remove oxides or paint. The electrical connection must be carried out in accordance with EN standard 60079-0
“Paragraph 15 – Connection facilities for earthing or bonding conductors”. The cable section must comply with Table 10
and in any case must not be less than 4 mm2.
In case of ambient temperature not listed in the table LUBRICANTS RECOMMENDED BY MOTOVARIO, please contact
MOTOVARIO TECHNICAL SERVICE. If the temperature is lower than -30°C or higher than 60°C use special mixture
sealing rings.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
13

Check that all accessible surfaces exceeding the temperature limits set by standard EN ISO 13732-1 are
suitably marked with the symbol of standard EN ISO 7010, CAUTION – HOT PARTS.
Table of FIXING SCREW TIGHTENING TORQUE with resistance class 8.8 - 10.8 - 12.9
Mn [Nm]
+5% / -10%
8.8 10.810.8 12.912.9
M 3 1,3 1,9 2,3
M 4 3,0 4,4 5,1
M 5 5,9 8,7 10,2
M 6 10,3 15,1 17,7
M 8 25 36 43
M 10 49 72 85
M 12 85 126 147
M 14 133 202 237
M 16 215 316 370
M 18 306 435 560
M 20 436 618 724
M 22 600 851 997
M 24 750 1064 1245
M 27 1111 1579 1848
M 30 1507 2139 2504
M 33 2049 2911 3407
M 36 2628 3735 4370
M 39 3417 4858 5685
M 42 4212 5999 7070
M 45 5278 7518 8847
M 48 6366 9067 10609
M 52 8210 11693 13684
M 56 10232 14572 17053
M 60 12726 18125 21210
M 64 15303 21795 25505
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
14

8. SPECIFIC ASSEMBLING
8.1 OUTPUT SHAFT CONNECTIONS
8.1.1 Solid shaft
Before going ahead with the assembly of the elements, carefully clean the contact surfaces and grease them to reduce the
risk of seizure and contact oxidation.
It is essential to assemble and disassemble the connecting parts to the shafts with the help of tie rods and extractors,
using the threaded hole at the top of the shaft end and avoiding shocks and blows that may damage bearings, spring
rings or other components, please refer to Fig. 1, 2 and 3.
Rotating elements with an external peripheral speed greater than 20 m/s must be dynamically balanced.
In all cases where the ingoing and/or outgoing movement is operated by external transmissions (belt and pulley, chains,
gears…), ensure that:
The resulting radial and axial loads do not exceed the limit values indicated on the gear reducer’s plate. Loads beyond
those allowed result in premature wear and failures, as well as overheating of the gear reducer and bearings;
The chain transmissions, in particular, are not preloaded and that in case of linear speeds exceeding 1 m/s, they are
kept at the right tension by special tensioners;
See the information supplied by the following figures 1-2-3.
Fig. 1 Example of correct installation of a part to the output shaft of a gear reducer. We recommend to avoid using
inadequate tools.
Always follow the instructions reported in the installation manual of the part to be mounted. Also make sure that it
is compatible with the environmental class in which it will be installed.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
15

Fig. 2, 3: Examples of correct and incorrect installation ( ) on the output shaft of the gear reducer.
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
16

8.1.2 Hollow shaft with key series PBH
Series PBH gear reducers may be supplied with the optional Motovario installation/removal kit for the driven shaft. Upon
request the supply includes:
1. Fixing screw;
2. Safety ring;
3. Lug nut for PBH;
4. Thrust disk.
Assembly
Install the safety ring (2), insert the lug
nut/washer(3), tighten the fixing screw (1)
of the Motovario installation kit on the
shaft end of the driven machine.
Removal
Fit the thrust disk (4) and lug nut/washer
(3) from the Motovario removal kit
between the driven machine's shaft and
the safety ring (2). Insert the safety ring
(2), and tighten the fixing screw (1). You
can now extract the gear reducer from the
shaft.
Assembly Removal
8.1.3 Hollow shaft with key series PBC
Series PBC gear reducers may be supplied with the optional Motovario axial washer for the driven shaft. Upon request the
supply includes:
1. Mounting bolt
2. Axial washer
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
17

8.1.4 Hollow shaft with key series PBZ
Series PBZ gear reducers may be supplied with the optional Motovario installation/removal kit for the driven shaft. Upon
request the supply includes:
1. Screw;
2. Safety ring;
3. Axial washer.
Assembly Removal
MHD reducers
QL0336 ∕ REV.2
Instructions for installation, use and maintenance
18