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® Installation and Maintenance Manual Gearmotors K Series IMM-0018EN December 2022...
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CONTENTS DISCLAIMER The official language chosen by the Product manufacturer is English. No liability is assumed as a result of translations in other languages not in compliance with the original meaning. In case of conflicting language versions of this document, the English original prevails.
CONTENTS 1 VERSION TRACKING ........................5 MANUAL APPLICABILITY AND SUPPORTED MODELS ..............5 2 HOW TO USE THIS MANUAL ......................6 3 UNIT DESIGNATION ......................... 7 DETAILED UNIT DESIGNATION ......................7 NAMEPLATE UNIT DESIGNATION ...................... 8 4 STANDARD TYPE GEARBOX PARTS LISTS .................. 9 SIZE: K00...K20...
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CONTENTS 8 MECHANICAL INSTALLATION ...................... 39 INSTALLING CUSTOMER SHAFT WITH SHOULDER ............... 40 INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER ..............41 DISASSEMBLING CUSTOMER SHAFT WITH SHOULDER ............... 42 DISASSEMBLING CUSTOMER SHAFT WITHOUT SHOULDER ............43 SHAFT TIGHTENING TORQUES VALUES ARE AS SHOWN ............. 44 RECOMMENDED SHAFT DIMENSIONS FOR KT...00 TYPES ............
1 VERSION TRACKING File name Revision Date Changes description IMM-0018EN_Rev.00 Gearmotors K 17/10/2022 - Changed layout Series IMM-0018EN_Rev.01 Gearmotors K 07/12/2022 - Updated "Use the breather plug" page 37 Series 1.1 MANUAL APPLICABILITY AND SUPPORTED MODELS Models Gearmotors K Series IMM-0018EN - Installation and Maintenance Manual Dana Incorporated...
2 HOW TO USE THIS MANUAL Take attention to the following safety and warning signs for proper understanding and quick reference. Table 1: Indicates an imminently hazardous situation which, if DANGER not avoided, will result in death or serious injury. Indicates an imminently hazardous situation which, if WARNING not avoided, could result in death or serious injury.
3 UNIT DESIGNATION 3.1 DETAILED UNIT DESIGNATION NOTE: Detailed K Series gear units designation for ordering (This Designation is different from the short nameplate designation) Brake 00- 5 Nm 10- 100 Nm 01- 10 Nm 20- 200 Nm L-220V 02- 25 Nm 30- 300 Nm P-24V 04- 40 Nm...
UNIT DESIGNATION 3.2 NAMEPLATE UNIT DESIGNATION NOTE: Nameplate unit designation is a short abbreviation from the detailed designation. A sample name plate for K Series Type KR373.00.100L / 4a Serial N.: 100052892 MADE IN TURKEY Power : Ratio: 51.05 Speed rpm.
4 STANDARD TYPE GEARBOX PARTS LISTS 4.1 SIZE: K00...K20... 4.1.1 TYPE: 00 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Spacer Pinion Circlip Plug Pinion Shaft Oil Seal Housing Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.2 TYPE: 01L NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Circlip Pinion Closing Cap Plug Pinion Shaft Circlip Housing Shim Ring Bearing Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.3 TYPE: 01R NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Shim Ring Pinion Bearing Plug Gear Housing Spacer Circlip Spacer Bearing Circlip Gear Closing Cap Pinion Shaft Circlip Bearing...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.4 TYPE: 02L NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Pinion Shaft Bearing Pinion Shim Ring Plug Circlip Output Shaft Housing Shim Ring Circlip Bearing...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.5 TYPE: 02R NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Bearing Pinion Gear Plug Spacer Housing Spacer Circlip Circlip Bearing Closing Cap Gear Circlip Pinion Shaft Bearing Output Shaft...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.6 TYPE: 03L NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Oil Seal Pinion Pinion Shaft Circlip Plug Shim Ring Bearing Housing Circlip Circlip Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.7 TYPE: 03R NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Circlip Pinion Oil Seal Plug Pinion Shaft Circlip Housing Shim Ring Bearing Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.8 TYPE: 04 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Circlip Pinion Oil Seal Plug Pinion Shaft Circlip Housing Shim Ring Bearing Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.9 TYPE: 05 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Oil Seal Pinion Pinion Shaft Circlip Plug Shim Ring Bearing Housing Circlip Circlip Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.1.10 TYPE: 08 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Oil Seal Pinion Pinion Shaft Circlip Plug Shim Ring Bearing Housing Circlip Circlip Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.2 SIZE: K27...K97... 4.2.1 TYPE: 00 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Pinion Pinion Shaft Output Shaft Plug Cover Plate Closing Cap Housing Bolt...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.2 TYPE: 01 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Shim Ring Pinion Pinion Shaft Plug Cover Plate Shim Ring Housing Bolt Closing Cap Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.3 TYPE: 02 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Bolt Pinion Bolt Closing Cap Plug Oil Seal Circlip Housing Circlip Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.4 TYPE: 03 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Pinion Shaft Flange Pinion Cover Plate Bolt Plug Bolt Closing Cap Housing Oil Seal Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.5 TYPE: 04 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Shim Ring Pinion Pinion Shaft Plug Cover Plate Shim Ring Housing Bolt Closing Cap Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.6 TYPE: 05 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Cover Plate Bolt Pinion Bolt Closing Cap Plug Oil Seal Circlip Housing Circlip Shim Ring...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.7 TYPE: 08 NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Pinion Shaft Flange Pinion Cover Plate Bolt Plug Bolt Closing Cap Housing Oil Seal Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.8 TYPE: 0S NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Pinion Shaft Shrink Disk Pinion Cover Plate Plug Bolt Bolt Housing Oil Seal Closing Cap Circlip...
STANDARD TYPE GEARBOX PARTS LISTS 4.2.9 TYPE: 0E NOTE: Standard types basic part diagram. Parts may differ for special applications. Standard Part List Standard Part List Standard Part List Bolt Ekstruder Housing Pinion Oil Seal Bolt Plug Circlip Bearing Housing Shim Ring Circlip Bearing...
5 SAFETY 5.1 INTENDED USE The gear reducer is designed for use in industrial machines. Please refer to our catalogue or our web page for the maximum permitted torques and speeds. The most important maximum permitted values are indicated on the nameplate of the product. But the whole data can be found on our product catalogues.
SAFETY 5.3 SAFETY INSTRUCTIONS 5.3.1 GENERAL SAFETY INSTRUCTIONS 5.3.1.1 Working on the gear reducer WARNING Inappropriately executed work can lead to injury or damage. Make sure that the gear reducer is only installed, maintained and dismantled by trained technicians. WARNING Foreign bodies spinning through the air can cause grave injury.
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SAFETY 5.3.1.4 Lubricant WARNING Extended, intensive contact with oils can lead to skin irritations. Avoid extended contact with oil, and clean oil off skin thoroughly. WARNING Hot oil can cause scalding. When changing oil, protect yourself against contacting hot oil. 5.3.1.5 Ambient Conditions DANGER If the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust.
SAFETY 5.4 TIGHTENING TORQUES All screwed connections for which a tightening torque is specified, must on principle be tightened with a calibrated torque wrench and checked. Use the following torques for the threaded bores over the gear unit housing. For connecting elements refer to the mechanical installation part.
6 THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTAL- NOTE: If geared motors are used, please also refer to the manual of the motor manufacturer. Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage.
THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MO- 6.2 STORAGE If the geared unit or geared motor will be stored up to 3 years refer to the following instructions; With Packing; Use corrosion protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface. Seal the unit in a plastic wrap and pack it in container.
7 INSTALLING THE GEAR UNIT 7.1 BEFORE YOU START • Observe the gear unit for damages of storage or transportation. If any damage please contact Dana Motion Systems Italia S.r.l.. • Be sure that you have all the equipment necessary for installing like; Spanners, torque wrench, shims and distance rings, fixing devices for input and output elements, lubricant, bolt adhesive etc.
INSTALLING THE GEAR UNIT 7.4 CHECK THE VOLTAGE SUPPLY The standard geared motors are supplied with 230/400 V 50/60 Hz up to 3 kW including 3 kW and 400/690 V 50/60 Hz over 3 kW and is indicated on the motors name plate unless it is differently ordered. In case of only gear unit is supplied from Dana Motion Systems Italia S.r.l.
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INSTALLING THE GEAR UNIT Standard type brakes basic wiring diagram DANGER The electric connection must be done by experienced electric technician. The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox/motor. Delayed Running Brake ( 220 V) Sudden Brake (220 V) R S T R S T N...
INSTALLING THE GEAR UNIT 7.5 CHECK THE MOUNTING POSITION The mounting position must be in accordance with the mounting position mentioned on the name plate. If different please con- tact Dana Motion Systems Italia S.r.l. for possibilities of using in a different mounting position. Refer to the mounting positions and oil quantities on this manual and adjust the oil level accordingly with the recommended oil types given on this manuel.
INSTALLING THE GEAR UNIT 7.9 COVER ABRASIVE AMBIENT If the gear unit will be placed on a abrasive ambient be sure that the output seals are covered so that no abrasive material, chemicals or water touches the seals. Any pressure coming from outside over the seals can cause that the out staying sub- stances to enter the gearbox and cause serious damage to the gear unit.
8 MECHANICAL INSTALLATION The gear unit can only be installed using the supplied connection points like foot and flange assembling points. DANGER To install the gear unit without the supplied connection points can cause serious injuries by loosening or braking the gear unit. Even the gear unit is installed totally correctly according this manual, be sure that no one will be harmed by accidentally brake downs or loosening.
MECHANICAL INSTALLATION 8.1 INSTALLING CUSTOMER SHAFT WITH SHOULDER Use anti-seize assembling paste available in your market. Use a brush to apply the paste. Fasten the bold as shown below. Short retaining bolt (standart scope of delivery) Lock washer Washer Circlip Hollow shaft Customer Shaft Dana Incorporated...
MECHANICAL INSTALLATION 8.2 INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER Use anti-seize assembling paste available on your market. Use a brush to apply the paste. Fasten the bold as shown indicated Short retaining bolt (standart scope of delivery) Lock washer Washer Circlip Spacer Hollow shaft Customer Shaft...
MECHANICAL INSTALLATION 8.3 DISASSEMBLING CUSTOMER SHAFT WITH SHOULDER Disassemble the bolt and take out the parts as shown Short retaining bolt Circlip Lock washer Hollow shaft Washer Customer Shaft Use the disassemble set from YILMAZ REDÜKTÖR and fasten the bold as shown bellow to take out the out- put shaft.
MECHANICAL INSTALLATION 8.4 DISASSEMBLING CUSTOMER SHAFT WITHOUT SHOULDER Disassembly the bolt and take out the parts as shown Short retaining bolt (standart scope of delivery) Spacer Lock washer Hollow shaft Washer Customer Shaft Circlip Use the disassembly set from YILMAZ REDÜKTÖR and fasten the bold as shown bellow to take out the out- put shaft.
MECHANICAL INSTALLATION 8.8 ASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK Loosen the bolts of the shrink disk Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow. The surfaces must be free from oil or any dirt. The solvent must be removed from the surfaces as well. Dana Incorporated IMM-0018EN - Installation and Maintenance Manual...
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MECHANICAL INSTALLATION Insert the shaft and tighten the bolts as shown. Be sure that there is a clearance between the shrink disk shoulder and the hollow shaft shoulder of the gearbox. Welle von Kunde Ringaus bronze Hohlwelle Schrumpscheibe Table 9: Tightening Type Bolt...
MECHANICAL INSTALLATION 8.9 DISASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK Loosen the bolts of the shrink disk and take out the shaft. Dana Incorporated IMM-0018EN - Installation and Maintenance Manual...
MECHANICAL INSTALLATION 8.10 ASSEMBLING GEAR UNIT WITH TORQUE ARM The following connecting possibilities are available. Use one position which is the most suitable. IMM-0018EN - Installation and Maintenance Manual Dana Incorporated...
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MECHANICAL INSTALLATION Assemble the parts as shown bellow Gear Unit Assembled Shaft Bolt Spacer Ring Machine Extension Torque Arm Spacer Ring Rubber Buffer Bolt Dana Incorporated IMM-0018EN - Installation and Maintenance Manual...
MECHANICAL INSTALLATION 8.13 FITTING OUTPUT SHAFT ELEMENTS Use the following illustration to assemble output shaft units Gear shaft end Thrust bearing Coupling hub 8.14 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS Output Shaft unit (transmission elements) must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit.
MECHANICAL INSTALLATION 8.15 FITTING COUPLINGS By fitting couplings be sure that there is some clearance between the two elements By fitting couplings be sure that there is no eccentricity between the two shafts. By fitting couplings be sure that the two shafts are not angular miss-aligned. IMM-0018EN - Installation and Maintenance Manual Dana Incorporated...
9 MAINTENANCE & INSPECTION Under normal ambient and working conditions the gear unit should be checked according the following intervals. (For definition of normal working conditions refer to the product catalogue: “Selecting Gearbox” section); Table 13: Every 3.000 working hours Every 10.000 working Every 25.000 working Item to check /replace...
LUBRICATION 10.3.3 K.28.. - K.97.. FOUR STAGE K SERIES OIL LEVEL PLUGS Symbols: Drain Plug Oil Filling Vent Plug Oil Level Table 17: Oil Quantities (lt) Type A / B A / B A / B A / B A / B A / B K.284 1,2 / 0.25...
LUBRICATION 10.3.4 K.27.. - K.97.. FIVE-SIX STAGE K SERIES OIL LEVEL PLUGS Symbols: Drain Plug Oil Filling Vent Plug Oil Level Table 18: Oil Quantities (lt) Tip / Type / Typ A / B A / B A / B A / B A / B A / B...
LUBRICATION 10.4 MOUNTING POSITIONS Figured mounting positions of M1 to M6 are determined as reference of directional position of the gearbox. Mounting surfaces are not binding. IMM-0018EN - Installation and Maintenance Manual Dana Incorporated...
11 TROUBLESHOOTING GUIDE WARNING All the operations bellow must be done by authorized and skilled mechanician/electrician. Inform Dana Motion Systems Italia S.r.l. before making any change to the gearbox. Only oil change is allowed to change with- out information. Do not make any think if you are not sure what you are doing and contact Dana Motion Systems Italia S.r.l.. Any change or operation done without the information of Dana Motion Systems Italia S.r.l.
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TROUBLESHOOTING GUIDE Problem Observation Remedy Measure the surface temp. using a temperature measuring de- vice under full load. If the temp is under +80 Celsius this will make no harm to the gearbox and is normal. All ATEX conforming gear- boxes and standart worm gearboxes are designed to work under You are using Worm Gear Box max.
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TROUBLESHOOTING GUIDE Problem Observation Remedy Observe exactly where the oil is comming out. It could be seal or plug point where it comes out and leakes over the housing. If this Oil is Leaking Oil Leakage from Housing is your case goto ID 018/019. If you are sure oil comes out from housing than housing has some micro split / crack.
12 DISPOSAL If your product is no longer of use and you wish to dispose of it, refer to the instructions here. If you have any questions regarding ecological disposal methods, please consult our service points given on the backside of this manuel. 12.1 DISPOSAL OF OIL Lubricants (oil and greases) are hazardous substances, which can contaminate soil and water.
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