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INSTALLING THE GEAR UNIT

Dana Incorporated

IMM-0017EN - Installation and Maintenance Manual

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)

Delayed Running Brake ( 24 V)

Sudden Brake (24 V)

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3

R S T

A

A

M

3

R S T N

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3

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Summary of Contents for Dana E Series

Page 1: ... Installation and Maintenance Manual December 2022 IMM 0017EN Gearmotors E Series ...

Page 2: ...lish original prevails Dana shall not be liable for any misinterpretation of the content here into Photos and illustrations might not represent the exact product Copyright 2022 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or oth erwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR R...

Page 3: ...ASE OF FIRE 26 5 5 1 SUITABLE EXTINGUISHING AGENTS PROTECTIVE EQUIPMENT 26 5 5 2 UNSUITABLE EXTINGUISHING AGENTS 26 6 THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTALLED 27 6 1 TRANSPORTATION 27 6 2 STORAGE 27 7 INSTALLING THE GEAR UNIT 28 7 1 BEFORE YOU START 28 7 2 CHECK THE SHAFT DIMENSIONS TO FIT 28 7 3 CHECK THE AMBIENT TEMPERATURE 28 7 4 CHECK THE VOLTAGE SUPPLY 29 7 5 CHECK TH...

Page 4: ...e Manual 9 MAINTENANCE INSPECTION 42 10 LUBRICATION 43 10 1 OIL TYPES 43 10 2 CHANGING THE OIL 44 10 3 MOUNTING POSITIONS 45 10 4 OIL QUANTITIES 46 11 TROUBLESHOOTING GUIDE 47 12 DISPOSAL 50 12 1 DISPOSAL OF OIL 50 12 2 DISPOSAL OF SEALING 50 12 3 DISPOSAL OF METAL 50 ...

Page 5: ...ACKING 1 1 MANUAL APPLICABILITY AND SUPPORTED MODELS File name Revision Date Changes description IMM 0017EN_Rev 00 Gearmotors E Series 00 17 10 2022 Changed layout IMM 0017EN_Rev 01 Gearmotors E Series 01 07 12 2022 Updated Use the breather plug page 31 Models Gearmotors E Series ...

Page 6: ...nd modified gear units ask Dana Motion Systems Italia S r l for validity This manual does not cover 94 9 EC compatible gearboxes For 94 9 EC contact Dana Motion Systems Italia S r l Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates an imminently hazardous situation which if not avoided could result in death or serious injury Indicates...

Page 7: ...tput Shaft and with Flange 03 Flanged and Hollow Shaft Output 04 With Double Shaft Output 05 Double Flanged and Double Output Shaft 06 With Shaft Extension on the Motor Fan Cover Side 07 With Double Input Shaft 08 Double Flanged and Hollow Output Shaft 10 100Nm 20 200 Nm 30 300 Nm 40 400 Nm Motor Size For EV types For ENTypes PoleNumber 90S 4 FrameLenght Motorsize A06 63 B5 A10 100 B5 A20 200 B5 B...

Page 8: ...iations Serial N Serial Number M Pos Mounting Position Type Designation A Type B Output Shaft C Motor Type NOTE Nameplate unit designation is a short abbreviation from the detailed designation M Pos Oil Ratio Type rpm Speed Power kW MADE IN TURKEY Serial N Oil Qty lt EV080 00 90S 4 100536041 1 1 62 23 M1 ISO VG320 Synthetic Oil 0 6 EV080 00 90S 4 A B C ...

Page 9: ...t diagram Parts may differ for special applications 1 2 3 4 5 6 7 8 11 10 9 12 13 14 15 16 17 18 19 Standard Part List 1 Oil Seal 2 Bolt 3 Side Cover 4 O ring 5 Bearing 6 Worm Wheel 7 Bearing 8 Housing 9 Closing Cap 10 Circlips 11 Bearing 12 Seal 13 Oil Plug 14 Worm Gear Standard Part List 15 Bearing 16 O Ring 17 Input Flange 18 Bolt 19 Seal Standard Part List ...

Page 10: ...RTANT Standard E 01 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 2 Solid Output Shaft 3 Seal 4 Bolt 5 Side Cover 6 O ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Circlips 15 Seal 16 Oil Plug Standard Part List 17 Worm Gear 18 Bearing 19 O ring 20 Input Flange 21 Bolt 22 Seal Standard Part List ...

Page 11: ...Standard E 02 type basic part diagram Parts may differ for special applications Standard Part List 1 Key 2 Solid Output Shaft 3 Bolt 4 Flange 5 Seal 6 Bolt 7 Side Cover 8 O Ring 9 Bearing 10 Worm Wheel 11 Bearing 12 Housing 13 Closing Cap 14 Circlips 15 Bearing 16 Circlips Standard Part List 17 Seal 18 Oil Plug 19 Worm Gear 20 Bearing 21 O Ring 22 Motor Flange 23 Bolt 24 Seal Standard Part List ...

Page 12: ...arts may differ for special applications 2 1 9 8 3 4 5 6 7 10 13 12 11 14 15 16 17 18 19 20 21 Standard Part List 1 Bolt 2 Flange 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Seal Standard Part List 15 Oil Plug 16 Worm Gear 17 Bearing 18 O Ring 19 Motor Flange 20 Bolt 21 Seal Standard Part List ...

Page 13: ...fer for special applications 20 21 22 23 2 1 1 1 15 14 3 4 5 6 7 8 9 10 13 12 11 16 17 18 19 Standard Part List 1 Key 2 Solid Output Shaft 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Circlips 15 Washer 16 Seal 17 Oil Plug 18 Worm Gear 19 Bearing 20 O Ring 21 Input Flange 22 Bolt 23 Seal Standard Part List ...

Page 14: ...applications 6 7 8 9 13 16 15 14 18 19 20 21 22 23 24 25 5 4 12 11 2 10 4 5 17 1 1 1 3 Standard Part List 1 Key 2 Solid Output Shaft 3 Circlips 4 Bolt 5 Flange 6 O Ring 7 Bolt 8 Side Cover 9 O Ring 10 Bearing 11 Worm Wheel 12 Bearing 13 Housing 14 Closing Cap 15 Circlips 16 Bearing 17 Circlips 18 Seal 19 Oil Plug 20 Worm Gear 21 Bearing 22 O Ring 23 Input Flange 24 Bolt 25 Seal Standard Part List ...

Page 15: ...may differ for special applications 3 4 5 6 7 10 13 12 11 14 15 16 17 18 19 20 21 2 1 9 8 1 2 Standard Part List 1 Bolt 2 Output Flange 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Seal Standard Part List 15 Oil Plug 16 Worm Gear 17 Bearing 18 O Ring 19 Input Flange 20 Bolt 21 Seal Standard Part List ...

Page 16: ...t diagram Parts may differ for special applications 14 16 17 18 20 15 19 1 2 3 4 5 6 7 8 11 10 9 12 13 Standard Part List 1 Seal 2 Bolt 3 Side Cover 4 O ring 5 Bearing 6 Worm Wheel 7 Bearing 8 Housing 9 Closing Cap 10 Circlips 11 Bearing 12 Seal 13 Oil Plug 14 Worm Gear Standard Part List 15 Key 16 Bearing 17 O Ring 18 Flange 19 Bolt 20 Seal Standard Part List ...

Page 17: ...r special applications 17 19 20 21 23 18 22 3 4 5 6 7 8 9 10 13 12 11 15 16 14 1 2 1 Standard Part List 1 Key 2 Solid Output Shaft 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Circlips 15 Seal 16 Oil Plug Standard Part List 17 Worm Gear 18 Key 19 Bearing 20 O Ring 21 Giriş Flange 22 Bolt 23 Seal Standard Part List ...

Page 18: ...applications 4 3 2 11 10 5 6 7 8 9 12 15 14 13 17 18 19 20 21 22 23 24 16 1 1 Standard Part List 1 Key 2 Solid Output Shaft 3 Bolt 4 Flange 5 Seal 6 Bolt 7 Side Cover 8 O Ring 9 Bearing 10 Worm Wheel 11 Bearing 12 Housing 13 Closing Cap 14 Circlips 15 Bearing 16 Circlips 17 Seal 18 Oil Plug Standard Part List 19 Worm Gear 20 Key 21 Bearing 22 O Ring 23 Input Flange 24 Bolt 25 Seal Standard Part Li...

Page 19: ...s may differ for special applications 3 4 5 6 7 10 13 12 11 14 15 2 1 9 8 16 18 19 20 22 17 21 Standard Part List 1 Bolt 2 Flange 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Seal 15 Oil Plug 16 Worm Gear Standard Part List 17 Key 18 Bearing 19 O Ring 20 Motor Flange 21 Bolt 22 Seal Standard Part List ...

Page 20: ...al applications 3 4 5 6 7 8 9 10 13 12 11 16 17 2 1 1 1 15 14 18 20 21 22 24 19 23 Standard Part List 1 Key 2 Solid Output Shaft 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Circlips 15 Washer 16 Seal 17 Oil Plug 18 Worm Gear Standard Part List 19 Key 20 Bearing 21 O Ring 22 Input Flange 23 Bolt 24 Seal Standard Part List ...

Page 21: ...ations 6 7 8 9 13 16 15 14 18 19 5 4 4 5 17 1 1 1 3 12 11 2 10 20 22 23 24 26 21 25 Standard Part List 1 Key 2 Solid Output Shaft 3 Circlips 4 Bolt 5 Output Flange 6 Seal 7 Bolt 8 Side Cover 9 O Ring 10 Bearing 11 Worm Wheel 12 Bearing 13 Housing 14 Closing Cap 15 Circlips 16 Bearing 17 Circlips 18 Seal 19 Oil Plug 20 Worm Gear 21 Key 22 Bearing 23 O Ring 24 Input Flange 25 Bolt 26 Seal Standard P...

Page 22: ...differ for special applications 3 4 5 6 7 10 13 12 11 14 15 2 1 9 8 1 2 16 18 19 20 22 17 21 Standard Part List 1 Bolt 2 Output Flange 3 Seal 4 Bolt 5 Side Cover 6 O Ring 7 Bearing 8 Worm Wheel 9 Bearing 10 Housing 11 Closing Cap 12 Circlips 13 Bearing 14 Seal 15 Oil Plug 16 Worm Gear Standard Part List 17 Key 18 Bearing 19 O Ring 20 Input Flange 21 Bolt 22 Seal Standard Part List ...

Page 23: ... to be operated in the frequency entries so that the data provided on nameplate catalogue of the gear unit is not exceeded and is accordance with the nameplate catalogue The speed range will be provided on the name plate if Dana Motion Systems Italia S r l is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this ...

Page 24: ...ar the gear reducer WARNING Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suitable safety equipment like gloves WARNING Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A1 EN13857 WARNING An ...

Page 25: ...the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust Entering sub stances inside the gear unit from seals can damage the gear unit Observe the safety instructions for outdoor use EN12100 2010 WARNING Standard gearboxes are allowed to work in ambient temperatures between 5 to 40ºC unless differently specified on the nameplate Using the gear unit...

Page 26: ... itself is not combustible However it usually contains a synthetic or mineral gear oil Please observe the following if the gear reducer is situated in a burning environment 5 5 1 SUITABLE EXTINGUISHING AGENTS PROTECTIVE EQUIPMENT Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit 5 5 2 UNSUITABLE EXTINGUISHING AGENTS B...

Page 27: ...nder roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 ºC Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should ...

Page 28: ...s NOTE This manual is not for 94 9 EC ATEX conforming gear units For 94 9 EC conforming gear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres Type Hollow Shaft Diameter Hollow Shaft Toleran...

Page 29: ...ctric motors For different voltages please contact Dana Motion Systems Italia S r l For gear units supplied without motor refer to the motor manufacturers user manual Table 5 Basic motor connection wiring diagram DANGER Using wrong connection or voltage can damage the electric motor or environment DANGER The electric connection must be done by experienced electric technician The gearbox the motor ...

Page 30: ...gram 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 Delayed Running Brake 24 V Sudden Brake 24 V M 3 R S T A A M 3 R S T N A M 3 S R N T A N M 3 R S T ...

Page 31: ...ighten the plug again If no oil comes out take out the filling plug and add oil until oil comes out from the level plug and tighten both plugs after finish Be sure you are using the correct oil mentioned on the oil tables on this manual 7 8 CHECK SHAFT ENDS AND MOUNTING FACES Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be pr...

Page 32: ...nter the gearbox and cause serious damage to the gear unit If pressure or abrasive material can not be prevented from coming over the sealing contact Dana Motion Systems Italia S r l for solutions 7 10 CHECK ACCESSIBILITY TO FILLING BREATHER AND DRAIN PLUGS The filling breather and drain plugs must be freely accessible for further checking and service DANGER Abrasive material chemicals water posit...

Page 33: ...be in accordance with your application Check the product catalogue for permitted radial loads and calculation Secure the gear unit using 8 8 or higher quality bolts 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...

Page 34: ... and Maintenance Manual 8 1 INSTALLING CUSTOMER SHAFT WITH SHOULDER Use anti seize assembling paste available on your market Use a brush to apply the paste Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlips 5 Hollow Shaft 6 Customer Shaft ...

Page 35: ...17EN Installation and Maintenance Manual 8 2 SHAFT TIGHTENING TORQUES Use the following table for shaft tightening torques Type Bolt Tightining Torque Nm E 030 M5 5 E 040 M6 8 E 050 M10 20 E 063 M10 20 E 075 M12 30 E 080 M12 30 E 100 M16 40 E 125 M16 40 ...

Page 36: ...214 151 5 M6 6 20 5 0 35 0 30 0 55 0 40 0 20 E 050 25 50 55 50 70 5 98 158 208 239 173 M10 8 28 0 70 0 50 0 90 0 60 0 30 E 063 25 50 55 50 72 122 182 232 266 199 M10 8 28 1 10 0 90 1 40 1 00 0 40 E 075 35 65 72 65 116 120 197 264 352 235 M12 10 38 2 10 1 50 3 15 1 90 0 70 E 080 35 65 72 65 103 5 133 210 277 340 241 5 M12 10 38 2 25 1 60 3 00 2 00 0 90 E 100 40 80 87 80 114 156 249 330 384 276 M16 ...

Page 37: ...MECHANICAL INSTALLATION 37 Dana Incorporated IMM 0017EN Installation and Maintenance Manual 8 4 TORQUE ARM CONNECTION Use the torque arm connection according the following drawing L1 L2 L3 R1 R2 R3 ...

Page 38: ...38 MECHANICAL INSTALLATION Dana Incorporated IMM 0017EN Installation and Maintenance Manual Assemble the parts as shown bellow 1 Bolt 2 Washer 3 Bolt 4 Torque arm 5 Machine Connection Arm 6 Nut ...

Page 39: ...position refer to the following dimensions Table 7 Type b e d h R Part No E 030 22 14 10 85 25 9E030 E 040 31 14 10 100 25 9E040 E 050 38 16 10 100 32 9E050 E 063 49 5 16 10 150 36 9E063 E 075 49 5 25 20 200 45 9E075 E 080 49 5 25 20 200 45 9E080 E 100 57 5 30 25 250 50 9E100 E 125 72 30 25 300 55 9E125 R h d e b ...

Page 40: ...S Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 8 6 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS The 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 1 Hub ...

Page 41: ...ntenance Manual 8 7 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 eccentric between the two shafts By fitting couplings be sure that the two shafts are not angular miss aligned ...

Page 42: ...ery 4 000 working hours Every 10 000 working hours or every 3 years Every 25 000 working hours Check for oil leakage x Check for oil level x Check oil leakage from seal x Check Rubber buffer x Change if necessary Check Bearings Noise x Change if necessary Change Mineral Oil x See Below for details Change Synthetic PAO Oil x See Below for details Change Sealing x Change Bearing Grease x Change Bear...

Page 43: ...yn SG XP 680 Klüber synth GH 6 680 Mobil Gly goyle 680 Tivela S 680 Carter SY 680 20 50 460 Degol GS 460 Energsyn SG XP 460 Aphasyn PG 460 Klüber synth GH 6 460 Mobil Gly goyle 460 Tivela S 460 Carter SY 460 25 40 5 40 320 Degol GS 320 Energsyn SG XP 320 Aphasyn PG 320 Klüber synth GH 6 320 Mobil Gly goyle 320 Tivela S 320 Carter SY 320 30 30 0 30 220 Degol GS 220 Energsyn SG XP 220 Aphasyn PG 220...

Page 44: ... dable Oil CLP E 25 40 5 40 320 Tribol Bio Top 1418 320 Klüber synthGEM 2 320 Carter Bio 320 Mineral Grease 20 120 Working Temperature ºC Aralub HL3 Energrea se LS 3 Spheerol AP3 Centoplex 2 EP Mobilux EP 3 Alvania RL3 Multis Complex EP 2 Synthetic Grease 30 100 Working Temperature ºC Energrea se SY 2202 Petamo GHY 133 N Mobiltemp SHC 100 Cassida RLS 2 Multis Complex SHD 220 WARNING Extended inten...

Page 45: ...ncorporated IMM 0017EN Installation and Maintenance Manual 10 3 MOUNTING POSITIONS Figured mounting positions of M1 to M6 are determined as reference of directional position of the gearbox Mounting surfaces are not binding ...

Page 46: ...ble 10 M1 M2 M3 M4 M5 M6 Type M1 M2 M3 M4 M5 M6 E 30 0 025 0 04 0 02 0 04 0 04 0 04 E 40 0 07 0 10 0 12 0 10 0 10 0 10 E 50 0 15 0 15 0 15 0 15 0 15 0 15 E 63 0 30 0 40 0 25 0 40 0 40 0 40 E 75 0 45 0 60 0 40 0 65 0 65 0 65 E 80 0 60 0 80 0 50 0 80 0 80 0 80 E 100 1 7 2 1 1 2 2 1 2 1 2 1 E 125 3 1 3 6 2 0 3 6 3 6 3 6 ...

Page 47: ...ng driver or frequency inverter Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver frequency inverter and make direct voltage supply to the motor according the motors nameplate Still does not work go to ID 100 005 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turnin...

Page 48: ...nious Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bearings are defect Change bearings Goto ID 100 012 Gearbox is noisy Noise is random Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for sma...

Page 49: ...side gearbox Goto ID 10 025 Gearbox Housing is Defect You are using chain drive or pinion gear The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigit enough Check if you are using the correct diameter of chain drive and you are not exceed ing max allowed radial load Check the position of...

Page 50: ...s oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guidlines 12 2 DISPOSAL OF SEALING Remove the sealing rings from the gear reducer and clean them of oil and grease resudies Dispose of the sealings as composite material metal plastic 12 3 DISPOSAL OF METAL Divide up t...

Page 51: ...51 Dana Incorporated IMM 0017EN Installation and Maintenance Manual ...

Page 52: ...ine service parts ordering visit www danaaftermarket com Copyright 2022 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or otherwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES ...

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