DANA BREVINI K 00 Series Installation And Maintenance Manual Download Page 1

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Installation and Maintenance Manual

October 2022

IMM-0018EN

Gearmotors K Series

Summary of Contents for BREVINI K 00 Series

Page 1: ... Installation and Maintenance Manual October 2022 IMM 0018EN Gearmotors K 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: ... 4 2 7 TYPE 08 25 4 2 8 TYPE 0S 26 4 2 9 TYPE 0E 27 5 SAFETY 28 5 1 INTENDED USE 28 5 2 IMPROPER USE 28 5 3 SAFETY INSTRUCTIONS 29 5 3 1 GENERAL SAFETY INSTRUCTIONS 29 5 4 TIGHTENING TORQUES 31 5 5 CASE OF FIRE 31 5 5 1 SUITABLE EXTINGUISHING AGENTS PROTECTIVE EQUIPMENT 31 5 5 2 UNSUITABLE EXTINGUISHING AGENTS 31 6 THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTALLED 32 6 1 TRANSPORTA...

Page 4: ...G GEAR UNIT WITH TORQUE ARM 50 8 11 FOR THE FIXING BOLD POSITION REFER TO THE FOLLOWING DIMENSIONS 52 8 12 K 00 K 20 TORQUE ARM ASSEMBLY DETAILS 54 8 13 FITTING OUTPUT SHAFT ELEMENTS 55 8 14 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS 55 8 15 FITTING COUPLINGS 56 9 MAINTENANCE INSPECTION 57 10 LUBRICATION 58 10 1 OIL TYPES 58 10 2 CHANGING THE OIL 59 10 3 OIL PLUGS AND OIL QUANTITIES 60 10 3 1 K 00 ...

Page 5: ...tallation and Maintenance Manual 1 VERSION TRACKING 1 1 MANUAL APPLICABILITY AND SUPPORTED MODELS File name Revision Date Changes description IMM 0018EN_Rev 00 Gearmotors K Series 00 17 10 2022 Changed layout Models Gearmotors K 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: ...5 B09 90 B14 A18 180 B5 Gearbox Type K Serie Input Type R With Motor N IEC B5 B14 Flanged without Motor V IEC B5 B14 Flanged with Motor T Without Motor Housing Size 0 8 Revision Number 0 7 00 Hollow output shaft 01 Solid output shaft 02 Solid output shaft and with Flange 03 Flanged and hollow output shaft 04 With double output shaft 05 08 0S Shrink disk output 0E Extruder output Stage 2 Stages 3 S...

Page 8: ...M Pos Mounting Position Type Designation A Type B Shaft Arrangement Viewed from input side L Right Input Left Output R Left Input Right Output 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 KR373 00 100L 4a 100052892 3 51 05 28 M1 ISO VG 220 Mineral Oil 1 4 KR373 00 R A B ...

Page 9: ...4 2 1 2 2 21 22 23 27 26 25 23 22 21 5 8 7 6 5 4 2 3 2 10 12 13 14 15 16 17 18 16 19 20 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer Standard Part List 19 Spacer 20 Circlip 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Gear 27 ...

Page 10: ...2 23 18 16 8 10 4 15 21 28 19 7 12 25 29 27 16 2 3 2 2 1 2 11 2 26 24 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer Standard Part List 20 Circlip 21 Closing Cap 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Key 27 Gear 28 Spacer 2...

Page 11: ... 8 4 20 2 9 23 14 22 18 7 10 24 15 28 16 4 6 12 27 16 5 2 5 19 26 25 21 2 2 1 2 11 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip 21 Closing Cap 22 Circlip 23 Bearing 24 Output Shaft 25 Key 26 Key 27 Gear 28 Oil Seal Stand...

Page 12: ...10 5 5 22 30 23 16 15 12 8 4 21 31 16 19 2 3 2 2 1 2 11 26 2 24 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip 21 Closing Cap 22 Circlip Standard Part List 23 Bearing 24 Key 25 Output Shaft 26 Key 27 Gear 28 Spacer 29 Oil ...

Page 13: ...9 4 14 24 18 28 2 29 7 21 10 15 27 16 30 2 4 6 22 12 16 23 19 2 1 2 26 25 11 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip 21 Closing Cap 22 Circlip 23 Bearing 24 Output Shaft 25 Key 26 Key 27 Gear 28 Oil Seal 29 Flange 3...

Page 14: ...27 26 25 23 22 21 2 3 2 4 5 8 7 6 5 4 9 10 12 13 14 15 16 17 18 16 19 20 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip Standard Part List 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Gear 27 Spacer 28 Flang...

Page 15: ... 8 7 6 5 4 21 22 23 27 26 25 23 22 21 9 10 12 13 14 15 16 17 18 16 19 20 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer Standard Part List 20 Circlip 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Gear 27 Spacer 28 Flang...

Page 16: ...23 22 21 4 5 8 7 6 5 4 9 10 12 13 14 15 16 17 18 16 19 20 2 24 26 24 11 2 1 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer Standard Part List 20 Circlip 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Key 27 Gear 28 Spa...

Page 17: ... 22 27 28 23 29 30 25 9 10 12 13 14 15 16 17 18 16 19 20 24 26 2 3 2 29 30 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip Standard Part List 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Key 27 Gear 28 Spacer...

Page 18: ...21 22 23 27 26 25 23 22 21 9 10 12 13 14 15 16 17 18 16 19 20 2 29 28 2 3 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Bearing 6 Gear 7 Pinion Shaft 8 Key 9 Bolt 10 Cover Plate 11 Key 12 Pinion Shaft 13 Shim Ring 14 Circlip 15 Shim Ring 16 Bearing 17 Gear 18 Spacer 19 Spacer 20 Circlip Standard Part List 21 Oil Seal 22 Circlip 23 Bearing 24 Key 25 Output Shaft 26 Gear 27 Spacer 28 Fl...

Page 19: ...20 19 18 17 16 15 2 2 2 1 3 2 2 23 24 25 25 26 27 28 29 26 25 24 30 2 25 25 25 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Shim Ring Standard Part List 21 Key 22 Output Shaft 23 Closing Cap 24 Circlip 25 Shim Ring 26 Bearing...

Page 20: ... 10 9 8 7 6 5 4 2 2 3 2 2 1 24 25 26 26 27 28 29 30 27 26 26 26 26 25 24 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Key 8 Bearing 9 Spacer 10 Bearing 11 Shim Ring 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Output Shaft Standard Part List 21 Key 22 Key 23 Shim Ring 24 Closing Cap 25 Circlip 26 Shim Ring 27 Bear...

Page 21: ...7 28 28 29 30 31 32 29 28 28 28 28 33 34 2 2 2 1 2 2 3 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Output Shaft 21 Key 22 Key 23 Shim Ring 24 Flange Standard Part List 25 Bolt 26 Closing Cap 27 Circlip 28 Shim Ring 29 Bear...

Page 22: ...2 2 1 3 2 2 24 23 25 26 27 27 28 29 30 31 28 27 26 32 2 27 27 27 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Shim Ring 21 Key 22 Output Shaft Standard Part List 23 Flange 24 Bolt 25 Closing Cap 26 Circlip 27 Shim Ring 28 Bea...

Page 23: ... 10 9 8 7 6 5 4 2 2 3 2 2 1 22 24 25 26 26 27 28 29 30 27 26 26 26 26 25 24 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Key 8 Bearing 9 Spacer 10 Bearing 11 Shim Ring 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Output Shaft Standard Part List 21 Key 22 Key 23 Shim Ring 24 Closing Cap 25 Circlip 26 Shim Ring 27 B...

Page 24: ...29 30 31 32 29 28 28 28 28 33 34 2 2 2 1 2 2 3 2 15 22 24 25 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Output Shaft 21 Key 22 Key 23 Shim Ring 24 Flange Standard Part List 25 Bolt 26 Closing Cap 27 Circlip 28 Shim Ring 29 ...

Page 25: ... 2 2 2 1 3 2 2 24 23 23 24 25 26 27 27 28 29 30 31 28 27 27 27 27 26 25 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Shim Ring 21 Key 22 Output Shaft Standard Part List 23 Flange 24 Bolt 25 Closing Cap 26 Circlip 27 Shim Ri...

Page 26: ... 15 2 26 27 28 28 29 30 31 32 29 28 28 28 28 27 26 3 2 2 2 1 2 2 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Key 21 Output Shaft 22 Shim Ring Standard Part List 23 Shrink Disk 24 Cap 25 Bolt 26 Closing Cap 27 Circlip 28 Shim...

Page 27: ... 2 2 2 2 1 3 4 5 6 7 8 9 10 11 12 13 14 Standard Part List 1 Pinion 2 Plug 3 Housing 4 Circlip 5 Shim Ring 6 Gear 7 Bearing 8 Spacer 9 Bearing 10 Shim Ring 11 Key 12 Pinion Shaft 13 Cover Plate 14 Bolt 15 Oil Seal 16 Circlip 17 Shim Ring 18 Bearing 19 Gear 20 Shim Ring 21 Key 22 Hollow shaft 23 Circlip 24 Shim Ring 25 Flange 26 Bolt Standard Part List 27 Ekstruder Housing 28 Bolt 29 Bearing 30 Key...

Page 28: ... 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 29: ...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 30: ...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 31: ... 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 32: ...damage Contact Dana Motion Systems Italia S r l for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation NOTE If geared motors are used please also refer to the manual of the motor manufacturer DANGER Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of your gea...

Page 33: ...er 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 be...

Page 34: ...fer 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 Tolerance H7 Output Shaft Diameter Output Shaft Tolerance DIN748 Up to 50mm k6 Over 50mm m6 Flange Centering...

Page 35: ...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 36: ...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 37: ...orrect 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 protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or paint ing of the housing 7 9 COVER ABRASIVE AMBIENT...

Page 38: ...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 39: ... Manual 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 1 Short retaining bolt standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Hollow shaft 6 Customer Shaft ...

Page 40: ...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 1 Short retaining bolt standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Spacer 6 Hollow shaft 7 Customer Shaft ...

Page 41: ...nd take out the parts as shown 1 Short retaining bolt 2 Lock washer 3 Washer 4 Circlip 5 Hollow shaft 6 Customer Shaft Use the disassemble set from YILMAZ REDÜKTÖR and fasten the bold as shown bellow to take out the out put shaft For disassemble sets look the following pages 1 Retaining bolt 2 Circlip 3 Fixed Nut 4 Forcing Washer 5 Hollow shaft 6 Customer Shaft ...

Page 42: ...arts as shown 1 Short retaining bolt standart scope of delivery 2 Lock washer 3 Washer 4 Circlip 5 Spacer 6 Hollow shaft 7 Customer Shaft Use the disassembly set from YILMAZ REDÜKTÖR and fasten the bold as shown bellow to take out the out put shaft For disassembly sets look the following pages 1 Retaining bolt 2 Circlip 3 Fixed Nut 4 Forcing Washer 5 Hollow shaft 6 Customer Shaft ...

Page 43: ...llation and Maintenance Manual 8 5 SHAFT TIGHTENING TORQUES VALUES ARE AS SHOWN Type Bolt Tightening Torques Nm K 00 M6 10 K 10 M10 48 K 20 M12 84 K 27 M12 84 K 28 M16 206 K 37 M16 206 K 47 M16 206 K 57 M20 415 K 67 M20 415 K 77 M24 714 K 87 M24 714 K 97 M24 714 ...

Page 44: ...3 114 65 27 22 1 M12 30 38 10 K 28 34 7 12 43 11 5 M20 40 39 50 124 70 28 26 2 M16 38 43 12 K 37 39 7 12 43 11 5 M20 40 39 50 138 75 35 28 2 M16 38 43 12 K 47 49 7 12 53 5 13 5 M20 50 49 60 165 87 41 37 3 M16 38 53 5 14 K 57 59 7 16 64 17 5 M24 60 59 75 188 101 44 43 3 M20 44 64 18 K 67 69 7 16 74 5 19 5 M24 70 69 85 248 115 78 55 4 M20 44 74 5 20 K 77 89 7 20 95 24 5 M30 90 89 110 287 140 83 64 4...

Page 45: ...6x9H 37 36 64 58 63 5 31 35 4 140 157 166 18 35 20 20 M10x70 M10x90 M10x100 K37 N45x2x30x21x9H 47 46 74 41 45 4 185 25 45 24 32 M16x110 K47 N50x2x30x24x9H 55 51 84 46 50 4 215 25 55 24 32 M16x130 K57 N65x2x30x31x9H 72 66 104 61 65 4 246 25 65 30 40 M20x150 K67 N70x2x30x34x9H 72 71 119 66 70 4 308 25 75 30 40 M20x210 K77 N85x3x30x27x9H 90 86 139 5 79 85 6 363 26 90 30 40 M20x240 K87 N100x4x30x24x9H...

Page 46: ...W35x2x30x16x8f 37 58 11 7 40 38 94 4 00 M10x24 K37 W45x2x30x21x8f 47 75 18 7 50 48 88 4 00 M16x38 K47 W50x2x30x24x8f 55 85 18 7 60 54 16 4 00 M16x38 K57 W65x2x30x31x8f 72 95 17 8 70 68 99 4 00 M20x44 K67 W70x2x30x34x8f 72 105 17 8 80 74 18 4 00 M20x44 K77 W85x3x30x27x8f 90 121 16 10 95 91 02 6 00 M20x44 K87 W100x4x30x24x8f 110 140 20 10 110 108 37 8 00 M24x52 K97 W120x4x30x28x8f 130 160 23 12 125 ...

Page 47: ...l 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 ...

Page 48: ...a clearance between the shrink disk shoulder and the hollow shaft shoulder of the gearbox 1 Welle von Kunde 2 Ringaus bronze 3 Hohlwelle 4 Schrumpscheibe Table 9 Type Bolt Quantity Tightening Torque Nm K 00 M5 6 4 K 10 M6 5 12 K 20 M6 7 12 K 27 M6 7 12 K 28 M6 8 12 K 37 M6 8 12 K 47 M6 10 12 K 57 M8 7 30 K 67 M8 7 30 K 77 M10 9 59 K 87 M12 10 100 K 97 M12 12 100 ...

Page 49: ...MECHANICAL INSTALLATION 49 Dana Incorporated IMM 0018EN Installation and Maintenance Manual 8 9 DISASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK Loosen the bolts of the shrink disk and take out the shaft ...

Page 50: ...INSTALLATION Dana Incorporated IMM 0018EN Installation and Maintenance Manual 8 10 ASSEMBLING GEAR UNIT WITH TORQUE ARM The following connecting possibilities are available Use one position which is the most suitable ...

Page 51: ...N Installation and Maintenance Manual Assemble the parts as shown bellow 2 3 4 5 4 6 8 9 8 9 10 8 9 7 8 9 11 11 11 1 5 10 1 Gear Unit 2 Assembled Shaft 3 Bolt 4 Spacer Ring 5 Machine Extension 6 Nut 7 Torque Arm 8 Spacer Ring 9 Nut 10 Rubber Buffer 11 Bolt ...

Page 52: ...R273 10 56 28 Ø17 22 5 160 119 73 141 KR283 10 76 38 Ø22 27 5 192 140 77 150 KR373 10 76 38 Ø22 27 5 200 150 105 170 KR473 10 80 40 Ø22 27 5 250 182 155 210 KR573 10 105 52 5 Ø26 42 5 300 220 180 251 KR673 10 110 55 Ø26 42 5 350 245 200 260 KR773 10 155 77 5 Ø32 50 450 335 260 360 KR873 10 160 80 Ø32 55 550 400 263 410 KR973 10 190 95 Ø38 70 700 530 380 550 Std T1 T2 d b R h b1 h2 Ød b1 b h1 d b R...

Page 53: ...Type b e ød r h c K 273 62 36 ø11 25 160 12 K 283 63 60 ø16 5 35 200 12 K 373 63 60 ø16 5 35 200 12 K 473 78 60 ø16 5 35 250 12 K 573 73 5 100 ø25 48 300 12 K 673 105 5 100 ø25 54 380 15 K 773 131 5 100 ø25 58 450 15 K 873 155 120 ø32 70 550 20 K 973 195 120 ø38 75 700 20 L1 L2 L3 R1 R2 R3 c r b e ød h ...

Page 54: ...ION Dana Incorporated IMM 0018EN Installation and Maintenance Manual 8 12 K 00 K 20 TORQUE ARM ASSEMBLY DETAILS Table 12 Type b e d r h K 00 47 16 10 32 100 K 10 49 5 16 10 36 150 K 20 54 5 25 20 45 200 L1 L2 R1 R2 d h r b e ...

Page 55: ...NTS Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 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 1 Hub ...

Page 56: ...enance Manual 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 ...

Page 57: ...ry 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 Beari...

Page 58: ...syn 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 22...

Page 59: ...iodegra 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 Extende...

Page 60: ...L PLUGS For K002 and K003 this plug doesn t exist Please refer to oil quantities Table 15 Symbols Drain Plug Oil Filling Vent Plug Oil Level Oil Quantities lt Type M1 M2 M3 M4 M5 M6 K 002 0 3 0 6 0 5 0 8 0 65 0 65 K 003 0 3 0 6 0 5 0 8 0 65 0 65 K 102 0 55 0 8 0 85 1 1 0 8 0 8 K 103 0 5 0 7 0 8 1 0 0 8 0 8 K 202 1 0 1 35 1 5 1 7 1 4 1 4 K 203 0 9 1 25 1 4 1 4 1 6 1 3 M6 M5 M4 M3 M2 M1 ...

Page 61: ... Vent Plug Oil Level Oil Quantities lt Type M1 M2 M3 M4 M5 M6 K 273 0 8 1 8 2 2 2 3 1 4 1 5 K 283 1 2 2 4 2 5 2 9 1 9 1 7 K 373 1 4 3 3 3 4 4 0 1 9 2 2 K 473 2 7 5 9 6 5 7 8 4 0 4 5 K 573 4 1 9 0 9 7 11 5 5 5 6 6 K 673 8 7 16 3 18 0 22 5 11 7 13 2 K 773 13 0 28 0 30 0 35 0 18 0 20 0 K 873 28 0 49 0 46 0 63 0 30 0 36 0 K 973 47 0 85 0 84 0 117 0 77 0 64 0 M1 M4 M2 M3 M6 M5 ...

Page 62: ...2 4 0 25 2 5 0 25 2 9 0 25 1 9 0 25 1 7 0 25 K 374 1 4 0 25 3 3 0 25 3 4 0 25 4 0 0 25 1 9 0 25 2 2 0 25 K 474 2 7 0 4 5 9 0 4 6 5 0 4 7 8 0 4 4 0 0 4 4 5 0 4 K 574 4 1 0 5 9 0 0 5 9 7 0 5 11 5 0 5 5 5 0 5 6 6 0 5 K 674 8 7 0 9 16 3 0 9 18 0 0 9 22 5 0 9 11 7 0 9 13 2 0 9 K 774 13 0 1 0 28 0 1 0 30 0 1 0 35 0 1 0 18 0 1 0 20 0 1 0 K 874 28 0 2 2 49 0 2 2 46 0 2 2 63 0 2 2 30 0 2 2 36 0 2 2 K 974 4...

Page 63: ...5 1 5 0 5 K 285 286 1 2 0 54 2 4 0 8 2 5 0 6 2 9 0 8 1 9 0 6 1 7 0 6 K 375 376 1 4 0 65 3 3 0 95 3 4 0 7 4 0 0 95 1 9 0 7 2 2 0 7 K 475 476 2 7 1 2 5 9 2 1 6 5 2 0 7 8 2 1 4 0 1 4 4 5 1 4 K 575 576 4 1 1 2 9 0 2 1 9 7 2 0 11 5 2 1 5 5 1 4 6 6 1 4 K 675 676 8 7 2 0 16 3 3 4 18 0 3 1 22 5 3 4 11 7 2 8 13 2 2 8 K 775 776 13 0 2 0 28 0 3 4 30 0 3 1 35 0 3 4 18 0 2 8 20 0 2 8 K 875 876 28 0 2 0 49 0 3 ...

Page 64: ...ncorporated IMM 0018EN Installation and Maintenance Manual 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 ...

Page 65: ...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 66: ...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 67: ...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 68: ...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 69: ...69 Dana Incorporated IMM 0018EN Installation and Maintenance Manual ...

Page 70: ...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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