APEX DYNAMICS K Series User manual

KF S1 / S2 KF S3
KF S4 KH

User manual planetary gearboxes
K - series
Apex Dynamics BV The Netherlands Belgium
Churchilllaan 101 Tel. : [phone] Tel. : [phone]
NL-5705 BK Helmond E-mail: [email protected] E-mail: [email protected]
The Netherlands Web : www.apexdyna.nl Web : www.apexdyna.be


Page 2 of 13
Table of content

1. Explanation of this document 3
1.1 Symbols 3
1.2 Warning 3
2. Safety 4
2.1 Intended use 4
 2.2Qualiedpersonnel 4
2.3 General safety instructions 4
2.4 Standards and Guidelines 5
3. Product description 6
3.1Identicationplate 7
 3.2Orderingcode 7
4. Storage, packaging, transport and disposal 8
4.1 Storage 8
4.2 Packaging and transport 8
4.3 disposal 8
5. Assembly and commissioning 9
5.1 Assembly in general 9
5.2 Mounting the gearbox to the motor 9
5.3 Mounting the gearbox in an application 10
5.4 Operation 10
6. Maintenance 11
6.1 General 11
7.Malfunctions 12
7.1General 12
8. Service 13
8.1 General 13
8.2 Contact data 13


Page 2 of 13

Page 3 of 13
1. Explanation of this document

This user manual describes how to handle the Apex Dynamics planetary gear-
boxes during assembly and commissioning.
This manual applies to the following series:
KF en KH
This manual contains important information regarding the use and maintenance
of the gearboxes.
1.1 Symbols
The following warning symbols are used in this manual:
Information This symbol indicates important information that must be
observed for correct and safe installation of the gear units.
Warning This symbol indicates dangers and warnings.
Call for action This symbol indicates when something needs to be done.
1.2 Warning
Warnings must always be followed, failure to follow the warning instructions can
cause danger or cause the gearbox to malfunction.
Warnings are indicated as follows:
Type or source of danger
Action to avoid the danger.


Page 4 of 13
2. Safety
This chapter describes the safety regulations that must be observed for the safe
and danger-free use of planetary gearboxes.
Possible sources of danger and necessary safety regulations are also indicated.
2.1 Intended use
Planetary gearboxes are intended for industrial applications.
The specications as described in the factory documentation
must not be exceeded.
The planetary gearboxes may only be used if the machine in
which the gearboxes are installed complies with all guidelines
and regulations that apply to the machine in question.
2.2Qualiedpersonnel
All work with planetary gear units may only be performed by qualied personnel
and in compliance with current safety regulations.
Always make sure that the personnel has read and
understood the user manual!
2.3 General safety instructions
Improper use, incorrect installation or operation and overdue maintenance can
cause serious damage to property and/or personal injury.
Please observe the following safety instructions before com-
missioning the planetary gear units:
• Never make any changes or modications to the
gearboxes.
• Never perform work on the gearboxes other than those
described in this manual.
• Always make sure the gearbox type is visible and known.
• Never remove the type description and serial number
from the gearbox.
• Before commissioning, ensure that all axes are correctly
attached.
• Always ensure that possible sources of danger are
covered and/or secured (eg rotating parts).
• Always comply with the manufacturer’s conditions when
starting up.
• Never use damaged parts in combination with the gear
units.
• Always ensure su󰀩cient convection (heat dissipation)
when using the gearbox.


Page 4 of 13

Page 5 of 13
2.3 General safety instructions (continued)
• Gearboxes can heat up considerably during use. When
working on the gear unit, always allow it to cool down rst.
Always pay close attention to hot lubricants.
• Only work on the gearbox when it is stationary, the driving
motor is switched o󰀨 and secured against restarting.
• Have repairs carried out within the warranty period only
by Apex Dynamics.
2.4 Standards and Guidelines
2.4.1 Machinery Directive 2006/42/EG
A gearbox is considered a “machine component” and therefore not subject to the
EC Machinery Directive 2006/42/EC.
Using and startup the gearbox is prohibited within the scope of the EC
Machinery Directive until it has been determined that the machine in which the
gearbox is installed meets the regulations of the EC Machine Directive.
2.4.2 RoHs
All Apex Dynamics planetary gearboxes comply with the European RoHs
directive as mentioned in RoHs (2011/96 / EC). All our products are purely
mechanical and contain no electronic or electrical components.
2.4.3 REACH
According to the denitions of the European directive (EC 1907/2006 / EU)
regarding REACH, the planetary gear units that Apex Dynamics imports and / or
manufacters in the EU are not subject to registration.
2.4.4 ATEX
Apex Dynamics Inc., declares that the design, manufacture and inspection of
the products described in this manual are in accordance with the provisions of
Annex VIII (EHSR) of the ATEX Directive 94/9 / EC.
2. Safety


Page 6 of 13
• KF Serie
• Hypoid gearboxes
• Black coated steel housing
• Steel ouput shaft; hollow, with or without key or Spline DIN 5480
• Hypoid gear design, nominal torque from 18 up to 1600 Nm.
• 7 sizes from 62 up to 245mm
• Backlash 3 arcmin
• Lifetime libricated
• Protection class IP65, Operating temperature 0°C ~ +90°C
• KH Serie
• Hypoid gearboxes
• Black coated steel housing
• Steel ouput ange ISO 9409
• Hypoid gear design, nominal torque from 18 up to 1600 Nm.
• 7 sizes from 62 up to 245mm
• Backlash 3 arcmin
• Lifetime libricated
• Protection class IP65, Operating temperature 0°C ~ +90°C
For detailed specications, we refer to the product documentation
and / or website of Apex Dynamics.
3. Product description


Page 6 of 13

Page 7 of 13
3.1Identicationplate(laserengraved)
Each gearbox is executed with a laser-engraved type code.
Example:
APEX DYNAMICS, INC.
Model NO: KF060-S1
S/N: 1711106246
Ratio: 010:1
Backlash: ≤ 3 arcmin
3.2 Ordering code
The order code for an Apex Dynamics gearbox is structured as follows:
KF060-010-S1-... /SERVOMOTOR
Series
Size
Ratio
Output shaft
S1 = smooth shaft, without keyway
S2 = with key and keyway
S3 = DIN 5480
S4 = Hollow Shaft
Lubrication
Empty : Standard Lubrication
FG : Food Grade (NSF-H1 approved)
MT : Grease
LT : Low Temperature Grease
/SERVOMOTOR
Brand and type of the servomotor to be mounted
3. Product description


Page 8 of 13
4.1 Storage
The gearboxes must be stored dry and in original packaging.
Storage temperature, -30 ° C ~ + 60 ° C. Try to keep the storage time as short
as possible.
4.2 Packaging and transport
The gearboxes are packed in polystyrene or polyurethane foam lling, which
means that they are fully protected against transport damage during normal use.
Never drop a gearbox!
Transport a gearbox only in the original packaging!
Protect the packaging and its contents against moisture!
4.3 disposal
Always follow the applicable regulations when removing gearboxes!
Consult the local authority or local regulations for this.
Housing parts, gears, shafts and bearings of the gearboxes
must be disposed of as steel scrap. This also applies to the
aluminum parts, insofar as there is no separate collection.
Collect used lubricant and dispose it accordance within the
applicable regulations.
4. Storage, packaging, transport and disposal


Page 8 of 13

Page 9 of 13
Bolt size
Width across
at
Strength 8.8
Tightening torque
Strength 10.9
Tightening torque
Strength 12.9
Tightening torque
[mm] [Nm] [In-lbs] [Nm] [In-lbs] [Nm] [In-lbs]
M3 x 0.5P 2.5 1.3 12 1.8 16 2.1 19
M4 x 0.7P 3 3 27 4.1 37 4.9 44
M5 x 0.8P 4 6.1 55 8.2 73 9.8 87
M6 x 1P 511 98 14 124 17 151
M8 x 1.25P 6 25 222 34 302 41 364
M10 x 1.5P 8 49 434 67 594 80 709
M12 x 1.75P 10 85 753 116 1028 139 1232
M14 x 2P 12 137 1214 186 1648 223 1976
M16 x 2P 14 210 1860 286 2534 343 3038
5.1 Assembly in general
For correct operation and optimum service life, the following
instructions must be carefully observed:
• Ensure that the gearbox has su󰀩cient convection.
• Take care that the gearbox can dissipate su󰀩cient heat
through the output ange.
• A motor or other external heat sources can heat up the
gearbox. Therefore always inquire with the manufacturer /
supplier about the occurring motor temperatures.
• Always observe the applicable restrictions regarding the
protection class (see Chapter 3.).
5.2 Mounting the gearbox to the motor
The input side of the gearboxes is protected against corrosion, always ensure
that this protective layer is removed before assembly (degrease).
Always use the correct tools when mounting the motor on the gearbox.
Mount the motor according to the correct installation manual.
• An English-language mounting manual is supplied with
every gearbox.
• Mounting instructions in other languages can be
downloaded on: www.apexdyna.nl or www.apexdyna.com.
• Below a table is shown with the recommended tightening
torques for mounting bolts. Apex Dynamics uses quality
class 12.9.
5. Assembly and commissioning


Page 10 of 13
5.3 Mounting the gearbox in an application
The gearboxes from Apex Dynamics can be installed in any position.
The following must be taken into account when mounting the
gearbox:
• Always use the right tools and aids.
• Check if the gearbox is undamaged (no damage due to
transport or storage). In particular the output shaft, seals and
mounting surfaces.
• Ambient temperature within the specication of the gear unit.
• Output shafts and ange surfaces must be thoroughly
cleaned with anti-corrosion agents. Ensure that solvents do
not come into contact with seals.
• Tighten xing materials in accordance with the applicable
regulations (see also table with tightening torques in section
5.2).
• Ensure proper alignment of the output shaft.
• Applied transmission elements (like a coupling) must be
balanced and may not cause inadmissible radial and / or
axial forces.
• For timing belt pulley applications follow the specications of
the timing belt supplier. Be aware of excessive radial forces,
always check timing belt tension with appropriate measuring
equipment
5.4 Operation (commissioning)
Always allow the gearbox to run in rst (trial run). Increase the load and
circulation speed in two to three steps up to the maximum.
Pay attention to the following at a in run or trial run:
• Always check the maximum permissible input speed and
torque when starting up.
• Is the gearbox running smoothly?
• Are vibrations or unusual running noises occurring?
• Is there any leakage at the in- and output side of the
gearbox?
• Check whether the housing temperature remains within
the specied specication.
5. Assembly and commissioning