DANA BREVINI K Series Manual

®
Installation and Maintenance Manual
October 2022
IMM-0018EN
Gearmotors K Series

CONTENTS
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. 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 RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
DISCLAIMER

3IMM-0018EN - Installation and Maintenance Manual Dana Incorporated
CONTENTS
1 VERSION TRACKING ....................................................................................................................... 5
1.1 MANUAL APPLICABILITY AND SUPPORTED MODELS ..................................................................... 5
2 HOW TO USE THIS MANUAL .......................................................................................................... 6
3 UNIT DESIGNATION ......................................................................................................................... 7
3.1 DETAILED UNIT DESIGNATION ........................................................................................................... 7
3.2 NAMEPLATE UNIT DESIGNATION ...................................................................................................... 8
4 STANDARD TYPE GEARBOX PARTS LISTS .................................................................................. 9
4.1 SIZE: K00...K20... ................................................................................................................................. 9
4.1.1 TYPE: 00................................................................................................................................................ 9
4.1.2 TYPE: 01L............................................................................................................................................ 10
4.1.3 TYPE: 01R ........................................................................................................................................... 11
4.1.4 TYPE: 02L............................................................................................................................................ 12
4.1.5 TYPE: 02R ........................................................................................................................................... 13
4.1.6 TYPE: 03L............................................................................................................................................ 14
4.1.7 TYPE: 03R ........................................................................................................................................... 15
4.1.8 TYPE: 04.............................................................................................................................................. 16
4.1.9 TYPE: 05.............................................................................................................................................. 17
4.1.10 TYPE: 08.............................................................................................................................................. 18
4.2 SIZE: K27...K97... ............................................................................................................................... 19
4.2.1 TYPE: 00.............................................................................................................................................. 19
4.2.2 TYPE: 01.............................................................................................................................................. 20
4.2.3 TYPE: 02.............................................................................................................................................. 21
4.2.4 TYPE: 03.............................................................................................................................................. 22
4.2.5 TYPE: 04.............................................................................................................................................. 23
4.2.6 TYPE: 05.............................................................................................................................................. 24
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 TRANSPORTATION ............................................................................................................................ 32
6.2 STORAGE ........................................................................................................................................... 33
7 INSTALLING THE GEAR UNIT ....................................................................................................... 34
7.1 BEFORE YOU START ......................................................................................................................... 34
7.2 CHECK THE SHAFT DIMENSIONS TO FIT ........................................................................................ 34
7.3 CHECK THE AMBIENT TEMPERATURE ............................................................................................ 34
7.4 CHECK THE VOLTAGE SUPPLY ....................................................................................................... 35
7.5 CHECK THE MOUNTING POSITION .................................................................................................37
7.6 USE THE BREATHER PLUG .............................................................................................................. 37
7.7 CHECK THE OIL LEVEL ..................................................................................................................... 37
7.8 CHECK SHAFT ENDS AND MOUNTING FACES ............................................................................... 37
7.9 COVER ABRASIVE AMBIENT ............................................................................................................. 37
7.10 CHECK ACCESSIBILITY TO FILLING, BREATHER AND DRAIN PLUGS .......................................... 37

4
CONTENTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
8 MECHANICAL INSTALLATION ...................................................................................................... 38
8.1 INSTALLING CUSTOMER SHAFT WITH SHOULDER ....................................................................... 39
8.2 INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER ................................................................ 40
8.3 DISASSEMBLING CUSTOMER SHAFT WITH SHOULDER ............................................................... 41
8.4 DISASSEMBLING CUSTOMER SHAFT WITHOUT SHOULDER ........................................................ 42
8.5 SHAFT TIGHTENING TORQUES VALUES ARE AS SHOWN ............................................................. 43
8.6 RECOMMENDED SHAFT DIMENSIONS FOR KT...00 TYPES ........................................................... 44
8.7 K.00.. - K.97.. DIMENSIONS OF SPLINED HOLLOW SHAFT TO DIN 5480 ...................................... 45
8.8 ASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK .................................................................. 47
8.9 DISASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK ............................................................ 49
8.10 ASSEMBLING 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. - K.20. TWO - THREE STAGE HELICAL-BEVEL GEARED GEARBOXES OIL LEVEL PLUGS .. 60
10.3.2 K.27.. - K.97.. THREE STAGE K SERIES OIL LEVEL PLUGS ............................................................. 61
10.3.3 K.28.. - K.97.. FOUR STAGE K SERIES OIL LEVEL PLUGS............................................................... 62
10.3.4 K.27.. - K.97.. FIVE-SIX STAGE K SERIES OIL LEVEL PLUGS .......................................................... 63
10.4 MOUNTING POSITIONS .................................................................................................................... 64
11 TROUBLESHOOTING GUIDE ........................................................................................................65
12 DISPOSAL ....................................................................................................................................... 68
12.1 DISPOSAL OF OIL .............................................................................................................................. 68
12.2 DISPOSAL OF SEALING .................................................................................................................... 68
12.3 DISPOSAL OF METAL ........................................................................................................................ 68

5Dana IncorporatedIMM-0018EN - Installation 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

6Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
2 HOW TO USE THIS MANUAL
Take attention to the following safety and warning signs for proper understanding and quick reference.
Table 1:
Hazard pictograms
Table 2:
The operating instructions contain important information to ensure;
• Trouble-free operation
• Fulfilment of any rights to claim under guarantee
The operating instruction must be kept close to the gearbox and must be available in case it is needed.
This operating instruction is written for D series gear units and is applicable only for D series. If any different type of gearbox is
used please ask Dana Motion Systems Italia S.r.l. for the operating instructions of that type.
This instruction can be used only for standard type geared units of Dana Motion Systems Italia S.r.l.. For special application
and 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 a situation which, if not avoided, may result
in damage to components.
Indicates information which may make product service
easier to perform.
NOTE:
Important Information.
General danger
Electric current
Moving parts
NOTE:
EC Machinery Directive:
Within terms of the EC machinery directive 2006/42/EC, the gearboxes are considered as not autonomous machine, but
as a component to install in machines.
Operation is prohibited within the area of validity of the EC directive, until it has been determined that the machine, in
which this product is installed, corresponds to the regulations within this directive.
DANGER
WARNING
CAUTION
NOTICE

7Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
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)
A06
90 S / 4 : 63 B5 A10 : 100 B5 A20 : 200 B5
B06 : 63 B14 B10 : 100 B14 A22 : 225 B5
A07 : 71 B5 A11 : 112 B5 A25 : 250 B5
A08 : 80 B5 A13 : 132 B5 A31 : 315 B5
B08 : 80 B14 B13 : 132 B14
A09 : 90 B5 A16 : 160 B5
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 Stages
4 Stages
5 Stages
6 Stages
For KN Types
L-220V
P-24V
S-220 V
Z-24 V
10- 100 Nm
20- 200 Nm
30- 300 Nm
40- 400 Nm
50- 500 Nm
00- 5 Nm
01- 10 Nm
02- 25 Nm
04- 40 Nm
05- 50 Nm
Motor Size
For KV types
Pole Number
Frame Lenght
Brake

8
UNIT DESIGNATION
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
3.2 NAMEPLATE UNIT DESIGNATION
A sample name plate for K Series
Abreviations:
Serial N.: Serial Number
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
351.05
28 M1
ISO VG 220
(Mineral Oil) 1.4
KR373.00 R
AB

9Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
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.
9
11
24
4
2
1
2
2
21
22
23
27
26
25
23
22
21
5
87
6
5
4
2
3
2
10
12 13 14
15
16
17
18 16
19 20
Standard Part List
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Spacer
Standard Part List

10
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.1.2 TYPE: 01L
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
20
4
6
13
23
22
17
5
9
5
14
22
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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
29 Oil Seal
Standard Part List

STANDARD TYPE GEARBOX PARTS LISTS
11Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
4.1.3 TYPE: 01R
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
3
22
13
23
17
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
22
1
2
11
Standard Part List
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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
Standard Part List

12
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.1.4 TYPE: 02L
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
7
29
27
13
17
20
9
22
4
6
23
25
14
28
18
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Seal
30 Flange
31 Bolt
Standard Part List

STANDARD TYPE GEARBOX PARTS LISTS
13Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
4.1.5 TYPE: 02R
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
3
5
5
23
13
17
22
20
2
8
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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
30 Bolt
Standard Part List

14
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.1.6 TYPE: 03L
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
11
24
2
1
2
2
29
28
21
22
23
27
26
25
23
22
21
2
3
2
45
87
6
5
4
9
10
12 13 14
15
16
17
18 16
19 20
Standard Part List
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Flange
29 Bolt
Standard Part List

STANDARD TYPE GEARBOX PARTS LISTS
15Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
4.1.7 TYPE: 03R
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
11
24
2
1
2
2
28
29
2
3
2
45
87
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Flange
29 Bolt
Standard Part List

16
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.1.8 TYPE: 04
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
23
22
21
2
3
2
25
27
28
23
22
21
45
87
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Spacer
Standard Part List

STANDARD TYPE GEARBOX PARTS LISTS
17Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
4.1.9 TYPE: 05
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
2
24
11
2
1
2
45
87
6
5
4
23
22
21
21
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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
29 Flange
30 Bolt
Standard Part List

18
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.1.10 TYPE: 08
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
2
1
2
28
29
11
24
45
87
6
5
4
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
1Pinion
2Plug
3Housing
4Circlip
5Bearing
6 Gear
7PinionShaft
8Key
9Bolt
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 Flange
29 Bolt
Standard Part List

STANDARD TYPE GEARBOX PARTS LISTS
19Dana IncorporatedIMM-0018EN - Installation and Maintenance Manual
4.2 SIZE: K27...K97...
4.2.1 TYPE: 00
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
18
22
21
20
19
18
17
16
15
2
2
2
1
32
2
23
24
25
25
26
27
28
29
26
25
24
30 2
25
25
25
Standard Part List
1Pinion
2Plug
3Housing
4Circlip
5 Shim Ring
6 Gear
7Bearing
8Spacer
9Bearing
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
27 Pinion Shaft
28 Key
29 Gear
30 Shim Ring
Standard Part List

20
STANDARD TYPE GEARBOX PARTS LISTS
Dana Incorporated IMM-0018EN - Installation and Maintenance Manual
4.2.2 TYPE: 01
NOTE:
Standard types basic part diagram.
Parts may differ for special applications.
15
16
17
17
18
23
22
21 20
19
18
17
16
15
2
14
13
12
11
10 9
87
6
54
2
2
322
1
24
25
26
26
27
28
29
30
27
26
26
26
26
25
24 2
Standard Part List
1Pinion
2Plug
3Housing
4Circlip
5 Shim Ring
6 Gear
7Key
8Bearing
9Spacer
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 Bearing
28 Pinion Shaft
29 Key
30 Gear
Standard Part List