Geared motor

Instruction Manual

For safe operation

●The contents of this Instruction Manual should be carefully read and understood before
operating this product.
●The Instruction Manual should be delivered to a person who actually operate
this product.
●The Instruction Manual should carefully be kept in a convenient place for the operator.
In this Manual, the case of mishandling the equipment, are classified into two categories,
"Danger" and "Caution". The definition of the classifications are given with the corresponding
graphic symbol.

The case that the mishandling of the equipment may result in

Danger dangerous situation and may lead to serious of fatal injury to

personnel.

The case that the mishandling of the equipment may result in

Caution dangerous situation and may lead to medium to light injury or the
case that may result in damage to the equipment.

Please be aware that even items marked Caution may cause fatal accidents.
Therefore, be sure to follow the instructions.
 Danger
●Be sure to use an explosion-proof motor where any explosive or flammable gases
exist.
Failure to observe this warning may cause explosion, spark, fire, electric shock, physical injury and/or
damage to the equipment.

●The operator in charge of transportation, installation, wiring,operation, maintenance,

and inspection of the equipment should have enough knowledge and technical skill
for the product.
Failure to observe this warning may cause explosion, spark, fire, electric shock, physical injury and/or
damage to the equipment.

●Do not repair or wire the equipment with the electric power on. Be sure to cut the
power off before getting to work.
Failure to observe this warning may cause electrical shock.

●If the equipment is to be used in system of human transport, be sure to finish it with
a protective device for safety.
Failure to observe this warning may cause physical injury and/or damage to the equipment
By accidental falling.

●If the equipment is to be used with an elevator, be sure to finish it with a safety devise
to prevent the elevator from accidental falling.
Failure to observe this warning may cause physical injury and/or damage to the equipment
by accidental falling.

●Be sure not to get water or oil/grease into the brake unit.
Failure to observe this warning may cause accidental falling and/or runaway accident by
the decreased brake torque.
Contents

1 Motor Designation ………………………………………………………….P4

2 Check at Packing …………………………………………………………..P5
3 Transportation ……………………………………………………………...P5
4 Installation ………………………………………………………………...P6
5 Connecting with other Equipment ……………………………………….P7
6 Direction of Rotation ………………………………………………………P10
7 Wiring ……………………………………………………………………….P10
8 Operation ……………………………………………………………………P16
9 Inspection and Adjustment………………………………………………...P17
10 Troubleshooting ……………………………………………………….……P21
11 Disposal………………………………………………………………………P22
12 Warranty …………………………………………………………………….P23

Caution
●Do not use gearmotor under conditions other then specified in the name plate
or the product specification.
Failure to observe this warning may cause explosion, spark, fire, electric shock, physical injury,
and/or damage to the equipment.

●Do not insert your finger or any kind of object into the aperture of the gearmotor.
Failure to observe this warning may cause electrical shock, physical injury, fire and/or demage
to equipment.

●Do not use damaged gearmotor.

Failure to observe this warning may cause physical injury and/or fire.

●Do not use damaged gearmotor.

Failure to observe this warning may cause physical injury and/or fire.

●The manufacture will not warrant and will not be responsible for the product modified
or repaired by the user himself.
■ 2 Reduction Stage

1 MOTOR 7 Key 13 Bolt 19 2nd gear 25 Key

2 Motor shaft 8 3nd gear 14 Pin 20 Case 26 2nd pinion

3 H-S-RING 9 bearing 15 End bracket 21 Pinion 27 Bearing

4 BEARING 10 Oil seal 16 Bearing 22 Bearing

5 EYE BOLT 11 Output shaft 17 Key 23 Bearing

6 Oil inlet plug 12 Bolt 18 O-Ring 24 1st gear

■ 3 Reduction Stage
When unpacking the carton, please check up the following. If you have any problems or
questions, please do not hesitate to contact the nearest sales office or agent .

Caution
Check whether the product is same product as you ordered.
Installing wrong equipment may cause physical injury and/or damage to the equipment.

2.1 The ordered product and the contents indicated in the nameplate are correct.
Type, Reduction ratio, Motor capacity, Voltage, Frequency, ect

2.2 No accidental damage to the product during transportation, moisture, dust.

2.3 Screws or nuts are not loose.
2.4 Check the product condition(load, frequency of use, etc.) with connection machine
is same as you ordered.

Danger
When a product is lifted up for transportation, be sure not to enter underneath of the
lifted product.
Falling of product may cause serious injury

Caution
Be careful when transporting products to avoid falling down.
When an eyebolt or eyeplate is provided with gearmotor, be sure to confirm if there is
any loosening before using it.
After installing gearmotor to the other equipment, do not hoist the entire machine using
an eyebolt.
Failure to observe this warning may cause physical injury and/or damage to the equipment.
Proper installation of a product will ensure reliable service and maximum life.

Caution
●Do not place any inflammable object near the gearmotor.
Failure to observe this warning may cause fire.

●Do not place any object which may interfere with the ventilation around the
gearmotor.
Failure to observe this warning may cause abnormal overheating caused by the block of cool
air, which may cause burn injury and/or fire.

●Do not step up on a gearmoter or hang on it.

Failure to observe this warning may cause physical injury.

●Do not touch the edge of gearmotor or key groove in the bore with wet hand.
Failure to observe this warning may cause physical injury.

●In equipments like food machines, which must avoid oil, furnish with protective device
like oil pan, in order to protect from the oil leakage caused by failure or life of the
manufactured product.
Leaking oil may cause defective product.

●Vibrations that come out from the installation surface of gearmotor or from other
source should be minimized to under 0.5G.

4.1 Proper location for installation

Ambient Temperature : -10℃ ~ 40℃
Ambient Humidity : 85% max
Altitude : Sea level to 1,000 m max
Environment : Well ventilated place free from vapor and/or dust,
circumstances where any explosive and flammable gases exist.
Installation Location : Indoors

4.2 Direction of Installation

The product can be installed in any direction.(Due to a grease lubrication system.
No inversion of foreign article to the brake.

4.3 Method for Installation

Fix the product with the four bolts on a flat (Roughness of the surface should
be less then 0.2mm) and machine surface free from vibration.

Danger
●When connecting the gearmotor with load, make sure of the alignment of shaft,
the tension of the belt and parallelism of pulleys. In direct coupling, be sure to check
whether the alignment of shaft is extremely precise.
If the belt is to used, be sure to adjust its tension properly.
Also, before operation, inspect whether the setting bolts for pulleys and coupling are
securely tightened.
Failure to observe this warning may cause serious injury and/or damage to equipment due
to broken parts.

●Safe guards should be furnished around rotating part.

Failure to observe this warning may cause serious injury.

Please remove the rust protecting cover on the out put before you operate.
When installing a coupling device(coupling, sprocket, pulley, etc)on the gearmotor the fit
should be in the neighborhood of H7.
5.1 Direct Connection
When the machine is used with its shaft coupled together directly, use "flexible
coupling" and make sure that both ends are in alignment.
●An example of gear coupling

Allowance of Tolerance A 0.05 mm

Allowance of Tolerance B 0.04 mm

Tolerance X Specified by coupling maker

5.2 Attaching Chains. V-Belts, Gears etc.

① In any connection center of the shaft of the reducer and that of the other equipment
are parallel.
② The tension of the Chains/ V-Belts and the coupling of gear must
be perpendicular to the center of shaft.
③ When the machine is driven by rearing, gearmotor or reducer should be installed

setting up the center distance accurately and avoiding partial bearing of gear,
and the output shaft is pushed downward (refer to figure)
● Example for Gear Drive

④ Diameter of the chain sprocket wheel or gearing that is mounted on the output shaft;
the diameter should be 3 times as large as output diameter.
⑤ Tension of V-Belt : Excessive tensioning may result in damage of the bearings of the
shaft.
Tension of the chain : Excessive tensioning may result in damage of the bearings of
the shaft. If the chain is installed loosely, shock load will occur when the drive shaft
starts location, and this can results in damage to the reducer and the other equipment.
therefore, adjust the tension of the chain properly. (refer to figure)

Amount of slack for chains S=0.02L

L = SPAN

⑥ Point of load application on the output shaft

The gearing or chain sprocket wheel must be amounted so the point of load
application is a near as possible to the face of the unit to minimize overhung load.
● Proper Way of Use.

The tension of the Chains/ Pulley and sprocket are properly

V-Belts are properly set. positioned.

● Bed Example

The point of load is not near to the

The chain is too loose.
gearmotor.

⑦ When load is applied on the output shaft(over hung load), please make sure that it is
within the limit of allowable value.(Refer to Catalogue)
 Caution

Before coupling with other machine, be sure to check the direction of rotation.
Operation in wrong direction may cause serious injury and/or damage to the equipment.

The relation between the input shaft and the output shaft are shown below:

0.2 ~ 7.5 kW Capasity

Reduction Ratio 1/5 ~ 1/20(2 Reduction stage) same direction
Reduction Ratio 1/25 ~ 1/200(3 Reduction stage) counter direction

Danger
●When connecting the machine to the power cable, be sure to follow the Instruction
Manual.
Failure to observe this warning may cause electric shock or fire.
(In case of no terminal box, be sure to insulate a wire at the terminal area)

●Do not bend, pull, or tuck down power cables or motor lead wires forcibly.
Failure to observe this warning may cause electric shock.

●Be sure to ground the terminal of the earth wire.

Failure to observe this warning may cause electric shock.

●Be sure to use the electric current source specified in the name plate.
Failure to observe this warning may cause burnout of the motor and/or fire.
 Caution
●Do not touch terminals when inspecting the insulation resistants.
Failure to observe this warning may cause electric shock.

●Wiring should be properly made under the specified electrical

equipment engineering standard or the safe code.
Failure to observe this warning may cause electric shock, fire or physical injury.

●Our motor is not equipped with protective devices. The electrical equipment
engineering standards provide that an overload protection device should be installed in
a unit. Other protection devices such as circuit braker are also recommended to be
installed.
Failure to observe this warning may cause damage to the equipment, electric shock, fire or physical
injury.

●When rotating gearmotor alone, take off the key attached temporarily to the output
shaft.
Failure to observe this warning may cause physical injury.

●Check the direction of the rotation before connecting with the other machine.
Failure to observe this warning may cause damage to the equipment and/or physical injury.

●If drive motor with inverter make be sure to attach a control filter or a reactor to the
inverter.
●Voltage drop in the wiring should be kept within 2%.
Excessive length or wiring may cause steep voltage drop and makes the motor disable to start up.

●When reversing a gearmotor be sure to stop rotating and then start reversing.
Failure to observe this warning may cause damage to the equipment.

●For a gearmotor with brake, do not energize continuously to the brake unit during the
rest of motor.
The continuous supply may cause burning of brake coil and fire.

●If a gearmotor with brake used for the application such as lift, safety device for falling
accident should be employed.
To avoid accidental falling.
7.1 Wiring of Gearmotor
For standard gearmotors, wiring described below are recommended.

Wiring of instruction manual is only for our standard product.

If the wiring indicates on the product is different from our instruction manual please
contact to nearest sales office or agent.

■ 3-phase motor
￭Double Voltage
▪ 220V / 380V Wiring
220V (△ ) 380V (Y)

▪ 220V / 440V Wiring

220V (2Y) 440V (1Y)

 ￭Single Voltage

Single Voltage

To reverse rotation, exchange any two of R, S, T connection.

■Single-phase motor
￭ Single Voltage

3 Lines 4 Lines

To reverse rotation, separate ②from③ and To reverse rotation, exchange ③and④ as

connect ①wit③ as shown with dotted line. shown with dotted line.
7.2 Wiring for the gearmotor with brake
■3-phase motor
￭ AC BRAKE motor(B Type)

▪220V / 380V Wiring(Concurrent operate system)

220V (△ ) 380V (Y)

▪ 220V / 380V Wiring(Separate operate system)

220V (△ ) 380V (Y)

▪ Single Voltage

Concurrent operate Separate operate

￭ DC Brake Motor (B Type)

▪220V / 380V Wiring(Concurrent changing system)

AC220V AC380V

▪Single Voltage Wiring(Concurrent changing system)

Single Voltage
▪220V / 380V Wiring(Separate changing system)

AC220V AC380V

MC : Magnetic Contactor , PM : DC Power Supply, OLR : Over Load Relay

7.3 Cautions in operation with inverter

① Higher temperature rise, noise and vibration than that from the general power
source will be observed. Especially, low speed rotation which naturally reduce the fun
effect, may cause abnormal rise of temperature.
(More than 80˚C at the surface of the motor.)
② In the gearmotor with brake or with clutch/brake, malfunction of the brake may be
observed due to the voltage drop. In order to avoid this disadvantage, be sure to by
pass the inverter when wiring the brake clutch.
③ It is feasible to use inverter in the single-phase motor.
④ When using inverter in the 400V class motor, consult with Inverter manufacturer
concerning the micro surge voltage.
 Danger
●Do not operate gearmotor with the terminal box cover opened.
Failure to observe this warning may cause electric shock

●Do not approach or touch rotating parts such as a shaft while the machine is running.
Failure to observe this warning may cause physical injury.

●If power cut occurs, be sure to switch off the power supply of a machine.
Unexpected recovery of electric power service may cause physical injury and/or damage to
the equipment.

Caution
●The gearmotor becomes hot during operation, so do not touch.
Failure to observe this warning may cause burn injury.

●When gearmotor is found abnormal, stop running immediately.

Failure to observe this warning may cause electric shock, physical injury and/or fire.

●Do not overload a gearmotor.

Failure to observe this warning may cause demage to the equipment and/or physical injury.

●Do not touch the current applying part of condenser till the current be
completely discharged.
Failure to observe this warning may cause electric shock.

Caution
●When a single-phase motor is to be reversed, be sure to start reversing after
complete rest of motor.
Direction of rotation may not change and may cause running out of control.
8.1 Check up matter before turning the power switch on:
1 Wiring and connection are done properly
2 Fuses and thermal relays of proper capacities are used.
3 Installations and the connections with other machines are properly done.
4 Earth terminal is properly grounded

8.2 Check up matters at test running:

① Confirm the direction of rotation for 1~2 seconds after starting the motor with
unloaded condition.
When you find the rotation in the opposite direction, change the wiring.
② Practice, running-in of the motor unload condition. When no defects is
observed, add load gradually and eventually start operation with full load.

8.3 Check up matters during operation:

① Confirm that there is no abnormal noise or vibration at all. When such defect are
observed, stop operation immediately. Failure to observe this warning may cause
damage to the equipment and/or physical injury.
② Confirm that the surface temperature or a gear case or motor frame does not exceed
80˚C. Do not touch the surface with bare hands. Failure to observe this warning may
cause burn injury
 Danger
●When inspecting and/or adjusting the machine while it is in operation, do not touch
rotating parts such as shaft.
Failure to observe this warning may cause wind-in to the gear teeth and physical injury.

●When inspecting the gear touch surface, be sure to lock off the drive and driven
unit beforehand.
Failure to observe this warning may cause wind-in to the gear teeth and physical injury.

Danger

●While inspecting, be sure staff supporting personnel is outside to watch safety

conditions and keep in touch with inspector inside. It can be very slippery with lubricant
inside the equipment, do especially pay attention should be needed.
Failure to observe this warning may cause physical injury.

●Do not remove the cover of inspection window while the machine is in operation.
Failure to observe this warning may cause physical injury

(Inspection and Adjustment of the Brake Part)

●Do not operate the equipment while releasing brake by manual releasing lever.
Failure to observe this warning may cause accident by falling down of the equipment or by
running out of control.

●Before actual operation of the equipment, make sure the brake is functioning properly
by turning the switch on and off.
Failure to observe this warning may cause accident by falling down of the equipment or by
running out of control.

●Do not operate the equipment without fan cover after inspection and adjustment of
brake gap.
Failure to observe this warning may cause wind-in to the gear teeth and physical injury.

●Do not release the brake while the equipment is being loaded in theapplication such
as lift.
Failure to observe this warning may cause accidental falling.
 Caution
●When measuring the insulation resistance, do not touch the terminals.
Failure to observe this warning may cause electrical shock.

●Surface of a gearmotor becomes very hot. Therefore do not touch with bare hands.
Failure to observe this warning may cause burn injury.

●When measuring the insulation resistance of an explosion-proof type motor, confirm

that there is no gas, steam, or other explosive substance around.
Failure to observe this warning may cause explosion or ignition.

●When operation is found abnormal, diagnose the fault according to the instruction
manual. Do not operate the machine until the causes of fault are found and proper
measures are taken.
●Repairing, disassembling and assembling of the equipment should be done by an
experienced technician.
Failure to observe this warning may cause electric shock, physical injury, etc.

[Note]
In case of changing grease, oil seal or O-ring for the purpose of maintenance or
inspection, be sure to ask nearest sales office or agent. Please be note that we will not
be responsible for the defects caused by user's changing.

9.1 Daily Inspection : Items should be inspected every 2~3 days

Inspection Item Method Detail of inspection

Load current Rate of current specified in the name plate?

Ammeter
Noise No abnormal sound?
Hearing
Vibration No abnormal vibration on gear case and motor frame?
Touching
Surface Should be 80°C max.
Thermometer
Temperature No lubricant leakage from the joint part such as case, oilseal, bracket,
Viual check
Oilseal etc.?
9.2 Periodic Inspection (Operation 8 hours a day)
Inspection Item Interval Detail of inspection

Fixing Bolt 6months Check the looseness of the bolt and retight.

Chain and V-Bolt 6months Check the tension and adjust it to the proper tention.

Insulation resistance
6months Should be more then 1MΩ when insulate 500V
of the motor

Check if the gap is within the allowable limited of proper gap.

Brake GAP 6months
Repair it in the authorized factory.

When the abnormality is found during the daily inspection, take proper measure
according to the「Trobleshooting」of the instruction manual.

9.3 Caution Label

DSK G/M contains a caution label stick. In the case this labels get slippery or can not be recognize by
damage please contact our nearest sales office or agent immediately.

9.4 GREASE·OILSEAL·O-RING
① All series are employed with grease lubricant and they are sealed with determined
quantity of lubricant when shipping from our factory.
Therefore, machines are available for immediate use.
② Replacement or refill of the lubricant is hardly necessary. However, replicing it
once in 10.000 hours may help prolong the life of the reducer. For replacement of
lubricant, be sure to authorized factory.
③ Our machines are protected from grease leakage by oil seal or O-Ring, however, it
is recommended to protect the machine by an oil pan for safety sake.
Grease leakage may cause damage to the machine.
(Grease leakage may be observed when machine is in trouble or the machine is at
the end of life.)
④ The life of an oil seal may vary according to the condition of use.
Therefore replacement may be needed even within 10000 hours use.
For replacement of oil seal, be sure to use authorized factory.
10.1 Troubleshooting for gearmotor
Trouble Cause Troubleshooting

Failure of power Check the power source. Contact the power

supply supply company.

Disconnection of wire Check the electric circuit and repair the defect.

Bad contact of switch Repair or barter

Open circuit exist Check the electric circuit and repair the defect.

Measure resistance of winding & insulation,

Disconnection of
distinguish defect of winding defects of winding.
stator coil
Repair at authorized factory.

Damage of gear,
Repair at authorized factory.
The motor does shaft and bearing
not Defect of key of
Replace the key
rotate shaft sprocket or pulley
without load
One of 3-phase circuit is
Check motor terminal voltage, current,
opened and works
breakage of fuse or winding, repair defect.
as single-phase circuit

Load is to heavy Lower load to rotated or raise capacity.

Capacitor connection
forgotten Connect capacitor
(Single-phase motor)

Malfunction of governor
switch Repair at authorized factory.
(Single-phase motor)

Inversion of foreign
Removal of foreign article
Motor rotate article
in no load Abnormal
Damage of bearing
but noise Repair at authorized factory
wear of shaft
trouble
Damage or wear gear Repair at authorized factory
occurs
on load Overload Bad setting at improper
Revise setting value, or replace to regular one
relay acts selection of overload
 relay

Overload operation Reduce the load to rated

Breakage of Shortage of capacity of

Investigate and replace or revise setting value
fuse or fuse or breaker

work breaker Overload operation Reduce the load to rated

Overload operation Reduce the load to rated

Overvoltage or lower
Check the voltage and repair
voltage

전압 불평형 Check the wiring of power supply and repair

Overheat
Cooling wind passage Clean dust and foreign articles of cooling wind
is blocked passage

Short circuit of motor

Check wiring and repair at authorized factory
winding

Check length of connection and capacity of

Voltage drop
source and amend them.
Sudden drop
Overload operation Reduce the load to rated
of speed
Worn of gear caused
Repair at authorized factory
by leakage of lubricant

Bad installation Tighten the bolts and check horizon

Big vibration
Worn out gear or bearing Repair at authorized factory

Loosened bolts, screw,

Tighten the bolts, screw, nuts
nuts

Defect of oil seal Repair at authorized factory

Grease leakage
Defect of gear case Repair at authorized factory

Excessive quantity of
Adjust to proper quantity
grease
10.2 Troubleshooting for gearmotor with brake
Trouble Cause Troubleshooting

Break does not work Wrong wiring Check the wiring

Inversion of foreign
article or oil are Remove the foreign article or oil and repair at
adhered to the friction authorized factory.
disk
Break function is Life of frictional disk Replace frictional disk or repair at authorized factory.
not enough. Long
Excessive moment
brake time Reduce the load
of load inertia

Capacity of fuse
Revise setting value or replace to regular one
or circuit braker
AC switching
Change DC switching
(DC BRAKE)
Wrong brake wiring Check the wiring
Motor does not run.
Large brake gap Adjust the brake gap
Overheated motor.
Disconnection or
Thermal relay trips.
short of circuit of Replace the brake coil, or repair at authorized factory
Abnormal noise of
brake coil
brake.
Poor contact of switch Repair and replace the switch

High frequency
Reduce the frequency
of braking
Excessive rise
Excessive load torque
in temperature
ormoment of load Reduce the load
inertia

10.3 Part for replacement

Contact our nearest office, agent or sales office for the replacement brake parts. Please
note that we will not warrant any defect caused by improper replacement done by
customer.
 Caution
For disposal of the gearmotor; lubricant should be disposed as general industrial waste;
steel, aluminum and coil could be recycled.

12.1 Warranty term

The warranty term for the product shall be 1 year after the date of delivery or 2000
hour from the product starting operation.

12.2 Scope of Warranty

① The scope of warranty is limited to our manufacture.
② In the case that any failures on the product which the product is properly operated
under the condition that the product is properly treated, we will provide repair on the
product free of charge.
③ Free of charge in general, but if the product repair is not possible we will change to
new product.

12.3 Exception for Warranty

Warranty shall not be applied to the problems, troubles or damages on the product
which are caused by :
① improper operation of the product not in conformity with the rated data specified in
our catalogue.
② customer's improper operation of the product, product delivered which are
rendered by customer.
③ product modified or repaired by the user himself.
④ trouble cause by customer by using not authenticity parts.
⑤ disaster (flood, earthquake, fire, etc.)
 ⑥ secondary failure caused by the damage of customers equipment.
⑦ losses caused by the parts, driving units which are supplied by customer.
(example : electric motor, servomotor, etc.)
⑧ improper storage and maintenance of product, or improper handling of the product.
⑨ we are not responsible for the compensation against the loss of shutdown and/or for
the damage to the equipment which are not produced by us.

The items stipulated above are premised to apply to the transactions and use in
domestic(South Korea). In case of the use in other country, all the conditions are settled
by the prior discussion between customer and our Sales Department.

12.4 For unexpected trouble retain spare gearmotors.

12.5 Repair of the product after warranty term are in charge of customer.
And warranty shall not be applied to the problems, troubles or damages on
the product cause by not scope of our warranty.
 www.dsmachinery.co.kr
Headquarter Dongsan bldg. 276-4, Sungsu 2ga-3dong,
Sungdong-Ku, Seoul 133-123, Korea
Factory 863-4, Toegye-dong, Chunchon, Kangwon-do,
200-944, Korea
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