1. Manuals
  2. Brands
  3. DANA Manuals
  4. Industrial Equipment
  5. BREVINI EvoMax
  6. Installation and maintenance manual

DANA BREVINI EvoMax Installation And Maintenance Manual

Helical and bevel-helical gear reducers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
®
Installation and Maintenance Manual
Helical and bevel-helical gear reducers
Brevini EvoMax™
IMM-0012EN
August 2022

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BREVINI EvoMax and is the answer not in the manual?

Questions and answers

Related Manuals for DANA BREVINI EvoMax

Summary of Contents for DANA BREVINI EvoMax

  • Page 1 ® Installation and Maintenance Manual Helical and bevel-helical gear reducers Brevini EvoMax™ IMM-0012EN August 2022...
  • Page 2 © 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.

  • Page 3: Table Of Contents

    COMPACT DRIVES E3C, E4C ...S5, T6, U3, U4 ................37 4.10 DISPLAYS AND CONTROLS ......................38 4.11 TOOLS AND UTILITIES DESIGNED TO BE USED IN AREAS EXPOSED TO EXPLOSIVE HAZARDS 38 4.12 ACCESSORIES ........................... 38 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 4 FILLING OIL ............................102 6.18 COMMISSIONING ..........................103 6.19 CHECKS DURING GEAR UNIT TRIAL RUN IN EXPLOSIVE AREA ..........103 7 OPERATION ..........................104 NORMAL MODE ..........................104 SHUTTING DOWN THE GEAR UNIT ....................104 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 5 CHECKS PRIOR TO COMMISSIONING (CHECK LIST) ..............128 11.1.2 ADDITIONAL CHECKS PRIOR TO COMMISSIONING IN EXPLOSIVE AREA (CHECK LIST) ... 129 11.1.3 CHECKS DURING GEAR UNIT TRIAL RUN (CHECK LIST) .............. 129 11.2 DOCUMENTATION ........................... 130 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 6 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 7: General Information

    Brevini EvoMax™ – Helical gear reducers E2H, E3H, E4H – Bevel helical gear reducers E3B, E4B – Compact gear units E3C, E4C • Brevini EvoMax™ N • Brevini EvoMax™ D • Brevini EvoMax™ TS 1.2 VERSION TRACKING Table 1: File name...

  • Page 8: Explanation Of Symbols

    This combination of symbol and signal word indicates information and instructions regarding the proper use of the gear unit in potentially explosive areas. Failure to observe such a note increases the risk of explosion and may cause serious or fatal injury. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 9: Customer Service

    Lists without specific order Overview of alternative procedures 1.5 CUSTOMER SERVICE In case of technical queries, please contact our customer service: Table 4: Address Dana Motion Systems Deutschland GmbH Werner-Reimers-Straße 6 61352 Bad Homburg Phone +49 (0) 6172 102-0 e-mail service-piv@dana.com...

  • Page 10: Safety

    Additional, task-related safety notes are included in the following sections. 2.1 PROPER USE The Brevini EvoMax™ gear unit is designed to convert speed and torque after connection to the target system and is intended for use in explosive areas in accordance with the ATEX indication.

  • Page 11: Danger Through High Temperatures

    - Always ensure that all surfaces have cooled to ambient temperature prior to performing any work. - If the gear unit reaches a temperature of more than 90°C, contact DANA Motion System Deutschland GmbH immediately. Gear unit cooling may be necessary.

  • Page 12: Danger Through Moving Parts

    Heavy vibrations can lead to serious injury and chronic impairments to health over the long term. The source of vibrations must be mechanically isolated from its environs by means of vibration dampers. - Never disable the vibration dampers. - Keep out of the vibrating area during operation. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 13: Danger Through Noise

    - Only remain on the gear unit's site of operation for as long as necessary. - The standard DIN EN ISO 11690 “Acoustics recommended practice for the design of low-noise workplaces containing ma- chinery” must be observed. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 14: Danger Through Operating Fluids

    - Replace coolant regularly. - If there is a risk of skin contact, swallowing or inhaling, wear personal protective equipment: - Protective work clothing - Protective gloves - Light breathing protection - Safety goggles Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 15: Risks For The Gear Unit

    - If you notice a loss of oil, immediately stop the gear unit. Further operation is permissible only after examination of the fault cause. Consult DANA Motion System Deutschland GmbH immediately. For contact details, see "Customer service" page 9. 2.3 OPERATOR'S RESPONSIBILITY...

  • Page 16: Personnel Requirements

    Dana Motion Systems Deutschland GmbH service personnel Other work may be performed only by Dana Motion Systems Deutschland GmbH specialist personnel. Other personnel is not permitted to perform such work. To have the necessary work performed, contact Dana Motion Systems Deutschland GmbH customer service, see "Customer service"...

  • Page 17: Unauthorised Persons

    Industrial hard hat Industrial hard hats protect the head from falling objects, swinging loads and impacts on stationary objects. Safety goggles Safety goggles protect your eyes from flying debris and fluid sprays. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 18: Safety Devices

    Exceeding specified limits can cause an ignition source. Shutdown gearbox if it reaches these limits. For limits see "EX marking" page 21. Earth connection point Establish potential equalisation. DANGER Insufficient earthing can cause ignition sources. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 19: Operator's Safety Equipment

    Safety equipment for moving parts such as the input and output shaft • Safety equipment for shutting down the electrical power supply, protecting against inadvertent reactivation and prevention of uncontrolled/unintended operating states IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 20: Additional Symbols

    The-se components must be collected separately and taken to municipal collection points or disposed of by a specialised company. These components include light bulbs, capacitors that contain PCB, components that contain mercury, printed circuit boards, fluid crystal displays, batteries, external electrical lines and electrolytic capacitors. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 21: Technical Data

    3 TECHNICAL DATA NOTE: The data on the type plate and in the technical specification in DANA Motion System Deutschland GmbH's order con- firmation's applies. 3.1 EX MARKING Overview The EX marking contains the following information: Table 6: Group I...
  • Page 22 Non-electrical equipment for use in potentially explosive atmospheres according to ISO 80079- Ignition protection type Temperature class Surface temperature does not exceed 200°C Indicates the requirement of observing special envi-ronmental conditions, in this case ambient Additional marking tempera-ture (see section on “Technical data”). Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 23: Type Plate

    Transmission ratio i • Date of gear unit production • Oil type, viscosity grade VG and oil quantity [l] • Grease type, regreasing quantity and number of greasing points • Customer-specific data • Manufacturer IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 24: Design And Function

    Solid Shaft with key way Surface 3 Hollow shaft with key way Surface 4 Hollow Shaft with shrinc disc Surface 5 Flange shaft Surface 6 Solid Shaft with spline Hollow shaft with spline Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 25 Reforced bearing on output Mono block EN-GJS-500-7 Reforced bearing Botton part on input and output EN-GJS-400-18-LT top part Botton part Steel welded botton part Top part top part Top part botton part IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 26: Brief Description

    For critical applications and higher heat dissipation gear units are supplied with external lube systems with heat exchangers. (Stand by systems are supplied upon request) Motor – Pump – Filters –Heat Exchanger – Control Switches (Flow/Pressure/Temperature)- Condition Monitoring. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 27: Cooling Systems

    Slow speed shafts of vertical application are designed with grease lubrication to avoid any oil leakages and process safeties. Such gear units are also with oil retaining flanges to restrict oil flow to the Output Shaft drive end bearing and further leakages. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 28: Gear Unit Position

    4.3.1 MONOBLOCK HOUSING Helical gear units E2H, E3H, E4H Parallel gear unit Figure 4: Bevel helical gear units E3B, E4B Figure 5: Right-angle gear unit Compact drives E3C, E4C Compact gear unit Figure 6: Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 29: Split Housing

    Helical gear units E2H, E3H, E4H Figure 7: Housing version 12 Housing version 11 Figure 8: Bevel helical gear units E3B, E4B Housing version 12 Figure 9: Housing version 11 Figure 10: IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 30: Casing Surfaces

    4.5 SHAFT LAYOUTS AND DIRECTIONS OF ROTATION Table 12: Indication of directions of rotation Indication of bottom surface Additional shaft end or continuous shaft Position of pawl Hollow shaft with shrink disc only as of size 31 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 31 R1, R2, S5, T6, U3, U4 Housing version 11 R1, R2, S5, T6, U3, U4 Housing version 12 "Bevel helical Bevel-helical gears gear units E3B, R1, R2, S5, T6, U3, U4 E4B" page 34 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 32: Helical Gear Units E2H, E3H, E4H

    Shaft layouts and directions of rotation for helical gear units Figure 11: E4H t 50 E4H  50 E3H  50 E3H t 50 E2H + E4H Input shafts Output shafts Double extended input shafts Mounting positions and surface below Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 33 Helical gear units E2H, E3H, E4H Figure 12: Shaft layouts and directions of rotation for helical gear units E4H t 50 E4H  50 Input shafts Output shafts Backstop Mounting positions and surface below IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 34: Bevel Helical Gear Units E3B, E4B

    4.7 BEVEL HELICAL GEAR UNITS E3B, E4B Shaft layouts and directions of rotation for bevel helical gear units Figure 13: E3B-E4B E3B-E4B Input shafts Output shafts Double extended input shafts Mounting positions and surface below Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 35 DESIGN AND FUNCTION Bevel helical gear units E3B, E4B Figure 14: Shaft layouts and directions of rotation for bevel helical gear units E3B-E4B Input shafts Output shafts Backstop Mounting positions and surface below IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 36: Compact Drives E3C, E4C

    4.8 COMPACT DRIVES E3C, E4C ...R1 Figure 15: Shaft layouts and directions of rotation for compact drives E3C - E4C Input shafts Output shafts Double extended input shafts Backstop Mounting positions and surface below Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 37: Compact Drives E3C, E4C

    4.9 COMPACT DRIVES E3C, E4C ...S5, T6, U3, U4 Figure 16: Shaft layouts and directions of rotation for compact drives E3C - E4C Input shafts Output shafts Double extended input shafts Backstop Mounting positions and surface below IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 38: Displays And Controls

    Fastening materials for drive/power take-off elements • Lubricant (Molycote®) • Screw locking materials, e.g. Loctite 243 4.12 ACCESSORIES Electric gear unit Heating element Additionally purchased parts, see included operating manuals Additional accessories, see catalogue Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 39: Transport, Packaging And Storage

    5 TRANSPORT, PACKAGING AND STORAGE The various versions of the gear unit can differ substantially in terms of size and weight. The transport utilities are not included by DANA Motion System Deutschland GmbH. 5.1 SAFETY NOTES FOR TRANSPORT Suspended loads...

  • Page 40: Packaging

    - When cutting the tensioning straps, position yourself in such a way that the straps pose no danger when they spring back. - Dispose of tensioning straps correctly. Figure 17: Tensioning straps Protective equipment: • Protective gloves • Protective goggles Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 41 The packaging is adapted to the transport route and to the expected climatic conditions. The following packaging materials may be used: • Wood • Film • Poly-nets • BRANOrost corrosion-protection paper • Protective varnish • Desiccant sachets • Tensioning straps • Cardboard • UCI paper/UCI bags IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 42: Symbols On The Packaging

    Lift the package with the lifter truck at this point. Keep away from heat Use a cover to protect the gear unit from heat and direct sunlight. Keep away from cold Use a cover to protect the gear unit from cold. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 43 The layer of grease on the bare surfaces that acts as corrosion pro-tection has to be checked and renewed if nec- essary. See Chapter "Corrosion protection for the remaining bare surfaces" page 100 Do not step here Never step onto gear units, even if they are still packaged. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 44: Transport

    5.5 TRANSPORT 5.5.1 SLING POINTS ON THE GEAR UNIT The individual gear units can be lifted using shackles, ring bolts in accordance with DIN 580 or load rings (not included by DANA Motion System Deutschland GmbH). Select the lifting devices according to the total weight of the assembly to be lifted.
  • Page 45 The belt is for additional support only. Any lifting eyelets on the motor must not be used when transporting the gear unit-motor combination. Always pull the belt upwards perpendicular to the central axis. Use a transport cross bar when doing so. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 46: Notes On Transporting Gear Units

    The following notes must be observed for every gear unit transport: • The casings of the Brevini EvoMax™ models are dimensioned so that the forces resulting from operation are safely trans- mitted. The attachment points on the casings can only support the gear unit's weight.
  • Page 47 Suspension as far as possible using shackles or load blocks. NOTE: Any ropes, belts or chains must be used at right angles to the suspension point. Brevini EvoMax™ 2 with bell housing and motor Brevini EvoMax™ 2 with bell housing and motor Figure 21: Transport with cross bar.
  • Page 48 TRANSPORT, PACKAGING AND STORAGE Brevini EvoMax™ 2 with motor and clutch/brake on frame Figure 22: Brevini EvoMax™ 2 with motor and clutch/brake on frame Transport with cross bar. NOTE: The ropes or chains may be attached only vertically and only to the suspension points indicated on the frame.
  • Page 49 TRANSPORT, PACKAGING AND STORAGE Brevini EvoMax™ with motor and belt drive Figure 24: Brevini EvoMax™ with motor and belt drive Transport with cross bar. NOTE: Never use the motor mount or any suspension points on the motor for lifting. High-power gear unit combination with motor on frame...

  • Page 50: Lifting

    46, "Example of gear unit transport" page 46. Make sure that the transport package is suspended straight. Observe any eccentric centre of gravity if applicable. Begin transport. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 51: Storage

    At the DANA Motion System Deutschland GmbH plant, basic preservation as per Chapter "Basic gear unit preservation" page 53 was performed. If the gear unit was supplied with oil, please consult DANA Motion System Deutschland GmbH for details on preservation (see Chapter "Customer service" page 9 for contact details).

  • Page 52: State Of Preservation Of Gear Unit Upon Delivery

    Basic gear unit preservation "Basic gear unit preservation" page 53 – Basic gear unit preservation by Dana Motion Systems Deutschland GmbH using mineral, synthetic (poly-alpha-olefin) and biodegradable lubricant "Basic gear unit preservation by DANA Motion System Deutschland GmbH using mineral, synthetic (poly-alpha-olefin) and biodegradable lubricant" page 53 –...

  • Page 53: Basic Gear Unit Preservation

    To hermetically seal the gear unit, the bleeder screw is replaced by a dummy plug. DANA Motion System Deutschland GmbH securely stows the bleeder screw on the gear unit. The input and output shafts are preserved using BRANOrost paper. This preservation must not be damaged. If damaged, the BRANOrost paper must be replaced.
  • Page 54 ING PHYSIOLOGICALLY HARMLESS LUBRICANTS If DANA Motion System Deutschland GmbH has been informed that the gear unit will be employed in the food industry, the gear unit will be preserved using a phys-iologically harmless lubricant approved in accordance with NSF-H1.

  • Page 55: Subsequent Preservation By Customer

    TRANSPORT, PACKAGING AND STORAGE 5.7.3 SUBSEQUENT PRESERVATION BY CUSTOMER After the 18- or 6-month period of the DANA Motion System Deutschland GmbH basic preserva-tion has elapsed, the gear unit can be preserved for further planned stor-age as follows: Flammable gases...
  • Page 56 Corrosion Check the gear unit interior for corrosion. If there is any corrosion, contact DANA Motion System Deutschland GmbH. If there is no corrosion, apply preservation to the gear unit through suitable measures. The lubricant used must, in a hermetically sealed gear unit, guar-antee at least 18 months of corrosion protection, or at least 6 months if a physiologically harmless lubricant is used.
  • Page 57 Thus, including the basic preservation by DANA Motion System Deutschland GmbH, the gear unit can be stored for a maximum period of 36 months.
  • Page 58 Thus, including the basic preservation by DANA Motion System Deutschland GmbH, the gear unit can be stored for a maximum period of 36 months.

  • Page 59: Machine Trial With Subsequent Preservation

    Dryer cartridge Replace the dryer cartridge with intermediate oil expansion tank with the bleeder screw. NOTE: Draining the oil level eliminates the corrosion protection. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 60 The limit values as specified by the respective lubricant's manu-facturer apply. BRANOrost paper Preserve free input and output shafts using BRANOrost paper. Bare surfaces Lightly grease all other blank surfaces. See Chapter "Corrosion protection for the remaining bare surfaces" page 100 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 61: Installation And Commissioning

    Danger to life through incorrect installation and commissioning! Errors during installation or commissioning can lead to life-threatening situations and cause substantial damage. - Observe all specifications issued by DANA Motion System Deutschland GmbH in the following chapters and per- form all checks.
  • Page 62 - Never use a high-pressure jet for cleaning. Hosing down the gear unit with detergent and water is prohibited. This may dam- age seals and attached parts. - Observe the assembly and safety notes in the respective sections of this operating manual and in the operating instructions for the attached parts. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 63: Preparations

    Use plastic washers for screws and bolts suitable for existing explosive environment. Shunt resistance of plastic used < 109 Ω. • • Earth the gear unit and make sure not to generate static electricity. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 64: Installing The Gear Unit In All Category Atex Environments

    Protection type All gear unit versions comply with protection type IP55. DANGER Additional equipment has to be used according to "Additional safety equipment for use in explosive areas" page 18 and order-specific documentation. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 65: Fastening Bolts

    4x M56x400 E2H/E3H E3B/E4B E3C/E4C 8x M36x200 E2H/E3H E3B/E4B E3C/E4C 8x M36x250 E2H/E3H E3B/E4B E3C/E4C 8x M42x250 E2H/E3H E3B/E4B E3C/E4C 8x M42x320 E2H/E3H E3B/E4B E3C/E4C 8x M42x360 E2H/E3H E3B/E4B E3C/E4C 8x M42x450 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 66: Tightening Torque

    730 Nm 1800 Nm 1550 Nm 1100 Nm 2450 Nm 2100 Nm 1450 Nm 4100 Nm 3500 Nm 2460 Nm 5440 Nm 4530 Nm 3230 Nm 6730 Nm 5610 Nm 3990 Nm Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 67: Installation At Operation Site

    Gear unit and motor on a frame: – DANA Motion System Deutschland GmbH has aligned and connected the gear unit and motor appropriately. Connecting additional components To connect the lubrication system, connect it to the gear unit and connect any water lines to the water supply correctly.
  • Page 68 Slide belt pulleys fully onto the shaft towards the centre of the gear unit. "Figure 28" page 68 shows a retractor for fitting hubs to gear unit or motor shaft ends. If necessary, leave out the axial bearing (Fig. 32/A) on the retrac-tor. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 69: Overview Of Output Shaft Assembly

    "Assembly of output shaft as hollow shaft with keyway" page 70 • "Assembly of output shaft as hollow shaft with shrink disc" page 81 • "Assembly of output shaft as flanged coupling" page 91 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 70: Assembly Of Output Shaft As Hollow Shaft With Keyway

    Dimension the machine shaft material and keyway linkage at customer's side in accordance with the occurring loads. Observe the minimum key length specified in the dimensions sheet. If a longer key is to be used, align it symmetrically with the hollow shaft's longitudinal axis. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 71: Machine Shaft Dimensions

    M 24 x 70 32 x 18 M 20 M 24 x 70 32 x 18 M 20 M 24 x 70 36 x 20 M 20 M 24 x 70 40 x 22 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 72 63 x 32 Key of machine shaft and secured bolt are not in scope of delivery. Type of tolerance of the keyway width in the hollow shaft: P9. x) Bolts y) Key Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 73 M 24 x 70 32 x 18 M 20 M 24 x 70 32 x 18 M 20 M 24 x 70 36 x 20 M 20 M 24 x 70 40 x 22 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 74 63 x 32 Key of machine shaft and secured bolt are not in scope of delivery. Type of tolerance of the keyway width in the hollow shaft: P9. x) Bolts y) Key Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 75: Fitting The Gear Unit Onto The Machine Shaft

    Threaded rod • • Fastening bolt • Ejector screws Assembly Applying lithium grease Figure 34: Apply lithium grease (Chapter "Grease" page 109) into the hollow shaft and onto the machine shaft's end. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 76 Figure 36: NOTE: For ease of assembly, grease the threaded rod and nut with lubricant. Screw the threaded rod into the machine shaft. Observe the specified tightening torques (Chapter "Tightening torque" page 66). Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 77 Tighten the machine shaft using a nut until the shaft end con-nects with the end plate. Unscrewing threaded rod Unscrewing threaded rod Figure 38: Undo the nut and screw out the threaded rod. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 78 Secure the machine shaft with a fastening bolt. Bolt locking Bolt locking Figure 40: Additionally secure the fastening bolt with a suitable bolt lock. Observe the specified tightening torques (Chapter "Tighten- ing torque" page 66). Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 79: Removing The Gear Unit From The Machine Shaft

    - Use suitable lifting equipment with sufficient load capacity. See Chapter "Transport, packaging and storage" page 39. - Always secure the gear unit before releasing any connections. Disassembly Secure the gear unit against falling. Undoing the fastening bolt Figure 41: Undo the fastening bolt and remove it. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 80 For ease of disassembly, grease the ejector screws and the threads in the end plate with lubricant. Screw the two ejector screws into the threads in the end plate in order to detach the gear unit from the machine shaft. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 81: Assembly Of Output Shaft As Hollow Shaft With Shrink Disc

    Dimension the machine shaft material and keyway linkage at customer's side in accordance with the occurring loads. NOTE: Assemble and disassemble the shrink disc as per the instructions issued by the shrink disc's manufacturer. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 82: Machine Shaft Dimensions

    240 f6 M 20 245 g6 250 f6 M 20 245 g6 250 f6 M 20 260 g6 270 f6 M 20 270 g6 280 f6 M 20 290 g6 300 f6 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 83 240 f6 M 20 245 g6 250 f6 M 20 245 g6 250 f6 M 20 260 g6 270 f6 M 20 270 g6 280 f6 M 20 290 g6 300 f6 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 84: Fitting The Gear Unit Onto The Machine Shaft

    The shrink disc's clamping range between the hollow shaft and the machine shaft must remain free of grease under all circumstances. Prior to assembly of the gear unit, grease the hollow shaft and the machine shaft. Apply lithium grease to the machine shaft in the area of Ød3. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 85 Screwing in threaded rod NOTE: For ease of assembly, grease the threaded rod and nut with lubricant. Screw the threaded rod into the machine shaft. Observe the specified tightening torques (Chapter "Tightening torque" page 66). IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 86 Tighten the machine shaft using a nut until the shaft end con-nects with the end plate. Unscrewing threaded rod Figure 51: Unscrewing threaded rod Undo the nut and screw out the threaded rod. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 87 (Chapter "Tightening torque" page 66). Shrink disc Bolt locking Figure 53: Slide the untightened shrink disc onto the hollow shaft. For fitting the shrink disc, observe the separate instructions issued by the manufacturer. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 88: Positioning The Shrink Disk On The Output Shaft Of The Gearbox (Hollow Shaft)

    See Chapter "Corrosion protection for the remaining bare surfaces" page 100 NOTICE Using the wrong tightening torques can cause damage to property! Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 89: Removing The Gear Unit From The Machine Shaft

    Slightly loosen each screw by the same number of turns without fully removing them. Failure to loosen them evenly can result in individual screws becoming overloaded, which will result in a high risk of injury! IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 90 For ease of disassembly, grease the ejector screws and the threads in the end plate with lubricant. Screw the two ejector screws into the threads in the end plate in order to detach the gear unit from the machine shaft. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 91: Assembly Of Output Shaft As Flanged Coupling

    Figure 58: Flanged coupling dimensions Table 23: Bolt 1) 150 H7 M20x70 150 H7 M20x70 160 H7 M20x70 180 H7 M24x90 190 H7 M24x90 190 H7 M24x90 220 H7 M24x100 240 H7 M24x100 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 92 INSTALLATION AND COMMISSIONING Bolt 1) On request. Minimum bolt property class 8.8 according to ISO 898. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 93: Assembly Of Flanged Coupling With Compressed-Oil Interference Fit

    Make sure that the fitted hub is fixed and that it can cool in the intended position on the shaft. After joining, wait for the parts to cool to a temperature of approx. 20 to 25 °C. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 94 Once the waiting period has elapsed, screw the locking bolts into the connector threads. – The joint can be loaded. Flange surfaces Flange surfaces Figure 60: 13 - Clean the two front flange surfaces. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 95 Figure 62: NOTICE Damage through incorrect tightening torques! Tightening bolts Sequence according to "Figure 62" page 95. Observe the tightening torques (Chapter "Tightening torque" page 66). If necessary, use a hydraulic torque wrench. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 96: Disassembly Of Flanged Coupling With Compressed-Oil Interference Fit

    When retracting it, the hub must float on an oil film to prevent the shaft and hub from being damaged. Retraction must be per- formed in an even motion and without jarring. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 97 To avoid damage to the mating surfaces, continue pumping dis-assembly oil (e.g. SKF LHDF 900) into the gap and pull the hub off vertically, keeping it afloat on the oil film produced. Fit the disassembly utilities and the hydraulic cylinder “H” accord-ing to "Figure 64" page 97. NOTICE Pollution through escaping oil! IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 98 If, with a hub featuring several oil bores, the hydraulic cylinder fails to remove the hub from the shaft in a single stroke and thus needs to be repositioned, make sure that the hydraulic cylinder stops between two oil bores. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 99: Assembly Of Fin-Tube Integrated Cooler

    NOTICE Damage through condensation inside the gear unit body! If the gear unit is out of service, cooling water supply should be turned off to prevent condensation inside the gear unit body. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 100: Connecting To Power Supply

    The life of the preservative depends on the manufacturers' specifications and use instructions. These specifications and instruc- tions must be ob-served in full. NOTICE Unsuitable corrosion protection agents can be a burden on the environment and can damage the product and environment.. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 101: Checks Prior To Commissioning (Checklist)

    Make sure that the gearbox and attached parts cannot be damaged by falling objects. Make sure that at least 30° of any fans attached on the drive shaft are unob-structed to ensure sufficient air flow. See catalogue - Brevini EvoMax™, section on fan cooling IMM-0012EN - Installation and Maintenance Manual...

  • Page 102: Additional Pre-Commissioning Tests For Explosive Environments (Checklist)

    If a gearbox is fitted at an angle, check the oil level in the installa-tion position. In tilting gearboxes, move the gearbox into the home position, which is generally 0° in all directions. Please note the information in the order-specific documentation. Close all oil filler openings and secure them against inadvertent opening. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 103: Commissioning

    6.19 CHECKS DURING GEAR UNIT TRIAL RUN IN EXPLOSIVE AREA NOTE: Design modifications or a change of the tilt angle if set up at an angle require prior approval by DANA Motion System Deutschland GmbH. Prior consultation is required to maintain ATEX approval! •...

  • Page 104: Operation

    On gear units with cooling and lubrication system, disconnect the oil pump from its power source and secure it against unau-thorised activation. Consult DANA Motion System Deutschland GmbH on any further activity. Depending on the ambient conditions and the gear unit's service life, even a short planned gear unit downtime may neces- sitate preservation.

  • Page 105: Maintenance

    - Make sure to use the correct gear oil. Do not mix different synthetic lubricants with one another or with a mineral lubricant. - Do not clean the gearbox with a high-pressure cleaner, see Chapter "Removing dust" page 110 - Perform a safety and function test on completion of the maintenance work. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 106: Spare Parts

    The use of incorrect or faulty spare parts can put the personnel at risk, lead to damage, malfunctions or complete failure and to explosions in explosive areas. - Only use genuine DANA Motion System Deutschland GmbH spare parts or spare parts approved by DANA Motion System Deutschland GmbH.

  • Page 107: Maintenance Schedule

    The following sections describe the maintenance work required for optimal and fault-free operation of the gear unit. If regular inspections show increased wear, reduce the maintenance intervals to match the actual wear. In case of questions regarding the maintenance work and intervals, contact DANA Motion System Deutschland GmbH Chapter "Customer service" page 9.

  • Page 108: Oil Change Schedule

    - latest after 2 years (12000h) for mineral based oil. For High Power gearboxes series: - latest after 1 year (8800h) for synthetic oil - latest after 1 year (5000h) for mineral based oil Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 109: Oil Type Selection

    If the gearbox is subsequently painted, the sealing lips of the oil seals, breather screws, hoses, nameplate, stickers and rubber elements must be masked off. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 110: Removing Dust

    In gear units with an oil gauge or oil level sight glass, the oil level must be at the marking or in the center of the gauge while the gear unit is not in operation and the oil surface has calmed down. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 111 Reinsert the dipstick fully and then pull it back out again. – The oil level must lie between the markings. Top up the oil if necessary Chapter "Filling oil" page 102. Dispose of the cloth correctly. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 112: Oil Change

    This will prevent any contaminants from the oil barrel entering the gear unit. – The correct fluid level can be seen using the oil sight glass, dipstick, oil gauge or overflow opening. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 113: Servicing External Oil Circuit

    Disconnect heater element from power supply and allow to cool. Secure heater from being switched on inadvertently. Allow oil to cool. Check heater elements for deposits and damage. Remove any deposits or replace heater element. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 114: Checking Flexible Transmission Elements On Couplings

    8.8.9 CHECKING AND ADJUSTING BELT TENSION • Personnel: – Service personnel • Protective equipment: – Protective gloves – Safety goggles Check the belt tension and adjust if necessary, see the manufac-turer's operating instructions. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 115: Relubricating Taconite Seals And Non-Contact Labyrinth-Type Seals With Lubricating Grease

    Every 3,000 operating hours or after 6 months at the latest, inject lithium grease into the lubrication points of the taconite seals or non-contact labyrinth-type seals (flat-type grease nipple AR ¼ DIN 3404) until lithium grease is expelled from the seal. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 116: Replacing Coolant

    Clean the workspace and remove any escaped substances such as fluids, processing materials or similar. Make sure that all the gear unit's safety equipment is fully func-tional. Make sure that nobody remains inside the danger zone. Remove any warning signs and notices that were attached. Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 117: Faults

    If faults occur frequently, reduce the maintenance intervals to match the actual loads. Observe the shorter intervals for employment in explosive areas. In the event of faults that cannot be remedied based on the following notes, consult DANA Motion System Deutschland GmbH Chapter "Customer service" page 9.
  • Page 118 Unsuitable motor speeds Check frequency conver-ter. Insufficient alignment Align the gear unit. Shut down the gear unit. Check the oil. Contact Oil contaminated by for-eign Dana Motion Systems Deutschland GmbH cus- bodies Unusual, irregular noises tomer service. System sluggish Check system.
  • Page 119 Sealing lip of shaft seal ring fold- con-tact Dana Motion Systems Deutschland ed over GmbH customer service. Replace shaft seal ring. Contact Dana Motion Shaft seal ring faulty Systems Deutschland GmbH customer service. Incorrect alignment of V-belt Align V-belt pulley and check belt tension.

  • Page 120: Troubleshooting Work

    FAULTS 9.4 TROUBLESHOOTING WORK 9.4.1 REPLACING SHAFT SEALS Contact customer service. • Personnel: – Specialist for explosive areas – Dana Motion Systems Deutschland GmbH • Special tool: – Sandpaper grain size 400 • Materials: – Permanently elastic sealant Check shaft's seal ring clearance fit for damage.

  • Page 121: Replacing Roller Bearings On Gear Units With Split Casings In Explosive Areas

    Check order-specific documentation. DANGER Not replacing or replacing late can cause a potential ignition source. NOTE: Before beginning work on the roller bearings, contact DANA Motion System Deutschland GmbH, Chapter "Customer service" page 9. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 122 Zones 1 and 21 Replacement interval: latest at the calculated service life Lnmr2. For storage shelf-life, see technical gear unit specification. Personnel: • Dana Motion Systems Deutschland GmbH • Specialist for explosive areas Special tool: • Tools approved for the existing explosive area Drain oil Chapter "Oil change"...
  • Page 123 Zones 2 and 22 Replacement interval: latest at the calculated service life Lnmr10. For storage shelf-life, see technical gear unit specification. Personnel: • Dana Motion Systems Deutschland GmbH • Specialist for explosive areas Special tool: • Tools approved for the existing explosive area Drain oil Chapter "Oil change"...

  • Page 124: Replacing Roller Bearings On Gear Units With Monobloc Casings In Explosive Areas

    Replacement interval: latest at the calculated service life Lnmr10. For storage shelf-life, see technical gear unit specification. NOTE: Contact DANA Motion System Deutschland GmbH customer service. For contact details, see Chapter "Customer serv- ice" page 9. 9.6 COMMISSIONING AFTER TROUBLESHOOTING After troubleshooting, perform the following steps for recommission-ing: Check all previously undone threaded connections for tightness and secure them against inadvertent release.

  • Page 125: Dismantling And Disposal

    Once the gear unit's service life has expired, the gear unit needs to be dismantled and disposed of in an environmentally sound manner. Disposal service If desired, DANA Motion System Deutschland GmbH can provide professional disposal. Contact customer service Chapter "Customer service" page 9. 10.1 SAFETY NOTES FOR DISMANTLING...

  • Page 126: Disassembly

    Dismantling the output shaft as hollow shaft with shrink disc • Chapter "Removing the gear unit from the machine shaft" page 89 • Dismantling the output shaft as flanged coupling • Chapter "Assembly of output shaft as flanged coupling" page 91 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...

  • Page 127: Disposal

    - If in doubt, consult your local municipal authorities or special disposal companies on matters of environmentally sound dis- posal. • If desired, we can provide professional disposal. Please contact our service department. IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...

  • Page 128: Appendix

    Make sure that the gearbox and attached parts cannot be damaged by falling objects. Make sure that at least 30° of any fans attached on the drive shaft are unob-structed to ensure sufficient air flow. See catalogue - Brevini EvoMax™, section on fan cooling Dana Incorporated...

  • Page 129: Additional Checks Prior To Commissioning In Explosive Area (Check List)

    Make sure that the gearbox and attached parts cannot be damaged by falling objects. Make sure that at least 30° of any fans attached on the drive shaft are unob-structed to ensure sufficient air flow. See catalogue - Brevini EvoMax™, section on fan cooling 11.1.3 CHECKS DURING GEAR UNIT TRIAL RUN (CHECK LIST)

  • Page 130: Documentation

    APPENDIX 11.2 DOCUMENTATION The following documents serve as templates for copying: • Preservation record • Oil change log • Instruction protocol Dana Incorporated IMM-0012EN - Installation and Maintenance Manual...
  • Page 131 IMM-0012EN - Installation and Maintenance Manual Dana Incorporated...
  • Page 132 Copyright 2022 Dana Incorporated For product inquiries or support, All content is subject to copyright by Dana and may not visit www.dana.com. be reproduced in whole or in part by any means, ® For other service publications, visit electronic or otherwise, without prior written approval.

Table of Contents