DANA Brevini Posiplan BPH Series Installation And Maintenance Manual Download Page 3

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IMM-0005EN Posiplan (MT-5215-0806)

Dana Incorporated

INTRODUCTION: ............................................................................................................................... 5

TECHNICAL DATA: ........................................................................................................................... 7

CODE DESCRIPTION ................................................................................................................................... 7
CONFIGURATIONS ...................................................................................................................................... 8

DELIVERY STATE: ............................................................................................................................. 9

PACKING, HANDLING, RECEIVING AND STORAGE: .................................................................... 10

INSTALLATION: ................................................................................................................................. 15

GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS ............................................................. 15

GEAR UNIT INSTALLATION ON VARIOUS TYPES OF MACHINE SHAFT: ................................... 19

GEAR UNITS WITH “K” TYPE SHAFT .......................................................................................................... 19

MACHINE SHAFT WITH SHOULDER: ..................................................................................................... 19
MACHINE SHAFT WITH NO SHOULDER ............................................................................................... 20

GEAR UNIT WITH “S” TYPE SHAFT ............................................................................................................ 21
GEAR UNITS WITH “D” TYPE SHAFT .......................................................................................................... 22

MACHINE SHAFT WITH SHOULDER: ..................................................................................................... 22
MACHINE SHAFT WITH NO SHOULDER ............................................................................................... 23

ACCESSORY INSTALLATION INSTRUCTIONS: ............................................................................. 25

LUBRICATION: .................................................................................................................................. 27

GEAR UNIT LUBRICATION .......................................................................................................................... 27

VISCOSITY .............................................................................................................................................. 27
ADDITIVES ............................................................................................................................................... 27

EXPANSION TANK ....................................................................................................................................... 28
LUBRICANT TABLE ...................................................................................................................................... 30

CHECKS: ............................................................................................................................................ 32

FIRST START-UP CHECKS .......................................................................................................................... 32

VALUES TABLE TORQUE SETTING BOLTS ........................................................................................... 32

NO-LOAD TESTS .......................................................................................................................................... 33

MAINTENANCE: ................................................................................................................................ 34

ROUTINE MAINTENANCE ............................................................................................................................ 34
OIL CHANGE ................................................................................................................................................ 34
UNSCHEDULED MAINTENANCE ................................................................................................................. 34

Summary of Contents for Brevini Posiplan BPH Series

Page 1: ... Installation and Maintenance Manual IMM 0005EN May 2021 Posiplan MT 5215 0806 ...

Page 2: ...nt 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 2021 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 other wise without prior written approval THIS INFORMATION IS NOT INTENDED FOR...

Page 3: ...ASSEMBLY WITH COUPLING 17 DISASSEMBLING THE COUPLING 18 GEAR UNIT INSTALLATION ON VARIOUS TYPES OF MACHINE SHAFT 19 GEAR UNITS WITH K TYPE SHAFT 19 MACHINE SHAFT WITH SHOULDER 19 MACHINE SHAFT WITH NO SHOULDER 20 GEAR UNIT WITH S TYPE SHAFT 21 GEAR UNITS WITH D TYPE SHAFT 22 MACHINE SHAFT WITH SHOULDER 22 MACHINE SHAFT WITH NO SHOULDER 23 ACCESSORY INSTALLATION INSTRUCTIONS 25 MOTOR ASSEMBLY 25 UN...

Page 4: ...INDEX Dana Incorporated IMM 0005EN Posiplan MT 5215 0806 SCRAP DISPOSAL 35 MACHINE DEMOLITION 35 ECOLOGICAL INFORMATION 35 TROUBLESHOOTING 36 CONFORMITY CERTIFICATE UNI EN 10204 2 1 37 SERVICE NETWORK 38 ...

Page 5: ...ation A clear understanding of the following terms is essential to understanding this manual DANGER ZONE an area within or around a machine in which the health or safety of exposed persons is at risk EXPOSED PERSON any person inside or partly inside a danger zone OPERATOR the person charged with installing operating adjusting maintaining or cleaning the machine TRAINED ENGINEER a specialist design...

Page 6: ...any civil or penal liabilities and furthermore invalidates the warranty GENERAL WARNINGS Installation personnel should be trained on the following aspects of machine safety Risks of accident Operator safety equipment PPE personal protection equipment goggles gloves hard hat etc General safety precautions and all specific standards prescribed in international directives and national legislation in ...

Page 7: ...sential technical data on the functional and constructive features of the gear unit hence it must be visible and undamaged at all times 1 Type or gear unit 2 Date of production month year country of production 3 Description 4 Gear unit output 5 Reduction ratio 6 Gear unit input 7 Info 8 Bar code 9 Serial number CODE DESCRIPTION B 3 L K 400 160 XX B Orthogonal axes P Parallel axes Number of reduc t...

Page 8: ...NS Dana Incorporated IMM 0005EN Posiplan MT 5215 0806 CONFIGURATIONS SYMBOL DESCRIPTION Magnetic and oil drain plug Oil level plug Oil breather and filling plug SERIE BPH SERIE PH B3 B6 B7 B8 V5 V6 B3 B6 B7 B8 V5 V6 ...

Page 9: ... be used in particularly aggressive conditions a special paint finish will be required External machined parts of the gear unit such as the ends of the hollow and non hollow shafts support surfaces alignment pins etc are protected with a rust inhibitor oil tectyl Internal parts of the gear unit casings and drives are also protected with rust inhibitor oil Unless otherwise specified in the sales ag...

Page 10: ...h wrapping that can with stand normal industrial environments HANDLING To move packaged gear units use lifting equipment that is appropriate for the type of packaging and for which the capacity is clearly indicated Never tilt or turn the packed gear unit upside down during transport Dana Incorporatedproducts are packed and shipped in crates or on pallets depending on the specific case CAUTION ...

Page 11: ...wooden wedges under the crate or pallet to make lifting easier When using a hoist or any lifting system with a hook make sure that the load is evenly balanced and securely slung and that only approved equipment is used When gear units are packed on pallets make sure that the lifting equipment does not damage the gear unit When lifting and moving packages avoid any violent impacts or bumps ...

Page 12: ...hen the product is unloaded Packaging must be disposed of as follows cut the straps with shears warning the ends may hit the operator cut or pull off the wrapping cut the internal strap warning the ends may hit the operator remove the machine from the pallets Notify the Dana Incorporated Service Department if you find any damage defects or missing parts tel 390425594162 Fax 390425585821 The strap ...

Page 13: ...ive anticorrosion grease or oil Fill the gear unit full with an appropriate oil see section 7 4 Store the gear unit in a dry place at a temperature between 5 C and 30 C Protect the packing from dust dirt and humidity Before removing the machine from its packing make sure it is solidly attached to the lifting equipment so that it cannot slide or flip over NOTE When stored for extended periods of mo...

Page 14: ...ot stack Do not walk on or rest pieces on top of the package Do not store any other materials inside the packing Store the packing well away from pedestrian or vehicular traffic routes If possible position wooden wedges between the bottom of the packing and the floor ...

Page 15: ...o move in the axial plane The gear unit must be anchored so that the small radial oscillations present in swinging systems are possible Elastic components such as Belleville washers elastic pads shock absorbers articulated stay rods or similar should be used These are need to prevent any dangerous additional loads on the gear unit Appropriate safety precautions should also be foreseen to prevent d...

Page 16: ...reaction arm there are also 1 1H7 tolerance holes pos 5 for calibrated journal pins when fitting gear units with reaction rod Take the reaction arm and align it with the mounting pin holes on the fork of the rod pos 4 and with hole H7 pos 5 on the gear unit Insert the calibrated journal pin and tighten it with the nut pos 1 leaving the rod free to rotate around the calibrated journal pin Insert th...

Page 17: ... new there is no need to disassemble it and grease it When servicing the coupling disassemble it and grease the zones marked C see fig 4 Fit the coupling in its seat on the gear unit shaft without tightening the bolts positioning it as shown in a see Fig 4 If the gear unit works in the vertical plane with the relative output shaft facing downwards make sure the joint cannot slip off and fall whate...

Page 18: ... front surfaces of the inner and outer rings are on the same plane see Fig 4 pto S DISASSEMBLING THE COUPLING Gradually loosen the anchor bolts working your way round in a circle Loosen each bolt by just a quarter of a turn to start with to avoid bending and seizing If the coupling rings don t spring apart naturally after the bolts have been unscrewed transfer some of the bolts two bolts at 180 or...

Page 19: ...n the threaded rod the two shafts will abut against each other see Fig 6 Securing unscrew the threaded rod nut pos 4 and take it out of its seat Replace the rod pos 4 with screw pos 6 torquing it down fully to the torque value shown in Values Table Torque Setting Bolts p 32 using an intermediate threadlocker Dana Incorpo rated recommends LOCTITE 601 see Fig 7 Disassembly remove the anchor bolt pos...

Page 20: ...it shaft is tight against the machine shaft use a threaded rod pos 4 of an appropriate size Now insert the backplate pos 3 then the inner retaining ring pos 5 into their relative seats and tighten the threaded bar to bring the two shafts tight against each other see fig 9 Securing unscrew the threaded rod pos 4 and take it out of its seat Replace the rod pos 4 with screw pos 6 torquing it down ful...

Page 21: ...ing the connecting toothing Slot them together without exerting too much pressure on each part To make sure the machine shaft rests tight against the backplate pos 3 to be subsequently fitted use a threaded rod pos 4 of an appropriate size Now insert the backplate pos 3 then the inner retaining ring pos 5 securing the backplate pos 3 Now when you tighten the threaded rod nut the machine shaft will...

Page 22: ... unit female shaft pos 2 then take the coupling andinsert it into its seat without tightening the bolts Align the axes of the gear unit female shaft pos 2 as much as possible with the machine male shaft pos 1 then bring the two shafts together Slot them together without exerting too much pressure on each part To make sure the female gear unit shaft is tight against the machine shaft use a threaded...

Page 23: ...n the gear unit female shaft securing it by inserting the retaining ring pos 5 Insert 2 bolts pos 7 into the two threaded holes on the backplate pos 3 and screw them until they touch the machine shaft pos 1 Now give them alternately one full turn each see Fig 18 MACHINE SHAFT WITH NO SHOULDER Assembly Lubricate the coupling seat pos 9 on the gear unit female shaft pos 2 then take the coupling andi...

Page 24: ...instructions on how to secure the coupling see section Assembly with coupling p 17 see Fig 20 Disassembly the first thing to do is remove the coupling For instructions on how to do this see section Disassembling the coupling p 18 Disassembling the coupling Remove the anchor bolt pos 6 and the backplate pos 8 from their relative seats Insert 2 bolts pos 7 into the two threaded holes on the backplat...

Page 25: ...or bolts to the torque value listed in section Values Table Torque Setting Bolts p 32 see Fig 22 CENTRAL JOINT VERSION in this version if you want to disassemble the coupling half pos 2 when connecting to the motor but have already filled the gear unit with oil you need to be careful because when you remove the coupling half the oil may escape from the gear unit So to remove the coupling half pos ...

Page 26: ...atively you can heat the relative compo nent to 80 100 C Lubricate the grooves with a thin layer of grease or a no grip lubricant and tighten anchor bolts to the torque value listed in section Values Table Torque Setting Bolts p 32 Fig 23 NOTE Dana Incorporated recommends you assemble the motor with the central joint in position because in refitting it you could damage the rotating retaining ring ...

Page 27: ...nti foaming and anti oxidant additives it is important to use lubricating oils with additives that have EP Extreme Pressure and anti wear properties and that conform to ISO 6743 6 L CKC or DIN 51517 3 CLP Clearly the slower the gear unit speed the stronger the EP characteristics the product must have Not to be overlooked is that fact that the che mical compounds replacing hydrodynamic lubrication ...

Page 28: ...reaches the top of the open plug in the top part of the gear unit replace the plug Keep filling until the oil reaches the min visual level plug on the tank fill to just above this level Replace the plug Never fill as far as the max visual oil level to leave room for the hot oil to expand Turn the gear unit a few times to get rid of any air pockets then check the levels again a A breather b MAX lev...

Page 29: ... 0806 Fig 26 Type of soap Stearate hydroxide lithium 12 or equivalent Consistency NLGI No 2 Base oil Mineral oil with viscosity from 100 to 320 cST at 40 C Additives Corrosion or rust inhibitors Viscosity index 80 minimum Pour point 10 C maximum Sfiato Ingrassatore ...

Page 30: ...imol Optigear BM 150 Optigear BM 220 Optigear BM 320 Q8 Goya NT 150 Goya NT 220 Goya NT 320 Repsol Super Tauro 150 Super Tauro 220 Super Tauro 320 Shell Omala 150 Omala 220 Omala 320 Texaco Meropa 150 Meropa 220 Meropa 320 TotalFinaElf Carter EP 150 Carter EP 220 Carter EP 320 Tribol 1100 150 1100 220 1100 320 LUBRICANT SYNTETIC ISO VG 150 ISO VG 220 ISO VG 320 Agip Blasia SX 220 Blasia SX 320 Ara...

Page 31: ...uto FG 68 Gear oil 220 Keystone Nevastane SL 32 Nevastane SL 46 Nevastane SL 68 Nevastane EP 150 Nevastane EP 220 Nevastane EP 320 KLÜBER Klüberfood 4 NH1 32 Klüberfood 4 NH1 46 Klüberfood 4 NH1 68 Klüberfood 4 UH1 150N Klüberfood 4 UH1 220N Klüberfood 4 UH1 320N MOBIL Mobil SHC Cibus 32 Mobil SHC Cibus 46 Mobil SHC Cibus 68 Mobil SHC Cibus 150 Mobil SHC Cibus 220 Mobil SHC Cibus 320 NILS Mizar 32...

Page 32: ... kN Nm kN Nm kN Nm kN Nm 3x0 5 1 2 0 9 1 5 1 1 2 3 1 8 3 4 2 6 4 0 3 4x0 7 2 1 1 6 2 7 2 4 1 3 1 6 0 4 5 7 0 5 3 5x0 8 3 5 3 2 4 4 4 6 7 6 1 9 8 8 9 11 5 10 4 6x1 4 9 5 5 6 1 6 8 9 4 10 4 13 8 15 3 16 1 17 9 7x1 7 3 9 3 9 0 11 5 13 7 17 2 20 2 25 23 6 30 8x1 9 9 14 5 12 2 18 18 9 27 28 40 32 47 9x1 25 9 3 13 6 11 5 16 8 17 2 25 25 37 30 44 10x1 5 14 5 26 6 18 33 27 50 40 73 47 86 10x1 25 15 8 28 1...

Page 33: ...D TESTS After a short running time 5 10 minutes check oil levels under no load conditions topping up any that have gone down and checking that all anchor nuts and bolts are properly tightened 30x3 5 144 772 178 955 280 1500 300 2130 467 2500 30x2 165 850 204 1060 321 1670 457 2370 535 2380 D X P MM 4 8 5 8 8 8 10 8 12 9 kN Nm kN Nm kN Nm kN Nm kN Nm ...

Page 34: ...t for each unit to be filled out and updated each time maintenance is performed OIL CHANGE Use the diagrams in section Configurations p 8 to locate the oil drain plug for the particular gear unit configuration con cerned Unscrew the drain and filler plugs to help the oil drain from the gear unit Once it is empty replace the drain plug Wash the inside of the gear unit with a suitable cleaning fluid...

Page 35: ...nit itself must be disposed of in accordance with environ mental restrictions without polluting the soil water or air The party receiving the materials is responsible for doing this in com pliance with applicable regulations in the country in which the machine is used Instructions for suitable waste treatment Iron aluminium and copper being recyclable these materials should be sent to an authorize...

Page 36: ...ion Level too high Lower oil leve Incorrect breather position Check breather position Oil leak from seals Clogged breather plug Unscrew and thorougly clean the plug Stiffening of seals due to prolonged storage Clean the area and check for leakage again after a few days Damaged or worn seals Contact a Dana Incorporated Service Centre Excessive vibrations Gear unit incorrectly installed Check machin...

Page 37: ...under its own responsability on the basis of the results of its standard tests aimed to verify products which are manufactured using the same materials and production method declares that the products comply fully with the order re quirements and with all technical norms corresponding to the official regulations ...

Page 38: ...38 Dana Incorporated IIMM 0005EN Posiplan MT 5215 0806 SERVICE NETWORK ...

Page 39: ...39 Dana Incorporated IMM 0005EN Posiplan MT 5215 0806 ...

Page 40: ...ine service parts ordering visit www danaaftermarket com Copyright 2021 Dana Incorporated All content is subject to copyright by Dana and may not be reproduced in whole or in part by any means electronic or otherwise without prior written approval THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE AND THIS NOTICE MUST REMAIN ON ALL COPIES ...

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