DANA BREVINI T Series Installation And Maintenance Manual Download Page 1

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Installation and Maintenance Manual

October 2022

IMM-0020EN

Gearmotors T Series

Summary of Contents for BREVINI T Series

Page 1: ... Installation and Maintenance Manual October 2022 IMM 0020EN Gearmotors T Series ...

Page 2: ...lish 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 R...

Page 3: ...TALLING THE GEAR UNIT 19 7 1 BEFORE YOU START 19 7 2 CHECK THE SHAFT DIMENSIONS TO FIT 19 7 3 CHECK THE AMBIENT TEMPERATURE 19 7 4 CHECK THE VOLTAGE SUPPLY 20 7 5 CHECK THE MOUNTING POSITION 22 7 6 USE THE BREATHER PLUG 22 7 7 CHECK THE OIL LEVEL 22 7 8 CHECK SHAFT ENDS AND MOUNTING FACES 22 7 9 COVER ABRASIVE AMBIENT 22 7 10 CHECK ACCESSIBILITY TO FILLING BREATHER AND DRAIN PLUGS 22 8 MECHANICAL ...

Page 4: ...l 9 MAINTENANCE INSPECTION 37 10 LUBRICATION 38 10 1 OIL TYPES 38 10 2 CHANGING THE OIL 39 10 3 MOUNTING POSITIONS 40 10 4 OIL PLUGS AND OIL QUANTITIES 41 11 TROUBLESHOOTING GUIDE 42 12 DISPOSAL 45 12 1 DISPOSAL OF OIL 45 12 2 DISPOSAL OF SEALING 45 12 3 DISPOSAL OF METAL 45 ...

Page 5: ...tallation and Maintenance Manual 1 VERSION TRACKING 1 1 MANUAL APPLICABILITY AND SUPPORTED MODELS File name Revision Date Changes description IMM 0020EN_Rev 00 Gearmotors T Series 00 17 10 2022 Changed layout Models Gearmotors T Series ...

Page 6: ...nd 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...

Page 7: ...intenance Manual 3 UNIT DESIGNATION 3 1 DETAILED UNIT DESIGNATION NOTE Detailed TT Series gear units designation for ordering This Designation is different from the short nameplate designation TT 57 00 K M1 TT t Output Type 00 0X 0S K M1 M2 M3 M4 M5 M6 ...

Page 8: ...reviations Serial N Serial Number M Pos Mounting Position Type Designation Serial Number Designation 10 4837 Year of manufacturing Order Number 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 TT37 00 K 104837 3 0 19 53 46 M5 VG320 Mineral 4 ...

Page 9: ...lt 5 Cover Plate 6 Plug 7 Plug 8 Circlip 9 Mounting Washer 10 Oil Seal 11 Circlip 12 Bearing 13 Washer 14 Gear 15 Output Hollow Shaft 16 Bearing 17 Circlip 18 Oil Seal 19 Key 20 Closing Cap 21 Bearing 22 Gear 23 Key 24 Pinion 25 Bearing 26 Shim 27 Washer 28 Circlip Standard Part List 29 Closing Cap 30 Oil Seal 31 Bolt 32 Input Shaft Cover 33 Bearing 34 Circlip 35 Key 36 Input Pinion Shaft 37 Beari...

Page 10: ...e 6 Plug 7 Plug 8 Circlip 9 Mounting Washer 10 Oil Seal 11 Circlip 12 Bearing 13 Washer 14 Gear 15 Output Hollow Shaft 16 Bearing 17 Circlip 18 Oil Seal 19 Key 20 Closing Cap 21 Bearing 22 Gear 23 Key 24 Pinion 25 Bearing 26 Shim 27 Washer 28 Circlip Standard Part List 29 Closing Cap 30 Oil Seal 31 Bolt 32 Input Shaft Cover 33 Bearing 34 Circlip 35 Key 36 Input Pinion Shaft 37 Key 38 Bearing 39 Ba...

Page 11: ...Plate 6 Plug 7 Plug 8 Bolt 9 Shrink Disc Protec Cover 10 Shrink Disc 11 Oil Seal 12 Circlip 13 Bearing 14 Washer 15 Gear 16 Output Hollow Shaft 17 Bearing 18 Circlip 19 Oil Seal 20 Key 21 Closing Cap 22 Bearing 23 Gear 24 Key 25 Pinion 26 Bearing 27 Shim 28 Washer 29 Circlip 30 Closing Cap Standard Part List 31 Oil Seal 32 Bolt 33 Input Shaft Cover 34 Bearing 35 Circlip 36 Key 37 Input Pinion Shaf...

Page 12: ... 7 Plug 8 Bolt 9 Shrink Disc Cover 10 Shrink Disc 11 Oil Seal 12 Circlip 13 Bearing 14 Washer 15 Gear 16 Output Hollow Shaft 17 Bearing 18 Circlip 19 Oil Seal 20 Key 21 Closing Cap 22 Bearing 23 Gear 24 Key 25 Pinion 26 Bearing 27 Shim 28 Washer 29 Circlip 30 Closing Cap Standard Part List 31 Oil Seal 32 Bolt 33 Input Shaft Cover 34 Bearing 35 Circlip 36 Key 37 Input Pinion Shaft 38 Key 39 Bearing...

Page 13: ... to be operated in the frequency entries so that the data provided on nameplate catalogue of the gear unit is not exceeded and is accordance with the nameplate catalogue The speed range will be provided on the name plate if Dana Motion Systems Italia S r l is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this ...

Page 14: ...ar the gear reducer WARNING Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suitable safety equipment like gloves WARNING Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A1 EN13857 WARNING An ...

Page 15: ...RNING Hot oil can cause scalding When changing oil protect yourself against contacting hot oil DANGER If the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust Entering sub stances inside the gear unit from seals can damage the gear unit Observe the safety instructions for outdoor use EN12100 2010 WARNING Standard gearboxes are allowed to work in...

Page 16: ... following if the gear reducer is situated in a burning environment 5 5 1 SUITABLE EXTINGUISHING AGENTS PROTECTIVE EQUIPMENT Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit 5 5 2 UNSUITABLE EXTINGUISHING AGENTS WARNING High temperature produce irritating steam Use a protective breathing apparatuses WARNING Do not sp...

Page 17: ...damage Contact Dana Motion Systems Italia S r l for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation NOTE If geared motors are used please also refer to the manual of the motor manufacturer DANGER Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of your gea...

Page 18: ...er roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 ºC Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be...

Page 19: ...ng gear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres Type Input Shaft Diameter Tolerance Hollow Shaft Diameter Tolerance Hollow Shaft Diameter with Shrink Disc Tolerance Customer Shaft ...

Page 20: ...ctric motors For different voltages please contact Dana Motion Systems Italia S r l For gear units supplied without motor refer to the motor manufacturers user manual Table 5 Basic motor connection wiring diagram DANGER Using wrong connection or voltage can damage the electric motor or environment DANGER The electric connection must be done by experienced electric technician The gearbox the motor ...

Page 21: ...gram DANGER The electric connection must be done by experienced electric technician The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor Delayed Running Brake 220 V Sudden Brake 220 V Delayed Running Brake 24 V Sudden Brake 24 V M 3 R S T A A M 3 R S T N A M 3 S R N T A N M 3 R S T ...

Page 22: ...orrect oil mentioned on the oil tables on this manual 7 8 CHECK SHAFT ENDS AND MOUNTING FACES Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or paint ing of the housing 7 9 COVER ABRASIVE AMBIENT...

Page 23: ...be in accordance with your application Check the product catalogue for permitted radial loads and calculation Secure the gear unit using 8 8 or higher quality bolts DANGER To install the gear unit without the supplied connection points can cause serious injuries by loosening or braking the gear unit Even the gear unit is installed totally correctly according this manual be sure that no one will be...

Page 24: ...n and Maintenance Manual 8 1 INSTALLING CUSTOMER SHAFT WITH SHOULDER Use anti seize assembling paste available on your market Use a brush to apply the paste Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft ...

Page 25: ... and Maintenance Manual 8 2 INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER Use anti seize mounting paste available on your market Use a brush to apply the paste Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft ...

Page 26: ... CUSTOMER SHAFT WITH SHOULDER Disassemble the bolt and take out the parts as shown Use the disassemble set from YILMAZ and fasten the bold as shown bellow to take out the output shaft For disassemble sets look the following pages 1 Retaining Bolt 2 Circlip 3 Lock Washer 4 Washer 5 Hollow Shaft 6 Customer Shaft ...

Page 27: ...USTOMER SHAFT WITHOUT SHOULDER Disassembly the bolt and take out the parts as shown Use the disassembly set from YILMAZ and fasten the bold as shown bellow to take out the output shaft For disassembly sets look the following pages 1 Retaining Bolt 2 Circlip 3 Lock Washer 4 Washer 5 Hollow Shaft 6 Customer Shaft ...

Page 28: ...and Maintenance Manual 8 5 SHAFT TIGHTENING TORQUES Use the following table for shaft tightening torques Table 6 Type Bolt Tightening torque Nm TT17 M10 36 TT27 M12 62 TT28 M16 153 TT37 M16 153 TT47 M16 153 TT57 M20 297 TT67 M20 297 TT77 M20 297 TT87 M24 513 TT97 M24 513 ...

Page 29: ...1 43 30 37 M12 38 10 TT28 40 17 28 M8 12 40 39 5 110 40 35 2 50 38 45 M16 43 12 TT37 45 22 34 M8 12 45 44 5 120 40 35 2 55 38 45 M16 48 5 14 TT47 50 22 36 M8 14 50 49 5 136 45 40 3 60 38 45 M16 53 5 14 TT57 60 22 42 M12 16 60 59 5 171 50 45 3 75 44 53 M20 64 18 TT67 70 22 48 M16 18 70 69 5 189 55 50 4 85 44 53 M20 74 5 20 TT77 80 26 54 M20 20 80 79 5 222 60 55 4 100 44 53 M20 85 22 TT87 100 26 70 ...

Page 30: ...l 8 7 ASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK Loosen the bolts of the shrink disk Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow The surfaces must be free from oil or any dirt The solvent must be removed from the surfaces as well ...

Page 31: ...ts as shown Be sure that there is a clearance between the shrink disk shoulder and the hollow shaft shoulder of the gearbox 1 Customer Shaft 2 Bronze Ring 3 Hollow Shaft 4 Shrink Disk Table 8 Type Bolt Tightening Torque Nm TT17 M8 30 TT27 M8 30 TT28 M8 30 TT37 M8 30 TT47 M10 59 TT57 M10 59 TT67 M12 100 TT77 M14 160 TT87 M14 160 ...

Page 32: ...ISK Loosen the bolts of the shrink disk and take out the shaft 8 9 ASSEMBLING GEAR UNIT WITH TORQUE ARM Use the torque arm connection according the following drawing The advised mounting positions are shown below According to the nature of load and direction For uniform and moderate loads fs 1 6 If direction of output shaft rotation is cw ...

Page 33: ... 33 Dana Incorporated IMM 0020EN Installation and Maintenance Manual If direction of output shaft rotation is ccw For heavy loads fs 1 6 If direction of output shaft rotation is cw If direction of output shaft rotation is ccw ...

Page 34: ...ng holes dimensions For the fixing holes refer to the following dimensions Table 9 Type a b b1 s TT17 132 118 16 10 TT27 160 138 20 12 TT28 174 152 20 14 TT37 200 170 24 16 TT47 232 205 26 18 TT57 288 254 30 22 TT67 332 292 34 24 TT77 378 344 38 26 TT87 442 395 42 28 TT97 496 462 46 32 a 2 b s b1 ...

Page 35: ...S Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 8 11 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS The Output Shaft unit transmission elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit 1 Hub ...

Page 36: ...ntenance Manual 8 12 FITTING COUPLINGS By fitting couplings be sure that there is some clearance between the two elements By fitting couplings be sure that there is no eccentric between the two shafts By fitting couplings be sure that the two shafts are not angular miss aligned ...

Page 37: ...Every 4 000 working hours Every 10 000 working hours or every 3 years Every 25 000 working hours Check for oil leakage x Check for oil level x Check oil leakage from seal x Check Rubber buffer x Change if necessary Check Bearings Noise x Change if necessary Change Mineral Oil x See Below for details Change Synthetic PAO Oil x See Below for details Change Sealing x Change Bearing Grease x Change Be...

Page 38: ... 220 Energol GR XP 220 Alpha SP 220 Klüberoil GEM 1 220 N Mobilgear XMP 220 Omala F220 Carter EP 220 20 20 150 Degol BG 150 Energol GR XP 150 Alpha SP 150 Klüberoil GEM 1 150 N Mobilgear XMP 150 Omala 150 Carter EP 150 25 10 100 Degol BG 100 Energol GR XP 100 Alpha SP 100 Klüberoil GEM 1 100 N Omala 100 Carter EP 100 Food Gra de Oil CLP NSF H1 15 25 320 Optileb GT 320 Klüberoil 4 UH1 320 N Mobil S...

Page 39: ...amage to the gear unit The oil change must be done by using the filling draining and level plugs according the mounting position illustrated in section ERRORE Destinazione riferi mento incrociato 1_34389 non trovato WARNING Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thorough WARNING Hot oil can cause scalding When changi...

Page 40: ...RICATION Dana Incorporated IMM 0020EN Installation and Maintenance Manual 10 3 MOUNTING POSITIONS Oil Plugs Table 12 Symbols Drain Plug Oil Filling and Vent plug Oil level M6 M1 M5 M3 M2 M4 M6 M4 M3 M5 M2 M1 ...

Page 41: ... eps M2 M3 eps M3 M4 eps M4 M5 eps M5 M6 eps M6 TT17 1 0 0 95 0 70 0 95 0 80 0 80 TT27 1 8 1 4 1 2 1 6 1 5 1 5 TT28 2 1 2 0 1 3 1 8 1 75 1 75 TT37 2 6 2 6 1 9 2 5 2 4 2 4 TT47 4 0 4 0 3 0 4 2 3 6 3 6 TT57 8 5 8 0 6 7 7 6 6 9 6 9 TT67 13 0 13 2 10 0 12 5 12 5 12 5 TT77 19 0 20 3 14 7 18 5 17 0 17 0 TT87 27 2 28 6 23 0 27 9 27 5 27 5 TT97 40 0 47 0 35 0 47 0 41 0 41 0 ...

Page 42: ...ng driver or frequency inverter Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver frequency inverter and make direct voltage supply to the motor according the motors nameplate Still does not work go to ID 100 005 Gearbox Does Not Start Up You hear some noise but both motor shaft and gearbox shaft is not turnin...

Page 43: ...nious Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bearings are defect Change bearings Goto ID 100 012 Gearbox is noisy Noise is random Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for sma...

Page 44: ...side gearbox Goto ID 10 025 Gearbox Housing is Defect You are using chain drive or pinion gear The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigit enough Check if you are using the correct diameter of chain drive and you are not exceed ing max allowed radial load Check the position of...

Page 45: ...s oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guidlines 12 2 DISPOSAL OF SEALING Remove the sealing rings from the gear reducer and clean them of oil and grease resudies Dispose of the sealings as composite material metal plastic 12 3 DISPOSAL OF METAL Divide up t...

Page 46: ...ine service parts ordering visit www danaaftermarket com 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 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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