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This document is an Installation and Maintenance Manual for Dana Brevini Gearmotors E Series, identified by the document number IMM-0017EN, dated December 2022. It provides comprehensive information for the proper installation, operation, and maintenance of these gear units.
The gear reducer is designed for use in industrial machines. It functions as a component within larger machinery, transmitting power and modifying torque and speed. The manual emphasizes that these gearboxes are not autonomous machines but rather components to be installed in a machine, and their operation is prohibited within the EC directive's validity area until the host machine complies with regulations. The gear units are intended for industrial applications and must be used in accordance with the information provided in this manual, the product catalogue, and the nameplate of the gearbox.
The manual details various E Series gear unit types (E....00, E....01, E....02, E....03, E....04, E....05, E....08, ET....00, ET....01, ET....02, ET....03, ET....04, ET....05, ET....08) with corresponding part lists and diagrams. Unit designation is thoroughly explained, including detailed ordering designations (e.g., EV 063.01 - 90S/4 - L05) and nameplate designations (e.g., EV080.00-90S/4). These designations specify gearbox type, housing size, input type (e.g., IEC B5/B14 Flange with/without Motor), motor size, pole number, frame length, motor size, brake type (e.g., 220V with/without fan, 24V with/without fan, and brake torque in Nm), and output shaft options (e.g., hollow shaft, solid shaft, flanged, double shaft). Shaft dimensions and tolerances are provided for various E Series models (E.030 to E.125), including hollow shaft diameter, hollow shaft tolerance (H8), output shaft diameter, output shaft tolerance (DIN748), flange centering shoulder diameter, and centering shoulder tolerance. Tightening torques for bolts ranging from M8 to M24 are specified, with values from 23 Nm to 640 Nm for class 8.8 bolts. The standard geared motors are supplied with 230/400 V 50/60 Hz up to 3 kW, and 400/690 V 50/60 Hz over 3 kW. Nominal powers at 400V, 50Hz are detailed for 2, 4, 6, and 8 pole numbers, indicating power ranges for 230V (D)/400V (Y) and 400V (D) connections. Oil quantities (in liters) are provided for different E Series types (E.30 to E.125) across six mounting positions (M1 to M6). Ambient temperature for standard gear units must be between +5 °C and +40 °C.
The manual stresses the importance of proper installation, including checking shaft dimensions, ambient temperature, voltage supply, and mounting position. It provides detailed instructions for installing customer shafts with shoulders, including the use of anti-seize paste and specific tightening torques. Guidance on fitting output shaft elements emphasizes placing transmission elements as close as possible to the gear unit to minimize radial load. Instructions for fitting couplings highlight the need for clearance between elements, ensuring no eccentricity between shafts, and preventing angular misalignment. The use of a breather plug is critical for operation, and the transport protection rubber must be removed before starting the gear unit. The manual includes basic motor connection wiring diagrams for standard 230/400 V 50 Hz AC electric motors and standard type brakes (delayed running and sudden brakes for 220V and 24V). Torque arm connection diagrams are provided for various configurations (L1, L2, L3, R1, R2, R3), along with a part list for assembling the torque arm.
A comprehensive maintenance and inspection schedule is outlined, with checks for oil leakage, oil level, rubber buffer, bearing noise, and changes of mineral oil, synthetic-PAO oil, sealing, bearing grease, and bearings at intervals of 3,000 working hours (6 months), 4,000 working hours, 10,000 working hours (3 years), and 25,000 working hours. An oil change interval chart correlates oil bath temperature (Celsius) with working hours for mineral, synthetic PAO, and synthetic PG oils. Oil types are specified based on ambient temperature ranges and lubrication methods (dip or forced), listing various brands like Aral, Castrol, Klüber, Mobil, Shell, and Total, including mineral oils (CLP) and synthetic oils (CLP PG, CLP HC). Food grade and biodegradable oils are also listed. Instructions for changing oil involve using filling, draining, and level plugs according to the mounting position. Troubleshooting guidance covers issues such as the gearbox not starting, excessive heating, noise, oil leakage, and motor problems, providing observations and remedies. Disposal instructions are given for oil (hazardous substance), sealing rings (composite material), and metal parts (iron, aluminum, non-ferrous heavy metal), emphasizing adherence to national guidelines. The manual highlights safety instructions, including warnings about improperly executed work, foreign bodies, hot surfaces, rotating machinery, unintentional machine start-up, non-operating safety devices, contact with oils, hot oil, and ambient conditions. It also specifies tightening torques for screwed connections.
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