DANA BREVINI D Series

Questions and Answers

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Brandon MckeeAug 13, 2025
How to troubleshoot a DANA Engine gearbox that does not start?
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  Ryan GillespieAug 13, 2025
  If your DANA Engine gearbox is not starting, verify that the voltage supply and frequency of your electrical connection match the motor's nameplate. Refer to the motor manufacturer's start-up manual. If the problem persists, the load might be too high for the motor. Detach the gearbox from the load/torque. If it starts working, the starting torque is insufficient, and a higher motor power is needed. For single-phase motors, also inspect the starting and running capacitors. If none of these steps resolve the issue, proceed to ID 100.
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Casey GeorgeAug 18, 2025
Why DANA Engine gearbox does not work in low speeds/frequencies?
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  alishagarciaAug 18, 2025
  When a DANA Engine gearbox doesn't work at low speeds or frequencies, it's often due to the frequency inverter's frequency being lowered for very low speeds. In such cases, the inverter and motor parameters must be optimized. Additionally, the gearbox efficiency can vary significantly at low speeds, especially in worm-gearboxes. The recommended frequency range is 20-70 Hz for worm-gearboxes and 10-70 Hz for Helical Gear Boxes. To resolve this, use higher motor power and a frequency inverter, or adjust the gearbox ratio to operate within the recommended frequency range.
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Clayton FergusonAug 25, 2025
What to do if DANA Engine gearbox does not start in the mornings?
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  Melissa MillerAug 25, 2025
  If the DANA Engine gearbox fails to start in the mornings or after extended periods of inactivity, and the ambient temperature is below +5 Celsius, the oil being used may not be suitable for the working conditions. Consider switching to oils with lower viscosity, consulting the manual for correct oil specifications. Alternatively, if feasible, operate in higher ambient temperatures. If the problem persists, a motor with higher power may be necessary.
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clarkpatriciaAug 30, 2025
Why DANA BREVINI D gearbox does not start after long time stop?
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  Amanda BergAug 30, 2025
  If the DANA Engine gearbox fails to start in the mornings or after extended periods of inactivity, this could be because the ambient temperature is below +5 Celsius. The oil is not in accordance with your working conditions. Change to lower viscosity oils. Observe this manual for using the correct oil. Working in higher ambient temperatures is another solution if possible. If the problem persists, you need higher motor power.
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Curtis WangNov 5, 2025
What to do if DANA BREVINI D Engine gearbox does not start?
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  feliciaburkeNov 5, 2025
  If the DANA Engine gearbox does not start, first check the voltage supply and frequency of your electrical connection to ensure they match the motor's nameplate specifications. Consult the motor manufacturer's start-up manual for guidance. Also, make sure the brake is functioning correctly by checking the brake manufacturer's manual and the wiring diagram. If the brake is supplied by Dana Motion Systems Italia S.r.l., refer to their manual for the correct wiring. If the brake still doesn't work, apply voltage directly to it according to its nameplate (e.g., 198V DC); a clicking noise should indicate it's opening. If you hear no noise, the brake or rectifier may be defective. If the brake works and you still face the same problem when supplying direct voltage to the motor, the load might be...

Summary

VERSION TRACKING

MANUAL APPLICABILITY AND SUPPORTED MODELS

Details the manual's applicability and the supported models for the gear units.

HOW TO USE THIS MANUAL

UNIT DESIGNATION

DETAILED UNIT DESIGNATION

Explains the detailed designation system for D series gear units, including various components.

NAMEPLATE UNIT DESIGNATION

Explains the nameplate unit designation, a short abbreviation from the detailed designation.

PART LIST OF STANDARD TYPE GEAR UNITS

D..00... TYPES FOR 2 AND 3 STAGED GEAR UNITS

Provides a part list and diagram for D..00... types of 2 and 3 staged gear units.

D..01... TYPES FOR 2 AND 3 STAGED GEAR UNITS

Provides a part list and diagram for D..01... types of 2 and 3 staged gear units.

D..02... TYPES FOR 2 AND 3 STAGED GEAR UNITS

Provides a part list and diagram for D..02... types of 2 and 3 staged gear units.

D..03... TYPES FOR 2 AND 3 STAGED GEAR UNITS

Provides a part list and diagram for D..03... types of 2 and 3 staged gear units.

D...0 S... TYPES FOR 2 AND 3 STAGED GEAR UNITS

Provides a part list and diagram for D...0S... types of 2 and 3 staged gear units.

D...0 E... TYPES FOR 3 STAGED GEAR UNITS

Provides a part list and diagram for D...0E... types of 3 staged gear units.

D..4 SERIES ADDITIONAL STAGE FOR 4 STAGE TYPES

Provides a part list and diagram for D..4 series additional stage for 4 stage types.

D SERIES 5-6 STAGES TYPES

Provides a part list and diagram for D series 5-6 stages types, including N type.

D SERIES MOTOR FLANGE FOR DIRECT COUPLED TYPES

Provides a part list for D series motor flange for direct coupled types.

DN..., DV...TYPES B5, B14 MOTOR FLANGE

Provides a part list for DN..., DV... types with B5, B14 motor flange.

DT... TYPES INPUT BEARING HOUSING WITH SOLID INPUT SHAFT

Provides a part list for DT... types with input bearing housing and solid input shaft.

SAFETY

INTENDED USE

Defines the intended use of the gear reducer in industrial machines and compliance with directives.

IMPROPER USE

Lists prohibited uses of the gear reducer that violate regulations or are unsafe.

GENERAL SAFETY INSTRUCTIONS

Provides general safety instructions for working on, operating, and maintaining the gear reducer.

LUBRICANT SAFETY PRECAUTIONS

Provides safety warnings regarding contact with lubricants and hot oil during maintenance.

AMBIENT CONDITIONS SAFETY

Details safety considerations for ambient temperatures and outdoor use of the gear unit.

TIGHTENING TORQUES

Lists specified tightening torques for screwed connections using a calibrated torque wrench.

CASE OF FIRE

Provides guidance on suitable and unsuitable extinguishing agents for gear reducer fires.

THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTALLED

TRANSPORTATION

Provides instructions and warnings for safe transportation and handling of the gear unit.

STORAGE

Provides instructions for storing the gear unit with or without packing to maintain its condition.

INSTALLING THE GEAR UNIT

BEFORE YOU START

Lists checks and preparations required before starting the installation of the gear unit.

CHECK THE SHAFT DIMENSIONS TO FIT

Details the table for checking shaft dimensions, tolerances, and flange/centering specifications.

CHECK THE AMBIENT TEMPERATURE

Specifies the required ambient temperature range for standard type gear units.

CHECK THE VOLTAGE SUPPLY

Provides guidelines for checking voltage supply, wiring diagrams, and safety precautions for electric motors.

CHECK THE MOUNTING POSITION

Ensures the mounting position matches the nameplate and provides compatibility notes.

USE THE BREATHER PLUG

Explains the use of breather plugs based on ambient conditions and mounting position.

CHECK THE OIL LEVEL

Describes how to check and adjust the oil level using level and filling plugs.

CHECK SHAFT ENDS AND MOUNTING FACES

Ensures connection elements are free of oil and dust before installation.

COVER ABRASIVE AMBIENT

Advises on protecting output seals from abrasive environments to prevent damage.

CHECK ACCESSIBILITY TO FILLING, BREATHER AND DRAIN PLUGS

Ensures filling, breather, and drain plugs are accessible for service.

MECHANICAL INSTALLATION

INSTALLING CUSTOMER SHAFT WITH SHOULDER

Instructions for installing a customer shaft with a shoulder using anti-seize paste and fasteners.

INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER

Instructions for installing a customer shaft without a shoulder using anti-seize paste and fasteners.

DISASSEMBLING CUSTOMER SHAFT WITH SHOULDER

Procedure for disassembling a customer shaft with a shoulder using specialized sets.

DISASSEMBLING CUSTOMER SHAFT WITHOUT SHOULDER

Procedure for disassembling a customer shaft without a shoulder using specialized sets.

SHAFT TIGHTENING TORQUES

Provides a table of shaft tightening torques for various gear unit types.

ADVISED SHAFT DIMENSIONS AND ACCESSORIES

Details recommended shaft dimensions and accessories, including diagrams and a specification table.

DIMENSIONS OF SPLINED HOLLOW SHAFT TO DIN 5480

Provides dimensions for splined hollow shafts according to DIN 5480 for specific gear unit types.

ASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK

Instructions for assembling a customer shaft with a shrink disk, including cleaning surfaces.

DISASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK

Procedure for disassembling a customer shaft with a shrink disk.

ASSEMBLING GEAR UNIT WITH TORQUE ARM

Instructions for assembling the gear unit using a torque arm connection, with diagrams.

FITTING OUTPUTSHAFT ELEMENTS

Illustrations and descriptions for assembling output shaft units and thrust bearings.

CORRECT POSITION OF OUTPUT SHAFT ELEMENTS

Guidance on placing output shaft transmission elements close to the gear unit for optimal radial load.

FITTING COUPLINGS

Instructions for fitting couplings, ensuring clearance, concentricity, and alignment of shafts.

MAINTENANCE & INSPECTION

LUBRICATION

OIL TYPES

Details various lubricant types, ISO VG classifications, and brand equivalents for different temperatures.

CHANGING THE OIL

Provides instructions on how to change the oil, including references to plugs and warnings.

MOUNTING POSITIONS

Illustrates the different mounting positions (M1-M6) for the gearbox, used as reference.

OIL PLUGS AND OIL QUANTITIES

Details oil plug locations and oil quantities for D series 2-3 stage gear units across mounting positions.

D SERIES 2-3 STAGE OIL LEVEL PLUGS

Illustrates oil plug symbols and provides oil quantities for D series 2-3 stage gear units by type and mounting.

D SERIES 4 STAGE OIL LEVEL PLUGS

Illustrates oil plug symbols and provides oil quantities for D series 4 stage gear units by type and mounting.

D SERIES 5-6 STAGE OIL LEVEL PLUGS

Illustrates oil plug symbols and provides oil quantities for D series 5-6 stage gear units by type and mounting.

TROUBLESHOOTING GUIDE

DISPOSAL

DISPOSAL OF OIL

Instructions for the safe and compliant disposal of used lubricants (oil and greases).

DISPOSAL OF SEALING

Instructions for the disposal of sealing rings as composite material.

DISPOSAL OF METAL

Instructions for the disposal of metal components of the gear reducer according to national guidelines.