DANA BREVINI K Series

Questions and Answers

J
Jennifer SmithAug 26, 2025
What causes oil to leak from my DANA Engine gearbox?
- R
  Rachel YoungAug 27, 2025
  Oil leaks can stem from several causes. If the ambient temperature is over +40 Celsius or the gearbox works non-stop for over 16 hours, replace the top plug with a breather plug, referring to the manual for proper usage. If that's not the case, the seal might be damaged. If you're using a breather plug, ensure it's correctly positioned at the top according to your mounting position and that the plug is sufficiently tight. Clean the plug and the rubber surface underneath it. If the oil is leaking from the housing itself, it may have a micro split or crack. If the oil leakage is from the cover, the sealing liquid under the cover may be split or defective; in this case, disassemble the cover, apply new sealing liquid, reassemble the cover, and tighten the bolts.
A
Amber TurnerAug 28, 2025
Why is my DANA Engine motor heating up?
- B
  Barbara PonceAug 28, 2025
  A motor can overheat for a couple of reasons. It might be running over its nominal current, indicating that the motor power is insufficient or that it's experiencing some overload. The motor itself may also be defective. Another cause could be a dusty environment. Check the motor fan hub and ribs to ensure they are free of dust. If you're using a forced external fan, verify that it is working. If you're using a frequency inverter at low speeds without a forced external fan, you might need one.
N
Nicholas WheelerAug 30, 2025
What to do if my DANA Engine gearbox is stopping too late?
- J
  Juan YoungAug 30, 2025
  Check the wiring diagram of the brake. There are two different kinds of brake wiring diagrams. The standard gearbox delivered from our factory is set to delayed braking. For sudden braking check the wiring diagram.
T
Todd BenjaminSep 1, 2025
Why does my DANA Engine gearbox move regularly on its mounting point?
- Q
  qbrownSep 1, 2025
  The movement of the gearbox is due to the runout of the shaft to which the gearbox is assembled. This is normal and does not harm the gearbox unless you are using a torque arm.
A
Amy LopezSep 3, 2025
Why does my DANA Engine gearbox move randomly on its mounting point?
- J
  James LiSep 3, 2025
  The movement of the gearbox is because of the runout and clearance of the shaft which you assemble the gearbox. Check the clearance of the assembling shaft and the clearances on your machine. This has no bad affect or harm to the gearbox unless you are using torque arm.
S
Sarah SandersSep 5, 2025
What to do if my DANA Engine gearbox does not start mornings or after a long stop?
- J
  Jeffrey PenaSep 5, 2025
  The oil may not be suitable for your working conditions. Try changing to lower viscosity oils, referring to this manual for correct oil selection. Another solution is to operate in higher ambient temperatures if possible. If the problem persists, you may need a higher motor power.
M
Michelle AlexanderSep 7, 2025
What causes a defect in my DANA Engine gearbox housing?
- J
  James DanielsSep 8, 2025
  The radial load or polygon effect of the chain may have caused the damage if you are using a chain drive or pinion gear. Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid enough. Check if you are using the correct diameter of chain drive and you are not exceeding max. allowed radial load. Check the position of your output element and re-calculate your radial load and check if this fit to the maximum allowed radial load.
E
Emily DiazSep 10, 2025
What to do if my DANA Engine gearbox is starting too late?
- B
  Barbara HernandezSep 10, 2025
  For fast opening of big brakes (over 100Nm), you may need shock transformators which is supplied by Dana Motion Systems Italia S.r.l..
R
rwestSep 12, 2025
What causes a defect in my DANA Engine output shaft?
- K
  Kevin HallSep 12, 2025
  The radial load or polygon effect of the chain may have caused the damage if you are using a chain drive or pinion gear. Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid enough. Check if you are using the correct diameter of chain drive and you are not exceeding max. allowed radial load. Check the position of your output element and re-calculate your radial load and check if this fit to the maximum allowed radial load.
B
Benjamin MeyerSep 14, 2025
What to do if my DANA Engine motor is running but the gearbox shaft does not turn?
- A
  Alvin LeblancSep 14, 2025
  Some part (key, gear) may be defect inside gearbox.

Summary

1 VERSION TRACKING

1.1 MANUAL APPLICABILITY AND SUPPORTED MODELS

Details the models for which the manual is applicable.

2 HOW TO USE THIS MANUAL

Safety and Warning Signs

Explains safety and warning signs for proper understanding.

EC Machinery Directive

Information on gearboxes as components within EC directives.

3 UNIT DESIGNATION

3.1 DETAILED UNIT DESIGNATION

Explains the detailed designation system for K Series gear units.

3.2 NAMEPLATE UNIT DESIGNATION

Explains the short abbreviation from the detailed designation.

4 STANDARD TYPE GEARBOX PARTS LISTS

4.1 SIZE: K00...K20...

Lists parts for K00-K20 size gearboxes by type.

4.2 SIZE: K27...K97...

Lists parts for K27-K97 size gearboxes by type.

5 SAFETY

5.1 INTENDED USE

Defines the proper industrial use of the gear reducer.

5.2 IMPROPER USE

Lists prohibited usages that exceed limits or regulations.

5.3 SAFETY INSTRUCTIONS

General warnings for working on, operating, and maintaining the gear reducer.

5.4 TIGHTENING TORQUES

Specifies tightening torques for screwed connections.

5.5 CASE OF FIRE

Suitable and unsuitable extinguishing agents and protective equipment.

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

6.1 TRANSPORTATION

Instructions for checking the gearbox upon arrival and during transport.

6.2 STORAGE

Guidelines for storing the geared unit with or without packing.

7 INSTALLING THE GEAR UNIT

7.1 BEFORE YOU START

Pre-installation checks for damages and necessary equipment.

7.2 CHECK THE SHAFT DIMENSIONS TO FIT

Table of shaft dimensions and tolerances for fitting.

7.3 CHECK THE AMBIENT TEMPERATURE

Specifies the acceptable ambient temperature range for operation.

7.4 CHECK THE VOLTAGE SUPPLY

Information on voltage supply and basic electric connection diagrams.

7.5 CHECK THE MOUNTING POSITION

Ensures mounting position matches nameplate for correct oil level.

7.6 USE THE BREATHER PLUG

Guidance on using breather plugs for specific conditions.

7.7 CHECK THE OIL LEVEL

Procedure for checking and adjusting the oil level.

7.8 CHECK SHAFT ENDS AND MOUNTING FACES

Ensures connection surfaces are free of oil and dust.

7.9 COVER ABRASIVE AMBIENT

Protects seals from abrasive environments.

7.10 CHECK ACCESSIBILITY TO FILLING, BREATHER AND DRAIN PLUGS

Ensures accessibility of plugs for checks and service.

8 MECHANICAL INSTALLATION

8.1 INSTALLING CUSTOMER SHAFT WITH SHOULDER

Steps for installing the customer shaft with a shoulder.

8.2 INSTALLING CUSTOMER SHAFT WITHOUT SHOULDER

Steps for installing the customer shaft without a shoulder.

8.3 DISASSEMBLING CUSTOMER SHAFT WITH SHOULDER

Steps for disassembling the customer shaft with a shoulder.

8.4 DISASSEMBLING CUSTOMER SHAFT WITHOUT SHOULDER

Steps for disassembling the customer shaft without a shoulder.

8.5 SHAFT TIGHTENING TORQUES VALUES ARE AS SHOWN

Table of shaft tightening torques by type.

8.6 RECOMMENDED SHAFT DIMENSIONS FOR KT...00 TYPES

Table of recommended shaft dimensions for KT...00 types.

8.7 K.00.. - K.97.. DIMENSIONS OF SPLINED HOLLOW SHAFT TO DIN 5480

Dimensions of splined hollow shafts according to DIN 5480.

8.8 ASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK

Steps for assembling the customer shaft with a shrink disk.

8.9 DISASSEMBLING CUSTOMER SHAFT WITH SHRINK DISK

Steps for disassembling the customer shaft with a shrink disk.

8.10 ASSEMBLING GEAR UNIT WITH TORQUE ARM

Shows different connecting possibilities for torque arm assembly.

8.11 FOR THE FIXING BOLD POSITION REFER TO THE FOLLOWING DIMENSIONS

Dimensions for fixing bolt positions for different mounting types.

8.12 K.00.. - K.20.. TORQUE ARM ASSEMBLY DETAILS

Details for assembling torque arms for K.00.. - K.20.. types.

8.13 FITTING OUTPUT SHAFT ELEMENTS

Illustration for assembling output shaft units.

8.14 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS

Placement of output shaft elements for optimal radial load.

8.15 FITTING COUPLINGS

Guidelines for fitting couplings to ensure proper alignment.

9 MAINTENANCE & INSPECTION

9.1 MAINTENANCE SCHEDULE

Intervals for checking and replacing gearbox components.

10 LUBRICATION

10.1 OIL TYPES

Table detailing lubricants based on temperature and brand.

10.2 CHANGING THE OIL

Instructions and warnings for changing the gearbox oil.

10.3 OIL PLUGS AND OIL QUANTITIES

Oil quantities for different gearbox types and mounting positions.

10.4 MOUNTING POSITIONS

Diagrams illustrating various mounting positions (M1-M6).

11 TROUBLESHOOTING GUIDE

Gearbox Does Not Start Up

Troubleshooting steps for gearbox startup issues.

Gearbox is Heating Up too Much

Troubleshooting steps for overheating issues.

Gearbox is noisy

Troubleshooting steps for gearbox noise issues.

Oil is Leaking

Troubleshooting steps for oil leakage issues.

Motor is heating up

Troubleshooting steps for motor overheating.

Gearbox Housing is Defect

Troubleshooting steps for gearbox housing defects.

Output Shaft is Defect

Troubleshooting steps for output shaft defects.

Gearbox is stopping too late

Troubleshooting steps for delayed braking.

Gearbox is starting too late

Troubleshooting steps for delayed starting.

Service Required

Instructions for when professional service is needed.

12 DISPOSAL

12.1 DISPOSAL OF OIL

Instructions for the proper disposal of used lubricant.

12.2 DISPOSAL OF SEALING

Instructions for the disposal of sealing materials.

12.3 DISPOSAL OF METAL

Instructions for the disposal of metal components.