DANA BREVINI V Series Manual

®
Installation and Maintenance Manual
October 2022
IMM-0021EN
Gearmotors V Series

CONTENTS
The official language chosen by the Product manufacturer is English. No liability is assumed as a result of translations in
other languages not in compliance with the original meaning. In case of conflicting language versions of this document, 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 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 RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.
DISCLAIMER

3IMM-0021EN - Installation and Maintenance Manual Dana Incorporated
CONTENTS
1 VERSION TRACKING ....................................................................................................................... 5
1.1 MANUAL APPLICABILITY AND SUPPORTED MODELS ..................................................................... 5
2 HOW TO USE THIS MANUAL .......................................................................................................... 6
3 UNIT DESIGNATION ......................................................................................................................... 7
3.1 DETAILED UNIT DESIGNATION ........................................................................................................... 7
3.2 NAMEPLATE UNIT DESIGNATION ...................................................................................................... 8
4 STANDARD TYPE GEARBOX PARTS LIST .................................................................................... 9
4.1 V... TYPES ............................................................................................................................................ 9
5 SAFETY ........................................................................................................................................... 10
5.1 INTENDED USE .................................................................................................................................. 10
5.2 IMPROPER USE ................................................................................................................................. 10
5.3 SAFETY INSTRUCTIONS ................................................................................................................... 11
5.3.1 GENERAL SAFETY INSTRUCTIONS................................................................................................... 11
5.4 TIGHTENING TORQUES .................................................................................................................... 13
5.5 CASE OF FIRE .................................................................................................................................... 13
5.5.1 SUITABLE EXTINGUISHING AGENTS, PROTECTIVE EQUIPMENT................................................... 13
5.5.2 UNSUITABLE EXTINGUISHING AGENTS ........................................................................................... 13
6 THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTALLED ............. 14
6.1 TRANSPORTATION ............................................................................................................................ 14
6.2 STORAGE ........................................................................................................................................... 15
7 INSTALLING THE GEAR UNIT ....................................................................................................... 16
7.1 BEFORE YOU START ......................................................................................................................... 16
7.2 CHECK SPLINED SHAFT DIMENSIONS AND TOLERANCES ........................................................... 17
7.3 CHECK DRUM CONNECTION FLANGE (OPTIONAL) DIMENSIONS AND TOLERANCES ............... 18
7.4 CHECK THE AMBIENT TEMPERATURE ............................................................................................ 18
7.5 CHECK THE VOLTAGE SUPPLY ....................................................................................................... 19
7.6 CHECK THE MOUNTING POSITION .................................................................................................21
7.7 USE THE BREATHER PLUG .............................................................................................................. 21
7.8 CHECK THE OIL LEVEL ..................................................................................................................... 21
7.9 CHECK SHAFT ENDS AND MOUNTING FACES ............................................................................... 21
7.10 COVER ABRASIVE AMBIENT ............................................................................................................. 21
7.11 CHECK ACCESSIBILITY TO FILLING, BREATHER AND DRAIN PLUGS .......................................... 21
8 MECHANICAL INSTALLATION ...................................................................................................... 22
8.1 FITTING OUTPUT SHAFT ELEMENTS ...............................................................................................23
8.2 CORRECT POSITION OF OUTPUT SHAFT ELEMENTS .................................................................... 23
8.3 FITTING COUPLINGS ........................................................................................................................ 24
9 MAINTENANCE & INSPECTION .................................................................................................... 25
10 LUBRICATION ................................................................................................................................ 26
10.1 OIL TYPES .......................................................................................................................................... 26
10.2 CHANGING THE OIL .......................................................................................................................... 27
10.3 OIL LEVELS,PLUGS AND QUANTITIES ............................................................................................. 28
10.4 MOUNTING POSITIONS .................................................................................................................... 29
11 TROUBLESHOOTING GUIDE ........................................................................................................30
12 DISPOSAL ....................................................................................................................................... 33
12.1 DISPOSAL OF OIL .............................................................................................................................. 33
12.2 DISPOSAL OF SEALING .................................................................................................................... 33
12.3 DISPOSAL OF METAL ........................................................................................................................ 33

4Dana Incorporated IMM-0021EN - Installation and Maintenance Manual

5Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
1 VERSION TRACKING
1.1 MANUAL APPLICABILITY AND SUPPORTED MODELS
File name Revision Date Changes description
IMM-0021EN_Rev.00 Gearmotors V
Series 00 17/10/2022 - Changed layout
Models
Gearmotors V Series

6Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
2 HOW TO USE THIS MANUAL
Take attention to the following safety and warning signs for proper understanding and quick reference.
Table 1:
Hazard pictograms
Table 2:
The operating instructions contain important information to ensure;
• Trouble-free operation
• Fulfilment of any rights to claim under guarantee
The operating instruction must be kept close to the gearbox and must be available in case it is needed.
This operating instruction is written for D series gear units and is applicable only for D series. If any different type of gearbox is
used please ask Dana Motion Systems Italia S.r.l. for the operating instructions of that type.
This instruction can be used only for standard type geared units of Dana Motion Systems Italia S.r.l.. For special application
and 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 a situation which, if not avoided, may result
in damage to components.
Indicates information which may make product service
easier to perform.
NOTE:
Important Information.
General danger
Electric current
Moving parts
NOTE:
EC Machinery Directive:
Within terms of the EC machinery directive 2006/42/EC, the gearboxes are considered as not autonomous machine, but
as a component to install in machines.
Operation is prohibited within the area of validity of the EC directive, until it has been determined that the machine, in
which this product is installed, corresponds to the regulations within this directive.
DANGER
WARNING
CAUTION
NOTICE

7Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
3 UNIT DESIGNATION
3.1 DETAILED UNIT DESIGNATION
Motor Size
Brake
L-230V
P-24V
S-230 V
Z-24 V
00- 5 Nm
01- 10 Nm
02- 25 Nm
04- 40 Nm
05- 50 Nm
Gearbox Type
V Serie
Input Type
Housing Size
3...7
R : With Motor
Revision Number
10- 100 Nm
20- 200 Nm
30- 300 Nm
40- 400 Nm
50- 500 Nm
Stage
3 Stages
Number of Poles
V R 5 7 3 . 1K - 132S / 4 - L10
132S / 4
Pole Number
Frame Length
Output Shaft with Spline (DIN5480)
1K Standard
1L Optional
1M Optional ( Only for VR673 )

8
UNIT DESIGNATION
Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
3.2 NAMEPLATE UNIT DESIGNATION
A sample name plate for V Series
Explanations:
Type: Unit designation
Serial N: Serial number of the gearbox
M. Pos.: Mounting Position
Power: Motor Power
Ratio: Ratio of the gearbox
Oil: Type and quantity of the oil in the gearbox
Speed: Output speed of the gearbox
Drum Dia.: Diameter of the crane's drum
Falls: It is the ratio between the lifting speed and the tangential velocity of the rope at the point where it is wrapping to drum
Class: Class of the crane
Lift. Sp.: Crane's lifting speed
Brake: Brake torque
NOTE:
Nameplate unit designation is a short abbreviation from the detailed designation.
kW
Type:
Serial N.:
Power: Ratio:
VR473.1K-112M/4-L05
100348988
461.85
M. Pos.: M5
rpm.
Speed: 23
Oil: Min. VG 320 5 lt.
Drum Dia.: Falls:
200 4/1
mm
Class.: 5 ton - M5(2m) / ISO4301(FEM1.001/III)
Lift. Sp.: Brake:
3.6 50
m/min. Nm.

9Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
4 STANDARD TYPE GEARBOX PARTS LIST
4.1 V... TYPES
NOTE:
Standard V... type basic parts diagram. Parts may differ for special applications.
1
2
3
5
6
7
8
9
10
4
4
3
3
3
12
13
14
15
16
17
19
20
21 22
23 24
25
26 27
28
29
30
3
3
18
11
Standard Parts List
1Housing
2Bolt
3Plug
4 Screw Bolt
5Seal
6OutputShaft
7Key
8Washer
9Spacer
10 Bearing
11 Cover
12 Bearing
13 Gear
14 Key
15 Shaft Gear
16 Bearing
17 Washer
18 Tube
19 Bolt
20 Side Cover
Standard Parts List
21 Spacer
22 Bearing
23 Shaft Gear
24 Key
25 Gear
26 Tube
27 Bearing
28 Gear
29 Bearing
30 Spacer
Standard Parts List

10 Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
5 SAFETY
5.1 INTENDED USE
The gear reducer is designed for use in industrial machines. Please refer to our catalogue or our web page for the maximum
permitted torques and speeds. The most important maximum permitted values are indicated on the nameplate of the product.
But the whole data can be found on our product catalogues. Using the product out of the product catalogue / nameplate's per-
mitted ranges will cancel the warranty/manufacturer declaration and Dana Motion Systems Italia S.r.l. will not take any respon-
sibility.
The gear units are intended for industrial machines and may only be used in accordance with the information provided in this
manual the product catalogue and the nameplate of the gearbox. They comply with the applicable standards and regulations
and meet the requirements of the directive 2006/42/EC. The gearbox must be started up, maintained and operated according
this manual. The gearbox most be incorporated with 2006/42/EC confirming parts/machines.
5.2 IMPROPER USE
The operation of the gear reducer is prohibited if:
• It was not mounted/installed according to regulations and this manual
• The gear reducer is very soiled
• It is operated without lubricant
• It is operated out of the permitted values provided on catalogues and/or nameplate.
NOTE:
A motor connected to the gear unit is only allowed 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 speed is allowed.
The electric motor and frequency inverter must be in accordance with 2006/42/EC.
NOTE:
If the gear units input is used with variable speed gear unit, this must be informed to Dana Motion Systems Italia S.r.l.
before ordering and on the nameplate the allowed maximum and minimum speeds (speed range) will be provided. If not
mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed.
NOTE:
If the gear unit will be driven by belt / coupling / chain drive etc. the gear unit is only allowed to be used according the
nameplate/catalogue entries. Different speed, higher motor power, higher radial/axial loads etc. than nameplate/cata-
logue is not allowed.
NOTE:
The ambient temperature must be between +5 - +40 ºC and no abrasive media must attack the paint and seals. If differ-
ent working conditions this must be informed to Dana Motion Systems Italia S.r.l. before ordering.
The gearbox maintenance (oil change / check ) must be done according this manual.
NOTE:
Every usage which exceeds the limits stated above, the nameplate and catalogue of the product (especially higher
torques and speeds) is not compliant with the regulations, and thus prohibited.

SAFETY
11Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
5.3 SAFETY INSTRUCTIONS
5.3.1 GENERAL SAFETY INSTRUCTIONS
5.3.1.1 Working on the gear reducer
5.3.1.2 Operation
5.3.1.3 Maintenance
WARNING
Inappropriately executed work can lead to injury or damage.
Make sure that the gear reducer is only installed, maintained and dismantled by trained technicians.
WARNING
Foreign bodies spinning through the air can cause grave injury.
Before putting the gear reducer into operation, check that there are no foreign bodies or tools near 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 unintentional start of the machine during maintenance work can lead to serious accidents.
Make sure no one can start the machine while you are working on it.
WARNING
Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating.
Make sure that all safety devices are mounted and active.

12
SAFETY
Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
5.3.1.4 Lubricant
5.3.1.5 Ambient Conditions
WARNING
Extended, intensive contact with oils can lead to skin irritations.
Avoid extended contact with oil, and clean oil off skin thoroughly.
WARNING
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 ambient temperatures between +5 to +40ºC unless differently specified on the
nameplate. Using the gear unit out of this range can cause damage to the gear unit or environment. Over +40 ºC ambient
conditions the gear unit surface temp could be so high causing burns when touched.

SAFETY
13Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
5.4 TIGHTENING TORQUES
All screwed connections for which a tightening torque is specified, must on principle be tightened with a calibrated torque
wrench and checked. Use the following torques for the threaded bores over the gear unit housing. For connecting elements
refer to the mechanical installation part.
Table 3:
5.5 CASE OF FIRE
The gear reducer itself is not combustible. However, it usually contains a synthetic or mineral gear oil.
Please observe the 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
Bolt Size Class Tightenning Torque [Nm]
M8 8.8 23
M10 8.8 43
M12 8.8 77
M16 8.8 190
M20 8.8 370
M24 8.8 640
WARNING
-High temperature produce irritating steam.
Use a protective breathing apparatuses.
WARNING
Do not spray with water!

14 Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
6 THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MOTOR IS INSTAL-
LED
Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without
damage. Points to take into consideration before you start to install the unit;
• You have received the correct operation manual of the your product.
• The gearbox and all its parts are transported without damage.
• The gearbox is stored correctly according the instructions in this manual
• You have the latest product catalogue or you have access to our web page
6.1 TRANSPORTATION
When the goods arrive, first check for any damage. If some damage observed, immediately contact the transport company and
inform about the 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 gear unit. Ensure that the load is
slowly and carefully handled and placed.
DANGER
Use the supplied eyebolts or lifting holes for lifting up the gear unit. The eyebolts are capable to carry the weight of
gearboxes only. Do not hang additional loads. Use suitable hoisting equipment which is capable to hold the gear
units weight. Refer to the catalogue for various types weights. See drawing bellow for hoisting point.
DANGER
Do not stay beneath / under the lifting/hoisting equipment which may cause serious injuries by falling down objects, accidental
movements, unexpected accidents.
䳑

THINKS TO CHECK BEFORE THE GEAR UNIT OR GEARED MO-
15Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
6.2 STORAGE
If the geared unit or geared motor will be stored up to 3 years refer to the following instructions;
With Packing;
Use corrosion protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface. Seal
the unit in a plastic wrap and pack it in container. A moisture indicator should be placed around the container to observe the
moisture. Relative atmospheric humidity should not exceed 50%. The container should be kept under 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 between 5 to 60 ºC. The gearbox must be
kept under enclosed roof with constant temperature and constant humidity not exceeding 50%. The storage should be free of
dust and dirt and ventilated with filter. If the gearbox is stored without packing it is recommended not to store more than 2 years
and regular check during this time is recommended.
If stored in open protect against insect damage.

16 Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
7 INSTALLING THE GEAR UNIT
7.1 BEFORE YOU START
• Observe the gear unit for damages of storage or transportation. If any damage please contact Dana Motion Systems Italia
S.r.l..
• Be sure that you have all the equipment necessary for installing like; Spanners, torque wrench, shims and distance rings,
fixing devices for input and output elements, lubricant, bolt adhesive etc.
NOTE:
This manual is not for 94/9/EC (ATEX) conforming gear units. For 94/9/EC conforming 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.

INSTALLING THE GEAR UNIT
17Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
7.2 CHECK SPLINED SHAFT DIMENSIONS AND TOLERANCES
Table 4:
Type
Splined Shaft Dimensions
ee1 cc1
c2 dd1 t1
V373.1K
75 90
55 22
48
W45x2x30x21x8f
DIN5480
ø50
(h6) 28
V373.1L 50 22
43
W40x2x30x18x8f
DIN5480
ø43
(h6) 23
V473.1K
95 110
60.5 27
51,5
W50x2x30x24x8f
DIN5480
ø55
(h6) 28
V473.1L 48 16
42
W45x2x30x21x8f
DIN5480
ø48
(h6) 27
V573.1K
115 140
69 28
61
W70x3x30x22x8f
DIN5480
ø75
(h6) 35
V573.1L 56 16
51
W65x2x30x31x8f
DIN5480
ø68
(h6) 35
V673.1K
132.5 157.5
84 32
74
W95x3x30x30x8f
DIN5480
ø100
(h6) 45
V673.1L 67 17
60
W75x2x30x36x8f
DIN5480
ø78
(h6) 44
V673.1M 75 21
68
W90x2x30x44x8f
DIN5480
ø92
(h6) 45
V773.1K
160 187.5
110 35
97
W110x4x30x26x8f
DIN5480
ø115
(h6) 67
V773.1L 97 21
89
W110x2x30x54x8f
DIN5480
ø113
(h6) 67
Ød
c1
c
e1 e1
e1
ee1
e
t1
c2
Ød1

18
INSTALLING THE GEAR UNIT
Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
7.3 CHECK DRUM CONNECTION FLANGE (OPTIONAL) DIMENSIONS AND TOLER-
ANCES
Table 5:
7.4 CHECK THE AMBIENT TEMPERATURE
The ambient temperature must be between +5 ºC to +40 ºC for standard type gear units. If different contact Dana Motion Sys-
tems Italia S.r.l. for special solutions.
Type Drum Connection Flange Dimensions
V373
GN25.V37.FK
V473
GN25.V47.FK
V573
GN25.V57.FK
+0.03
+0.01
0
-0.02
+0.2
0
A
Ø115
13
M12
A
30°
60°
30°
Ø41 Ø95
R4
Ø50
18
Ø85Ø138
19
50
15 N45x2x30x21x9H
DIN5480
R5
Ø55
21
Ø95Ø158
22
55
15 N50x2x30x24x9H
DIN5480
+0.03
+0.01
0
-0.02
+0.2
0
A
Ø130
16
M14
A
30°
60°
30°
Ø46 Ø110
Ø64 Ø130
R6
Ø75
24
Ø120Ø198
30
65
15 N70x3x30x22x9H
DIN5480
+0.03
+0.01
0
-0.02
+0.2
0
A
Ø165
19
M18
A
30°
60°
30°

INSTALLING THE GEAR UNIT
19Dana IncorporatedIMM-0021EN - Installation and Maintenance Manual
7.5 CHECK THE VOLTAGE SUPPLY
The standard geared motors are supplied with 230/400 V 50/60 Hz up to 3 kW including 3 kW and 400/690 V 50/60 Hz over 3
kW and is indicated on the motors name plate unless it is differently ordered.
In case of only gear unit is supplied from Dana Motion Systems Italia S.r.l. please observe the name plate of the electric motor
and the instructions of the supplier. Check the basic electric connection diagrams below. Use experienced electric technician.
The following wiring diagram is for standard 230/400 V 50 Hz AC electric 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 6:
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 and the brake must be grounded to prevent potential differences of earth and gearbox/mo-
tor.
Pole Number
Nominal Powers at 400V, 50Hz
230V ( D ) / 400 V ( Y ) 400V ( D )
2 or 4 ≤3 kW ≥4 kW
6≤2,2 kW ≥3 kW
8≤1,5 kW ≥2,2 kW
Starting Principle Direct Direct or Y/D
I =
L2L1
U1
W2
W2
ph
U1
W1V1
L3
W1
V2U2
V2
(230V)
U2
I1
I
3
U
L1
(230V)
U =U
U
I2
V1
I3
ph
(230V)
U
L2 L3
V2
L1 L2
U1 V1
I =I
ph
U1
W2 U2
U2
W1
L3
W1
V2
W2
I1 I2
V1
(400V)
L1
U
L2
I3
U
U =
ph
3
(400V)
U
L3
(400V)
U

20
INSTALLING THE GEAR UNIT
Dana Incorporated IMM-0021EN - Installation and Maintenance Manual
Standard type brakes basic wiring diagram
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
RST
A
A
M
3
RS T N
A
M
3
SR NT
A
N
M
3
RST