DANA BREVINI EvoMax Manual

®
Installation and Maintenance Manual
August 2022
IMM-0012EN
Helical and bevel-helical gear reducers
Brevini EvoMax™

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-0012EN - Installation and Maintenance Manual Dana Incorporated
CONTENTS
1 GENERAL INFORMATION ............................................................................................................... 7
1.1 ABOUT THIS MANUAL ......................................................................................................................... 7
1.2 VERSION TRACKING ........................................................................................................................... 7
1.3 MANUAL APPLICABILITY AND SUPPORTED MODELS ..................................................................... 7
1.4 EXPLANATION OF SYMBOLS ............................................................................................................. 8
1.5 CUSTOMER SERVICE .......................................................................................................................... 9
2 SAFETY ........................................................................................................................................... 10
2.1 PROPER USE ..................................................................................................................................... 10
2.2 GENERAL HAZARDS ......................................................................................................................... 10
2.2.1 DANGER THROUGH EXPLOSIVE ATMOSPHERES ........................................................................... 10
2.2.2 DANGER THROUGH HIGH TEMPERATURES.................................................................................... 11
2.2.3 DANGERS THROUGH ELECTRICAL ENERGY................................................................................... 11
2.2.4 DANGER THROUGH MOVING PARTS ............................................................................................... 12
2.2.5 DANGER THROUGH NOISE ............................................................................................................... 13
2.2.6 DANGER THROUGH OPERATING FLUIDS ........................................................................................ 14
2.2.7 RISKS FOR THE GEAR UNIT .............................................................................................................. 15
2.3 OPERATOR'S RESPONSIBILITY ....................................................................................................... 15
2.4 PERSONNEL REQUIREMENTS ......................................................................................................... 16
2.4.1 QUALIFICATIONS................................................................................................................................ 16
2.4.2 UNAUTHORISED PERSONS............................................................................................................... 17
2.5 PERSONAL PROTECTIVE EQUIPMENT ............................................................................................ 17
2.6 SAFETY DEVICES .............................................................................................................................. 18
2.6.1 SAFETY BARRIERS............................................................................................................................. 18
2.6.2 ADDITIONAL SAFETY EQUIPMENT FOR USE IN EXPLOSIVE AREAS .............................................. 18
2.6.3 OPERATOR'S SAFETY EQUIPMENT.................................................................................................. 19
2.7 ADDITIONAL SYMBOLS .................................................................................................................... 20
2.8 ENVIRONMENTAL PROTECTION ...................................................................................................... 20
3 TECHNICAL DATA .......................................................................................................................... 21
3.1 EX MARKING ...................................................................................................................................... 21
3.2 TYPE PLATE ....................................................................................................................................... 23
4 DESIGN AND FUNCTION ............................................................................................................... 24
4.1 ORDER DESIGNATION ...................................................................................................................... 24
4.2 BRIEF DESCRIPTION ......................................................................................................................... 26
4.2.1 GEAR CASING .................................................................................................................................... 26
4.2.2 GEAR INTERNALS .............................................................................................................................. 26
4.2.3 BEARINGS........................................................................................................................................... 26
4.2.4 OIL SEALS........................................................................................................................................... 26
4.2.5 LUBRICATION ..................................................................................................................................... 26
4.2.6 COOLING SYSTEMS........................................................................................................................... 27
4.2.7 AUXILIARY DRIVE UNITS.................................................................................................................... 27
4.2.8 ADDITIONAL ACCESSSORIES ........................................................................................................... 27
4.2.9 VERTICAL GEAR UNITS...................................................................................................................... 27
4.3 GEAR UNIT POSITION ....................................................................................................................... 28
4.3.1 MONOBLOCK HOUSING.................................................................................................................... 28
4.3.2 SPLIT HOUSING.................................................................................................................................. 29
4.4 CASING SURFACES .......................................................................................................................... 30
4.5 SHAFT LAYOUTS AND DIRECTIONS OF ROTATION ....................................................................... 30
4.6 HELICAL GEAR UNITS E2H, E3H, E4H ............................................................................................. 32
4.7 BEVEL HELICAL GEAR UNITS E3B, E4B .......................................................................................... 34
4.8 COMPACT DRIVES E3C, E4C ...R1 ................................................................................................... 36
4.9 COMPACT DRIVES E3C, E4C ...S5, T6, U3, U4 ................................................................................ 37
4.10 DISPLAYS AND CONTROLS .............................................................................................................. 38
4.11 TOOLS AND UTILITIES DESIGNED TO BE USED IN AREAS EXPOSED TO EXPLOSIVE HAZARDS 38
4.12 ACCESSORIES ................................................................................................................................... 38

4
CONTENTS
Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
5 TRANSPORT, PACKAGING AND STORAGE ................................................................................ 39
5.1 SAFETY NOTES FOR TRANSPORT ................................................................................................... 39
5.2 TRANSPORT INSPECTION ................................................................................................................ 39
5.3 PACKAGING ....................................................................................................................................... 40
5.4 SYMBOLS ON THE PACKAGING ...................................................................................................... 42
5.5 TRANSPORT ...................................................................................................................................... 44
5.5.1 SLING POINTS ON THE GEAR UNIT .................................................................................................. 44
5.5.2 NOTES ON TRANSPORTING GEAR UNITS........................................................................................ 46
5.5.3 EXAMPLE OF GEAR UNIT TRANSPORT ............................................................................................ 46
5.5.4 LIFTING ............................................................................................................................................... 50
5.6 STORAGE ........................................................................................................................................... 51
5.7 PRESERVATION ................................................................................................................................. 51
5.7.1 STATE OF PRESERVATION OF GEAR UNIT UPON DELIVERY ......................................................... 52
5.7.2 BASIC GEAR UNIT PRESERVATION .................................................................................................. 53
5.7.3 SUBSEQUENT PRESERVATION BY CUSTOMER.............................................................................. 55
5.7.4 MACHINE TRIAL WITH SUBSEQUENT PRESERVATION................................................................... 59
6 INSTALLATION AND COMMISSIONING ....................................................................................... 61
6.1 SAFETY NOTES FOR INSTALLATION AND COMMISSIONING ........................................................ 61
6.2 PREPARATIONS ................................................................................................................................. 63
6.3 ADDITIONAL ATEX REQUIREMENTS ................................................................................................63
6.4 INSTALLING THE GEAR UNIT IN ALL CATEGORY ATEX ENVIRONMENTS .................................... 64
6.5 FASTENING BOLTS ........................................................................................................................... 65
6.6 TIGHTENING TORQUE ...................................................................................................................... 66
6.7 INSTALLATION AT OPERATION SITE ............................................................................................... 67
6.8 OVERVIEW OF OUTPUT SHAFT ASSEMBLY .................................................................................... 69
6.9 ASSEMBLY OF OUTPUT SHAFT AS HOLLOW SHAFT WITH KEYWAY ........................................... 70
6.9.1 MACHINE SHAFT DIMENSIONS......................................................................................................... 71
6.9.2 FITTING THE GEAR UNIT ONTO THE MACHINE SHAFT................................................................... 75
6.9.3 REMOVING THE GEAR UNIT FROM THE MACHINE SHAFT............................................................. 79
6.10 ASSEMBLY OF OUTPUT SHAFT AS HOLLOW SHAFT WITH SHRINK DISC ................................... 81
6.10.1 MACHINE SHAFT DIMENSIONS......................................................................................................... 82
6.10.2 FITTING THE GEAR UNIT ONTO THE MACHINE SHAFT................................................................... 84
6.10.3 POSITIONING THE SHRINK DISK ON THE OUTPUT SHAFT OF THE GEARBOX (HOLLOW SHAFT) ..88
6.10.4 REMOVING THE GEAR UNIT FROM THE MACHINE SHAFT............................................................. 89
6.11 ASSEMBLY OF OUTPUT SHAFT AS FLANGED COUPLING ............................................................ 91
6.11.1 FLANGED COUPLING DIMENSIONS ................................................................................................. 91
6.11.2 ASSEMBLY OF FLANGED COUPLING WITH COMPRESSED-OIL INTERFERENCE FIT .................. 93
6.11.3 DISASSEMBLY OF FLANGED COUPLING WITH COMPRESSED-OIL INTERFERENCE FIT............. 96
6.12 ASSEMBLY OF FIN-TUBE INTEGRATED COOLER ........................................................................... 99
6.13 CONNECTING TO POWER SUPPLY ............................................................................................... 100
6.14 CORROSION PROTECTION FOR THE REMAINING BARE SURFACES ......................................... 100
6.15 CHECKS PRIOR TO COMMISSIONING (CHECKLIST) .................................................................... 101
6.16 ADDITIONAL PRE-COMMISSIONING TESTS FOR EXPLOSIVE ENVIRONMENTS (CHECKLIST) .. 102
6.17 FILLING OIL ...................................................................................................................................... 102
6.18 COMMISSIONING ............................................................................................................................ 103
6.19 CHECKS DURING GEAR UNIT TRIAL RUN IN EXPLOSIVE AREA .................................................. 103
7 OPERATION .................................................................................................................................. 104
7.1 NORMAL MODE ............................................................................................................................... 104
7.2 SHUTTING DOWN THE GEAR UNIT ................................................................................................ 104

CONTENTS
5Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
8 MAINTENANCE ............................................................................................................................ 105
8.1 SAFETY NOTES FOR MAINTENANCE ............................................................................................. 105
8.2 SPARE PARTS .................................................................................................................................. 106
8.3 HUMIDITY ......................................................................................................................................... 106
8.4 MAINTENANCE SCHEDULE ............................................................................................................ 107
8.5 OIL CHANGE SCHEDULE ................................................................................................................ 108
8.6 OIL TYPE SELECTION ..................................................................................................................... 109
8.7 GREASE ........................................................................................................................................... 109
8.8 MAINTENANCE WORK .................................................................................................................... 109
8.8.1 PREPARATION.................................................................................................................................. 109
8.8.2 REMOVING DUST ............................................................................................................................. 110
8.8.3 CHECKING OIL LEVEL...................................................................................................................... 110
8.8.4 OIL CHANGE ..................................................................................................................................... 112
8.8.5 SERVICING EXTERNAL OIL CIRCUIT............................................................................................... 113
8.8.6 CHECKING LINKING ELEMENTS ..................................................................................................... 113
8.8.7 CHECKING HEATER ELEMENTS FOR DEPOSITS........................................................................... 113
8.8.8 CHECKING FLEXIBLE TRANSMISSION ELEMENTS ON COUPLINGS ........................................... 114
8.8.9 CHECKING AND ADJUSTING BELT TENSION ................................................................................ 114
8.8.10 RELUBRICATING TACONITE SEALS AND NON-CONTACT LABYRINTH-TYPE SEALS WITH LUBRI-
CATING GREASE.................................................................................................................................................. 115
8.8.11 REPLACING COOLANT .................................................................................................................... 116
8.8.12 POST-MAINTENANCE MEASURES.................................................................................................. 116
9 FAULTS ......................................................................................................................................... 117
9.1 SAFETY NOTES FOR TROUBLESHOOTING ................................................................................... 117
9.2 FAULT INDICATORS ........................................................................................................................ 117
9.3 FAULT TABLE ................................................................................................................................... 117
9.4 TROUBLESHOOTING WORK ........................................................................................................... 120
9.4.1 REPLACING SHAFT SEALS .............................................................................................................. 120
9.4.2 REPLACING ROLLER BEARINGS ON GEAR UNITS WITH SPLIT CASINGS IN EXPLOSIVE AREAS .121
9.5 REPLACING ROLLER BEARINGS ON GEAR UNITS WITH MONOBLOC CASINGS IN EXPLOSIVE
AREAS ........................................................................................................................................................... 124
9.6 COMMISSIONING AFTER TROUBLESHOOTING ............................................................................ 124
10 DISMANTLING AND DISPOSAL .................................................................................................. 125
10.1 SAFETY NOTES FOR DISMANTLING .............................................................................................. 125
10.2 DISASSEMBLY ................................................................................................................................. 126
10.3 DISPOSAL ........................................................................................................................................ 127
11 APPENDIX ..................................................................................................................................... 128
11.1 CHECK LISTS ................................................................................................................................... 128
11.1.1 CHECKS PRIOR TO COMMISSIONING (CHECK LIST) .................................................................... 128
11.1.2 ADDITIONAL CHECKS PRIOR TO COMMISSIONING IN EXPLOSIVE AREA (CHECK LIST) ........... 129
11.1.3 CHECKS DURING GEAR UNIT TRIAL RUN (CHECK LIST) .............................................................. 129
11.2 DOCUMENTATION ........................................................................................................................... 130

6Dana Incorporated IMM-0012EN - Installation and Maintenance Manual

7Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
1 GENERAL INFORMATION
1.1 ABOUT THIS MANUAL
An indispensable part of this manual is the gear unit-specific technical specification, TS for short, in the appendix.
This manual allows safe and efficient handling of the gear unit. This manual is considered a component of the gear unit and
must be kept in the immediate vicinity of the gear unit and must be accessible to the personnel at any time.
Prior to any work, the personnel must have carefully read and understood the entire manual. For safe work, it is imperative that
all safety notes and instructions in this manual be observed.
In addition, all local work health and safety regulations and the general safety provisions for the gear unit's site of operation
apply.
Illustrations in this manual are intended to assist in general comprehension and may differ from the actual version.
This manual is for the following gear unit types:
• Brevini EvoMax™
– Helical gear reducers E2H, E3H, E4H
– Bevel helical gear reducers E3B, E4B
– Compact gear units E3C, E4C
• Brevini EvoMax™ N
• Brevini EvoMax™ D
• Brevini EvoMax™ TS
1.2 VERSION TRACKING
Table 1:
1.3 MANUAL APPLICABILITY AND SUPPORTED MODELS
Table 2:
File name Revision Date Changes description
IMM-0012EN_Rev.00 EvoMax 00 22/03/2022 - Document issued
IMM-0012EN_Rev.01 EvoMax 01 24/08/2022 - Added split housing sizes
Models
EvoMax product lines

8
GENERAL INFORMATION
Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
1.4 EXPLANATION OF SYMBOLS
Safety notes
Safety notes in this manual are indicated by symbols. The safety notes are introduced using signal words that express the haz-
ard's degree of danger.
Tips and recommendations
Special safety instructions
The following symbols are used in the safety instructions to draw attention to specific dangers:
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
This combination of symbol and signal word indicates a potential hazard that can cause slight or minor injury if not avoided.
NOTICE
This combination of symbol and signal word indicates a potential hazard that can cause property damage if not avoided.
NOTICE
This combination of symbol and signal word indicates a potential pollution hazard.
NOTE:
This symbol highlights useful tips and recommendations as well as information designed to ensure efficient and smooth
operation.
DANGER
This combination of symbol and signal word indicates an immediately-dangerous situation due to electric shock. If an instruc-
tion so marked is not heeded, severe or even fatal injuries can be the consequence.
DANGER
This combination of symbol and signal word indicates information and instructions regarding the proper use of the
gear unit in potentially explosive areas. Failure to observe such a note increases the risk of explosion and may cause
serious or fatal injury.

GENERAL INFORMATION
9Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
Additional symbols
This manual uses the following symbols to indicate instructions, effects, lists, references and other elements:
Table 3:
1.5 CUSTOMER SERVICE
In case of technical queries, please contact our customer service:
Table 4:
We are also always interested in hearing about information and experiences obtained through use and which may be of value
in improving our products.
Additional symbols Explanation
Step-by-step instructions
Effects of actions
References to sections within this manual and to other applicable documents
• Lists without specific order
Overview of alternative procedures
Address Dana Motion Systems Deutschland GmbH
Werner-Reimers-Straße 6
61352 Bad Homburg
Phone [phone]
e-mail service-pi[email protected]om
Internet www.piv-extruderdrives.com
www.dana-industrial.com

10 Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
2 SAFETY
This section provides an overview of all safety aspects important for the protection of people and for safe and fault-free oper-
ation. Additional, task-related safety notes are included in the following sections.
2.1 PROPER USE
The Brevini EvoMax™ gear unit is designed to convert speed and torque after connection to the target system and is intended
for use in explosive areas in accordance with the ATEX indication.
Proper use also includes observance of all specifications within this manual.
Any use other or beyond proper use shall be deemed improper use.
2.2 GENERAL HAZARDS
2.2.1 DANGER THROUGH EXPLOSIVE ATMOSPHERES
Incorrect site of operation
Explosion protection
DANGER
Danger through improper use!
Improper use of the Brevini EvoMax™ gear unit may result in danger.
- Operate the gear unit only within the specified limits (See "Technical data" page 21) and in accordance with the gear
unit-specific order confirmation.
- Never exceed the speed and torque specifications listed on the type plate.
- Never thermally overload the gear unit by applying excessive power.
- Never allow the roller bearings to slip through application of insufficient load.
- Never change the oil viscosity or oil type without prior consultation with DANA Motion System Deutschland GmbH.
- Never change the direction of rotation specified as permissible in the technical specifications or drawing.
- Operation in the wrong driving direction
- Operation outside specified ambient conditions
- Stepping on the gearbox or equipment
- Operation without proper lubrication
DANGER
Risk of explosion through operation at incorrect sites!
The standard version of the gear unit is not designed for operation in explosive areas. Use of a standard gear unit in
explosive areas may result in danger.
- If you plan to use a standard gear unit in an explosive area, always consult DANA Motion System Deutschland GmbH first.
- Never work on, in or in the vicinity of the gear unit in an explosive atmosphere. Observe the ATEX specifications listed on the
type plate. Observe the maximum permissible surface temperatures.
DANGER
Risk of explosion!
Introduction of ignition sources such as sparks, open lights and hot surfaces into the explosive area can cause ex-
plosions.
- Obtain a written work permit before beginning work in the explosive area.
- Never perform work in an explosive atmosphere.
- Only use tools approved for working in explosive areas.
Failure to observe these notes will eliminate the explosion protection.

SAFETY
11Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
Electrostatic charge generation through belt drives, fans, siphoning of synthetic oils
2.2.2 DANGER THROUGH HIGH TEMPERATURES
Hot surfaces
Hot gear oil
2.2.3 DANGERS THROUGH ELECTRICAL ENERGY
Connecting electrical components
DANGER
Risk of injury and explosion through static charge of moving materials!
Belt drives, running fans and siphoning or decanting synthetic oils can produce an electrostatic charge. Electrostatic
charge may cause serious injury. In explosive areas, there is a risk of explosion.
- Establish an electrically conductive connection between all parts of the casing and ensure equipotential bonding.
- Operate the gear unit in explosive areas only in accordance with the ATEX certification.
- Never work on, in or in the vicinity of the gear unit in an explosive atmosphere.
WARNING
Risk of burning through hot surfaces!
The gear unit's surface can reach high temperatures during operation. Skin contact with hot surfaces can cause severe skin
burns.
- Always wear thermally resistant safety clothing and protective gloves when working in the vicinity of hot surfaces.
- Always ensure that all surfaces have cooled to ambient temperature prior to performing any work.
- If the gear unit reaches a temperature of more than 90°C, contact DANA Motion System Deutschland GmbH immediately.
Gear unit cooling may be necessary.
WARNING
Risk of burning through hot gear oil!
The gear oil can become very hot during operation. Skin contact can result in burns. Inhaling oil vapours can cause lung dam-
age.
- Always allow the gear unit and gear oil to cool before performing any work.
- Never open covers while hot.
- Wear thermally resistant safety clothing and protective gloves.
- Wear breathing protection if there are oil vapours.
WARNING
Risk of injury when connecting electrical components!
Incorrect connection of electrical components may result in danger.
- When connecting electrical components (e.g. motor or hydraulic unit), observe the gear unit design and the intended site of
operation.
- Observe the components' electrical connection values.

12
SAFETY
Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
Faults due to short circuit
2.2.4 DANGER THROUGH MOVING PARTS
Rotating parts on the shafts
Belt drive
Pretensioned springs on thrust plate and brake
Vibrations
WARNING
Danger of injury due to faults!
Through short circuit in the electrical equipment faults in the entire system can occur. Faults can cause serious injuries.
- Connect all housing parts coupled to the local equipotential bonding busbar.
- Install an earth leakage circuit breaker to prevent ignition sparks and touch voltages if there is a fault.
WARNING
Risk of injury through rotating parts!
Input and output shafts or flanges may rotate. Contact with them can cause injury.
- A corresponding protective barrier must be installed over freely rotating gear unit parts.
- Perform work on the gear unit only when it is at a standstill and the drive unit is switched off.
- When working on the gear unit, the switched-off drive unit must be secured against switching on inadvertently.
WARNING
Risk of catching through belt drive!
There is a risk of injury through being caught and trapped by the belt drive.
- Perform work on the gear unit only when it is at a standstill and the drive unit is switched off.
- When working on the gear unit, the switched-off drive unit must be secured against switching on inadvertently.
- Observe the separate instructions issued by the belt's manufacturer.
WARNING
Risk of injury through springs under tension!
Pretensioned springs on the thrust plate and brake can cause serious injury.
- Relieve all spring tension before performing any work on the thrust plate or brake.
WARNING
Risk of injury through heavy vibration!
Heavy vibrations can lead to serious injury and chronic impairments to health over the long term. The source of vibrations must
be mechanically isolated from its environs by means of vibration dampers.
- Never disable the vibration dampers.
- Keep out of the vibrating area during operation.

SAFETY
13Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
High weight
Torsional moment
Sharp edges and pointed corners
Risk of slipping on slippery surfaces
2.2.5 DANGER THROUGH NOISE
Noise generated by gear units or fans
WARNING
Risk of crushing through high weight!
Due to its high weight, moving the gear unit can result in serious or even fatal injury.
- Use suitable lifting equipment with sufficient load capacity. See "Transport, packaging and storage" page 39.
- Always secure the gear unit before releasing any connections.
WARNING
Risk of injury through torsional momenta!
Tension within the system can produce torsional momenta in the shaft connections. When disconnecting the shafts, the tor-
sional momenta can cause injury and damage.
- Before beginning any work, relieve the system tension at suitable points.
WARNING
Danger of injury posed by sharp edges and pointed corners!
Sharp edges and pointed corners may cause skin grazes and cuts.
- Proceed with caution when working in the vicinity of sharp edges and pointed corners.
- If in doubt, wear safety gloves.
WARNING
Risk of slipping on slippery surfaces!
Soiling can make smooth surfaces slippery.
- Always remove any soiling immediately.
- Collect any oil that may have been spilled during this process immediately and dispose of it in an environmentally sound
manner.
- Wear non-slip safety shoes.
- Set up warning signs if necessary.
WARNING
Risk of injury through noise!
The noise level produced at the site of operation can cause serious damage to your hearing.
- Always wear hearing protection when working with loud gear units and systems.
- Only remain on the gear unit's site of operation for as long as necessary.
- The standard DIN EN ISO 11690 “Acoustics recommended practice for the design of low-noise workplaces containing ma-
chinery” must be observed.

14
SAFETY
Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
2.2.6 DANGER THROUGH OPERATING FLUIDS
Lubricants, gear oils, preservatives
Pressurised gases and liquids in the lubricant system
Bacteria in the coolant
WARNING
Danger to health through lubricants!
Contact with operating fluids can cause allergic reactions and skin irritation.
- Always wear protective gloves and safety goggles when handling operating fluids.
- Do not swallow, do not inhale vapours.
- In the event of inadvertent eye contact, rinse out the operating fluid with copious amounts of water and seek medical atten-
tion if necessary.
- In the event of skin contact, rinse off with copious amounts of water and soap.
- Observe the safety data sheets issued by the operating fluid's manufacturer.
WARNING
Lethal danger through hydraulic energies!
The lubricant system contains gases and liquids under pressure. This may cause serious injury.
- Before beginning any work on the lubricant system, relieve the system pressure completely. Fully depressurise the pressure
reservoir.
WARNING
Danger to health through bacteria in the coolant!
Bacteria can propagate in the coolant that may be detrimental to health in the event of skin contact, swallowing or inhaling.
- Replace coolant regularly.
- If there is a risk of skin contact, swallowing or inhaling, wear personal protective equipment:
- Protective work clothing
- Protective gloves
- Light breathing protection
- Safety goggles

SAFETY
15Dana IncorporatedIMM-0012EN - Installation and Maintenance Manual
2.2.7 RISKS FOR THE GEAR UNIT
Improper handling
Loss of oil
2.3 OPERATOR'S RESPONSIBILITY
Operator
The operator is that entity who runs the gear unit for commercial pur-poses or entrusts the gear unit to third parties for use and
who is le-gally responsible for the product during operation, including responsi-bility for the protection of the user, personnel
and third parties.
Operator's duties
The gear unit is used commercially. The operator is therefore subject to the legal provisions governing work health and safety.
In addition to the safety notes in this manual, the safety, work health and safety and environmental protection regulations ap-
plicable for the site of operation must be observed.
The following applies in particular:
• The operator is under obligation to obtain information on the applicable work health and safety regulations and to draft a
hazard assessment determining any additional risks resulting from the specific work conditions at the gear unit's site of op-
eration. The operator is obliged to implement this in the form of operating instructions for the operation of the gear unit.
• The operator needs to check constantly throughout the period of operation of the gear unit whether the operating instruc-
tions drafted correspond to the latest version of the regulations and, if necessary, must amend the instructions.
• The operator must clearly define and specify responsibilities regarding installation, operation, fault remedy, maintenance
and cleaning.
• The operator must ensure that all persons handling the gear unit have read and understood this manual. In addition, the
operator must regularly train the personnel (see appendix for instruction protocol) and inform them of the risks.
• The operator must supply the personnel with the required protective equipment and obligate the personnel to wear it.
The operator is further responsible for ensuring that the gear unit is always in technically flawless condition. The following there-
fore ap-plies:
• The operator must ensure that the maintenance intervals specified in this manual are observed.
• The operator must regularly check all safety equipment for correct operation and completeness.
DANGER
Risk of damage through improper handling of the gear unit!
Improper handling can cause the gear unit to overheat. The gear unit's leak tightness cannot be guaranteed if it is
overloaded.
- Avoid improper handling.
- Observe the specifications and information listed on the type plate.
- Only run a connected drive motor with a frequency converter if the specifications on the gear unit's type plate and the tech-
nical specifications in the order confirmation are observed.
- Do not perform any welding work on the gear unit.
- Do not use the gear unit as an earth point for welding work. Toothing and bearings may suffer irreversible damage through
fusing.
NOTICE
Gear unit damage due to lack of oil!
Insufficient oil supply can result in the gear unit overheating, thus causing damage.
- Check the oil supply regularly. See "Oil change schedule" page 108.
- If you notice a loss of oil, immediately stop the gear unit. Further operation is permissible only after examination of the fault
cause. Consult DANA Motion System Deutschland GmbH immediately. For contact details, see "Customer service" page 9.

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SAFETY
Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
2.4 PERSONNEL REQUIREMENTS
2.4.1 QUALIFICATIONS
The various tasks described in this manual demand a varying degree of qualification of the persons appointed to perform the
tasks.
Only such persons are permitted to perform any work that can be expected to perform the respective work reliably. Persons
with impaired reactions, e.g. due to intoxication by drugs, alcohol or medica-tion, are not permitted.
This manual lists the following qualifications for the persons appointed to perform the various tasks:
Electrically skilled person with additional explosion protection qualifications
Electrically skilled persons with additional explosion protection qualifi-cation are specifically trained for the tasks they are to
perform and knows the relevant standards and regulations.
Due to their technical training and their experience, electrically skilled persons with additional explosion protection qualification
can perform work on electrical systems and can identify and avoid potential risks.
Specialist for explosive areas
Specialists for explosive areas, due to their technical training, skills and experience as well as their knowledge of the applicable
standards and regulations, are able to perform work on systems or components in explosive areas. Specialists for explosive
areas are able to identify and avoid potential risks.
In addition, specialists for explosive areas are qualified to perform typical work on gear units such as aligning the shaft.
Service personnel
The following work may be performed by the customer's qualified personnel:
• Oil change (caution: risk of scalding – observe the separate chapter in this manual!)
• Temperature measurements
• Visual inspection through oil sight glass. Check gear wheels, shafts and bearings visually
• Filter change on external oil-coolant-lubricant system (observe the operating manual issued by the oil-coolant-lubricant sys-
tem's manufacturer)
• Replacement of the elastic segments if a corresponding coupling is used (observe the operating manual issued by the cou-
pling's manufacturer)
• Regreasing the couplings if a corresponding coupling is used (observe the operating manual issued by the coupling's man-
ufacturer)
• Vibration measurements
• Frequency analyses
• Regreasing of taconite labyrinth shaft seals
• Replacement of brake shoes (observe operating manual issued by brake shoes' manufacturer)
• Take an oil sample and send to PIV for an oil analysis
• For spare parts, repair or any other requests always have the type and serial number available and as well a detailed failure
description
Dana Motion Systems Deutschland GmbH service personnel
Other work may be performed only by Dana Motion Systems Deutschland GmbH specialist personnel. Other personnel is not
permitted to perform such work. To have the necessary work performed, contact Dana Motion Systems Deutschland GmbH
customer service, see "Customer service" page 9.
DANGER
Danger through insufficiently qualified personnel!
Insufficiently qualified personnel are unable to correctly assess the risks of handling the gear unit and risk causing
serious or fatal injury to themselves or other persons or ignition sources.
- Only allow specifically qualified persons to perform any work.
- Keep insufficiently qualified persons out of the work area.
- Cease all work while unauthorised persons remain in the danger zone and work area.

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2.4.2 UNAUTHORISED PERSONS
Instruction
The operator must instruct the personnel regularly. For ease of verifi-cation, the instruction protocol (see appendix) must be
filled in com-pletely and kept on record.
2.5 PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment is designed to keep people safe and protect them from health hazards during work.
When working with or on the gear unit, the personnel must wear the personal protective equipment indicated in the individual
sections of this manual.
Description of the personal protective equipment
The personal protective equipment is explained below:
Table 5:
WARNING
Risk to life for unauthorised persons due to hazards in the danger and working zone!
Unauthorised persons who do not meet the requirements described here will not be familiar with the dangers in the working
zone. Therefore, unauthorised persons face the risk of serious injury or death.
- Unauthorised persons must be kept away from the danger and working zone.
- If in doubt, address the persons in question and ask them to leave the danger and working zone.
- Cease work while unauthorised persons are in the danger and working zone.
Protective work clothing
Protective work clothing is tight-fitting work clothing with low re-sistance to tearing, with tight sleeves, and without
projecting parts.
Protective suits protect against dusts during cleaning operations.
Breathing protection
Breathing protection protects from hazardous dusts and oil mists.
Hearing protection
Hearing protection protects your hearing from damage through noise.
Industrial hard hat
Industrial hard hats protect the head from falling objects, swinging loads and impacts on stationary objects.
Safety goggles
Safety goggles protect your eyes from flying debris and fluid sprays.

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2.6 SAFETY DEVICES
2.6.1 SAFETY BARRIERS
Protection covers for rotating shaft ends and fans
Safety barriers prevent moving parts from being touched.
2.6.2 ADDITIONAL SAFETY EQUIPMENT FOR USE IN EXPLOSIVE AREAS
Resistance thermometer
Monitors the gear oil's temperature.
Earth connection point
Establish potential equalisation.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, aggressive chemicals, as
well as from contact with hot surfaces.
Safety footwear
Safety footwear protects the feet from crushing injuries, falling parts and slipping on a slippery substrate.
DANGER
Danger to life from nonfunctional safety devices!
If safety devices are not functioning or are disabled, there is a danger of serious injury or death or causing an ignition
source.
- Check that all safety devices are fully functional and correctly installed before starting work.
- Never disable or bypass safety devices.
- Ensure that all safety devices are always accessible.
NOTE:
Observe the operating manuals of additionally purchased parts.
DANGER
The proper use of the equipment in potentially explosive atmospheres requires the compliance with the Directive
2014/34/EU and its standards as well with the relevant national regulations.
In particular we refer to Chapter 1 Article 1 (1) b) of the said Directive. The adequate connection and the adequate
processing of the electrical signals of the sensors (e.g. via controlling devices and regulating devices) are essential elements
of the safety concept.
DANGER
Exceeding specified limits can cause an ignition source. Shutdown gearbox if it reaches these limits.
For limits see "EX marking" page 21.
DANGER
Insufficient earthing can cause ignition sources.

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Thermosensor
Monitors the gear oil's temperature.
Float-switch oil level monitor
Monitors the gear unit's oil level and switches off the drive unit in the event of an impermissible oil level drop in the gear unit.
Flow switch
Monitors the oil flow.
Pressure switch
Monitors the oil pressure.
Heating
Oil filter contamination indicator
Indicates the oil filter's contamination level.
Vibration sensor
Transmits generation of vibration to a monitor point.
2.6.3 OPERATOR'S SAFETY EQUIPMENT
If required, the operator must retrofit the following safety
•equipment:
• Emergency-off concept for the entire system in which the gear unit is installed
• Potential equalisation and residual-current device
• Safety equipment for moving parts such as the input and output shaft
• Safety equipment for shutting down the electrical power supply, protecting against inadvertent reactivation and prevention
of uncontrolled/unintended operating states
DANGER
Exceeding specified limits can cause an ignition source. Shutdown gearbox if it reaches these limits.
For limits see "EX marking" page 21.
DANGER
Sensor used at category 2 = zone 1 / 21
Low oil level can cause an ignition source shut down gearbox when it reaches limit specified for operation.
DANGER
Flow switch + Pressure switch
These are used if pump and overpressure valve are present
Circulation through overpressure valve and / or too small amount of oil flowing through pump can cause ignition
sources by overheating (see "Normal mode" page 104).
DANGER
Heating may be needed to reach specified viscosities. Too high viscosity can cuase excessive heat and thus an ig-
niton source.

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Dana Incorporated IMM-0012EN - Installation and Maintenance Manual
2.7 ADDITIONAL SYMBOLS
The following symbols and instruction signs are affixed in the work area. These symbols and instruction signs refer to the im-
mediate vi-cinity in which they are affixed.
2.8 ENVIRONMENTAL PROTECTION
The following environmentally hazardous substances are employed:
Gear oil
Gear oil may contain toxic substances. These must not enter the envi-ronment. Disposal must be handled by a disposal spe-
cialist.
Cooling lubricant and filters
Cooling lubricant and the filters used in cooling lubricant systems may contain toxic substances. These must not enter the en-
vironment. Dis-posal must be handled by a disposal specialist.
Corrosion protection
Corrosion protection can contain toxic substances. These substances should not get into the environment. Disposal must be
carried out by a specialised disposal company.
Paper on the shaft ends
The paper protecting the shaft ends and the blank function surface contains corrosion protection. Corrosion protection may
contain toxic substances. These must not enter the environment. Disposal must be handled by a disposal specialist.
Electrical and electronic components
Electrical and electronic components can be installed in attachment parts. Electrical and electronic components can contain
toxic materials. The-se components must be collected separately and taken to municipal collection points or disposed of by a
specialised company. These components include light bulbs, capacitors that contain PCB, components that contain mercury,
printed circuit boards, fluid crystal displays, batteries, external electrical lines and electrolytic capacitors.
DANGER
Danger due to illegible signage!
Over time, stickers and signs can get dirty or in some other manner become illegible, so that dangers cannot be rec-
ognized and necessary operating instructions cannot be followed. Thus an injury hazard occurs.
- Keep all safety, warning, and operating instructions that are affixed to the device in legible condition.
- Replace damaged signs or stickers immediately.
The correct direction of rotation is indicated by
an arrow.
The earth connection points are marked.
NOTICE
Danger of pollution through incorrect handling of environmentally hazardous substances!
Incorrectly handled environmentally hazardous substances may seriously damage the environment, particularly if disposed of
incorrectly.
- Always observe the notes below on handling environmentally hazardous substances and their disposal.
- If environmentally hazardous substances enter the environment by accident, immediately take appropriate measures. If in
doubt, notify the local authorities responsible of the damage and enquire as to suitable measures.