DANA Brevini Posiplan PH Series Manual

®
Installation and Maintenance Manual
IMM-0005EN
May 2021
Posiplan (MT-5215-0806)

INDEX
DISCLAIMER
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 2021 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 other-
wise, without prior written approval.
THIS INFORMATION IS NOT INTENDED FOR SALE OR RESALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES.

3IMM-0005EN Posiplan (MT-5215-0806) Dana Incorporated
INDEX
INTRODUCTION: ............................................................................................................................... 5
ORGANISATION OF THIS MANUAL ............................................................................................................ 5
PURPOSE OF THIS MANUAL ...................................................................................................................... 5
WARRANTY .................................................................................................................................................. 6
GENERAL WARNINGS ................................................................................................................................. 6
COPYRIGHT AND COPYING RESTRICTIONS .............................................................................................6
REVISIONS ................................................................................................................................................... 6
TRACKING LIST ............................................................................................................................................ 6
MODELS ....................................................................................................................................................... 6
TECHNICAL DATA: ........................................................................................................................... 7
CODE DESCRIPTION ................................................................................................................................... 7
CONFIGURATIONS ...................................................................................................................................... 8
DELIVERY STATE: .............................................................................................................................9
PACKING, HANDLING, RECEIVING AND STORAGE: .................................................................... 10
PACKING ...................................................................................................................................................... 10
HANDLING .................................................................................................................................................... 10
RECEPTION .................................................................................................................................................. 12
MOVING THE UNPACKAGED GEAR UNIT .................................................................................................. 13
STORAGE ..................................................................................................................................................... 13
INSTALLATION: ................................................................................................................................. 15
GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS ............................................................. 15
ASSEMBLY WITH REACTION ARM. ....................................................................................................... 15
ASSEMBLY WITH REACTION ROD ........................................................................................................ 16
ASSEMBLY WITH COUPLING ................................................................................................................ 17
DISASSEMBLING THE COUPLING. ........................................................................................................ 18
GEAR UNIT INSTALLATION ON VARIOUS TYPES OF MACHINE SHAFT: ................................... 19
GEAR UNITS WITH “K” TYPE SHAFT .......................................................................................................... 19
MACHINE SHAFT WITH SHOULDER: ..................................................................................................... 19
MACHINE SHAFT WITH NO SHOULDER ............................................................................................... 20
GEAR UNIT WITH “S” TYPE SHAFT ............................................................................................................ 21
GEAR UNITS WITH “D” TYPE SHAFT .......................................................................................................... 22
MACHINE SHAFT WITH SHOULDER: ..................................................................................................... 22
MACHINE SHAFT WITH NO SHOULDER ............................................................................................... 23
ACCESSORY INSTALLATION INSTRUCTIONS: ............................................................................. 25
MOTOR ASSEMBLY: .................................................................................................................................... 25
“UNIVERSALE 00” VERSION: ....................................................................................................................... 25
“CENTRAL JOINT” VERSION: ...................................................................................................................... 25
ACCESSORY INSTALLATION INSTRUCTIONS: .......................................................................................... 26
LUBRICATION: .................................................................................................................................. 27
GEAR UNIT LUBRICATION .......................................................................................................................... 27
VISCOSITY .............................................................................................................................................. 27
ADDITIVES ............................................................................................................................................... 27
EXPANSION TANK ....................................................................................................................................... 28
LUBRICANT TABLE ...................................................................................................................................... 30
CHECKS: ............................................................................................................................................ 32
FIRST START-UP CHECKS .......................................................................................................................... 32
VALUES TABLE TORQUE SETTING BOLTS ........................................................................................... 32
NO-LOAD TESTS .......................................................................................................................................... 33
MAINTENANCE: ................................................................................................................................ 34
ROUTINE MAINTENANCE ............................................................................................................................ 34
OIL CHANGE ................................................................................................................................................ 34
UNSCHEDULED MAINTENANCE ................................................................................................................. 34

4
INDEX
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
SCRAP DISPOSAL: ........................................................................................................................... 35
MACHINE DEMOLITION ............................................................................................................................... 35
ECOLOGICAL INFORMATION ...................................................................................................................... 35
TROUBLESHOOTING: ...................................................................................................................... 36
CONFORMITY CERTIFICATE - UNI EN 10204 - 2.1 ....................................................................... 37
SERVICE NETWORK ......................................................................................................................... 38

5Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
INTRODUCTION:
Dana Incorporated would like to thank you for choosing one of its products and is pleased to include you among its preferred
customers. We hope you will be satisfied with your gear unit.
ORGANISATION OF THIS MANUAL
A table of contents is provided on the first page to help you find subject matter quickly and to facilitate consultation. The indi-
vidual chapters are also logically structured to help you locate the information you need.
PURPOSE OF THIS MANUAL
This manual contains all the information you need to install, operate, and maintain gear units in conformity with applicable safety
standards and legislation.
A clear understanding of the following terms is essential to understanding this manual:
DANGER ZONE:
an area within or around a machine in which the health or safety of exposed persons is at risk.
EXPOSED PERSON:
any person inside or partly inside a danger zone.
OPERATOR:
the person charged with installing, operating, adjusting, maintaining or cleaning the machine.
TRAINED ENGINEER:
a specialist designated to undertake unscheduled maintenance or repairs that require special knowledge of the machine, its
functioning, safety devices and how they work.
For any doubts or iif the manual has been damaged or lost, do not hesitate to contact theDana Incorporated technical service
department.
Essential operator safety information
Damage could be caused to machine and/or machine parts.
Important information on operation being performed
NOTE:
Useful information.
CAUTION
WARNING
NOTICE

6
WARRANTY
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
WARRANTY
Dana Incorporated warrants that its products shall be free from defects fro a period of 12 months from the date the product is
shown to have been placed in operation and in any case for a maximum period of 18 months from the date of shipment. The
warranty is null and void in the event of damage caused by improper or unsuitable use, or use other than that for which the
product is commissioned.
• Dana Incorporated's warranty is limited to the repair or replacement of the defective product, subject to Dana Incorporated's
acceptance of the defect.
• Dana Incorporated shall not be liable for any damages, either material or economic, resulting from or caused by any defects.
Dana Incorporated will only be liable for repair or replacement of the product.
• This gear unit is only intended for use in the environments and applications for which it was designed.
• All other uses are deemed improper and are forbidden.
• Modification to or replacement of parts not authorized by Dana Incorporated may lead to accident and therefore releases
the manufacturer from any civil or penal liabilities, and furthermore invalidates the warranty.
GENERAL WARNINGS
Installation personnel should be trained on the following aspects of machine safety:
• Risks of accident.
• Operator safety equipment, PPE (personal protection equipment: goggles, gloves, hard hat, etc.)
• General safety precautions and all specific standards prescribed in international directives and national legislation in the
country of installation.
• On delivery, check that the gear unit has not been damaged during transport and that all accessories are intact.
• Before starting any work, operators must be familiar with machine features and must have read this manual in full.
COPYRIGHT AND COPYING RESTRICTIONS
Dana Incorporated reserves all rights. It is prohibited to reproduce in full or in part, the structure and contents of this manual,
unless expressly authorized by Dana Incorporated. Furthermore, it is equally prohibited to save contents on any type of support
(magnetic, magnetic-optical, microfilm, photocopies, etc.).
REVISIONS
Any modifications to or replacements of functional parts of the gear unit will lead to the issue of a new revision of this manual.
TRACKING LIST
MODELS
NAME REV. DATE DESCRIPTION
Manual Posiplan 00 04/07/2012 Document issued
IMM-0005ENPosiplan (MT-5215-0806) 01 15/10/2018
- Changed layout
- Updated "TECHNICAL
DATA:(p. 7)"

7Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
TECHNICAL DATA:
Each individual gear unit is fitted with an identification plate and a manufacturer's declaration (as per Appendix IIB) drawn up in
accordance with EC Directive 392 as amended. The identification plate provides essential technical data on the functional and
constructive features of the gear unit; hence it must be visible and undamaged at all times.
1 - Type or gear unit
2 - Date of production: month/year - country of production
3 - Description
4 - Gear unit output
5 - Reduction ratio
6 - Gear unit input
7 - Info
8 - Bar code
9 - Serial number
CODE DESCRIPTION
B 3 L K 400 160 XX
B=Orthogonal
axes; P=Parallel
axes
Number of reduc-
tion steps Reduction Size Output shaft Nominal ratio IEC ratio
8
9
4
6
3
5
7
2
1

8
CONFIGURATIONS
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
CONFIGURATIONS
SYMBOL DESCRIPTION
Magnetic and oil drain plug
Oil level plug
Oil breather and filling plug
SERIE BPH
SERIE PH
B3
B6
B7
B8
V5
V6
B3
B6
B7
B8
V5
V6

9Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
DELIVERY STATE:
Gear units are externally finished with a synthetic nitro-epoxy primer al nitro “RAL 5010”, unless otherwise specified in the sales
agreement. Such protection withstands normal industrial environments, including outdoor applications. If the machine is to be
used in particularly aggressive conditions, a special paint finish will be required. External machined parts of the gear unit, such
as the ends of the hollow and non-hollow shafts, support surfaces, alignment pins, etc. are protected with a rust-inhibitor oil
(tectyl). Internal parts of the gear unit casings and drives are also protected with rust-inhibitor oil. Unless otherwise specified in
the sales agreement, all gear units are supplied unlubricated; this is clearly stated on an adhesive label attached to the gear unit.

10 Dana Incorporated IIMM-0005EN Posiplan (MT-5215-0806)
PACKING, HANDLING, RECEIVING AND STORAGE:
PACKING
• Unless otherwise agreed in the sales agreement, all Dana Incorporated products are packed with wrapping that can with-
stand normal industrial environments.
HANDLING
To move packaged gear units, use lifting equipment that is appropriate for the type of packaging and for which the capacity is
clearly indicated.
Never tilt or turn the packed gear unit upside down during transport.
Dana Incorporatedproducts are packed and shipped in crates or on pallets, depending on the specific case.
CAUTION

HANDLING
11Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
If the packed gear units are unloaded from a fork-lift truck, make sure the weight is balanced on the forks.
If necessary, drive wooden wedges under the crate or pallet to make lifting easier.
When using a hoist or any lifting system with a hook, make sure that the load is evenly balanced and securely slung and that
only approved equipment is used. When gear units are packed on pallets, make sure that the lifting equipment does not damage
the gear unit
When lifting and moving packages, avoid any violent impacts or bumps.

12
RECEPTION
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
RECEPTION
On receipt of the machine, check that it corresponds with order specifications, and that the packaging and contents have not
been damaged during transport.
It may hit the operator when the product is unloaded.
Packaging must be disposed of as follows:
• cut the straps with shears(warning: the ends may hit the operator)
• cut or pull off the wrapping.
• cut the internal strap (warning: the ends may hit the operator)
• remove the machine from the pallets.
Notify the Dana Incorporated Service Department if you find any damage, defects or missing parts, tel. ++390425594162 Fax
++390425585821.
The strap securing the product to the packaging is sharp.
CAUTION

MOVING THE UNPACKAGED GEAR UNIT
13Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
MOVING THE UNPACKAGED GEAR UNIT
Before moving it, remove the wood blocks inserted in the packing to hold it stable during shipment. Lift the machine making
sure the load remains balanced during each operation.
STORAGE
If the product is to be stored for more than two months, proceed as follows:
• Coat the shafts and alignment pins with a film of protective anticorrosion grease or oil.
• Fill the gear unit full with an appropriate oil (see section 7.4).
• Store the gear unit in a dry place at a temperature between -5°C and +30°C
• Protect the packing from dust, dirt and humidity.
Before removing the machine from its packing, make sure it is solidly attached to the lifting equipment so that it cannot slide
or flip over.
NOTE:
When stored for extended periods of more than six months, the rotating seals will deteriorate. It is recommended to
check them periodically, turning the internal gears manually and rotating the input shaft. Replace the gaskets when the
machine is eventually started up.
CAUTION

14
STORAGE
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
•Donotstack.
• Do not walk on or rest pieces on top of the package.
• Do not store any other materials inside the packing.
• Store the packing well away from pedestrian or vehicular traffic routes.
• If possible, position wooden wedges between the bottom of the packing and the floor.

15Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
INSTALLATION:
GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS
The steps listed below must be followed when installing the product:
• During installation, check that the oil, breather, level and drain plugs are in the right position. This will vary depending on the
assembly position (see section "Configurations p. 8").
• The gear unit is normally supplied with a flange for coupling the electric, hydraulic and air motors.
• The customer is responsible for installing suitable safety guards around the input and output shafts as well as couplings,
pulleys and belts etc. in accordance with applicable safety standards in the country where the machine is used.
• For gear units installed outdoors, use rust-inhibitor paint, protect the oil guard and relative sliding guides with waterrepellent
grease and provide appropriate protection against bad weather.
• It is standard practice to grease both shafts using a rustinhibitor lubricant.
• Couplings must be made using suitable equipment.
• If the coupling proves difficult, stop and check alignment and tolerance of the driven machine shaft.
The gear unit was built to be supported by the shaft as a radial or axial load, hence it should be secured to prevent rotation
using a restriction free to move in the axial plane. The gear unit must be anchored so that the small radial oscillations present
in swinging systems are possible. Elastic components, such as Belleville washers, elastic pads, shock absorbers, articulated
stay rods or similar should be used.
These are need to prevent any dangerous additional loads on the gear unit.
Appropriate safety precautions should also be foreseen to prevent damage to people or things:
• breakage of the reaction restrictor and subsequent rotation of the gear unit on the machine shaft.
• accidental breakage of the machine shaft.
• Lubricate hinges and sliding parts using a suitable lubricant.
• Do not carry out any welding work involving the gear unit, even as an earth point.
ASSEMBLY WITH REACTION ARM.
Clean and degrease all surfaces of the gear unit and reaction arm to be coupled; lubricants or paints reduce the friction coeffi-
cient, impeding the efficient operation of the application. Also check that there are no dents, welding residues, etc. In addition
to the holes to attach the reaction arm, there are also two H7 tolerance holes for calibrated journal pins (see. Fig.1).
a - 1 + 1 H7 tolerance holes for calibrated journal pins
b - 4 + 4 holes for anchor bolts with reaction arm.
NOTE:
at each stage of the installation, make sure the right type of screws and bolts are used, i.e. compatible with the relative
nuts and/or anchoring structures).
NOTE:
Dana Incorporated advises against filling its products with oil prior to installation.
Fig. 1
AB

16
GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
Fit the reaction arm (pos. 1) to the gear unit, securing it with the number of bolts 4) defined at the design stage (minimum re-
commended class 8.8). Tighten the assembly to the specified torque value shown in "Values Table Torque Setting Bolts p. 32".
Clean gear unit and machine shafts carefully (pos. 3) then lubricate them with precision. Fit the gear unit onto the machine shaft
following the steps outlined in section 6 “Gear unit installation on various types of machine shaft”. Secure the reaction arm to
the machine structure (pos. 2) and tighten using the anchor bolts (minimum recommended class 8.8) to the torque value indi-
cated in "Values Table Torque Setting Bolts p. 32" (see Fig. 2).
a - 3 - Machine shaft Seat
ASSEMBLY WITH REACTION ROD
In addition to the standard holes to attach the reaction arm, there are also 1 + 1H7 tolerance holes (pos. 5) for calibrated journal
pins when fitting gear units with reaction rod.
Take the reaction arm and align it with the mounting pin holes on the fork of the rod (pos. 4) and with hole H7 (pos. 5) on the
gear unit. Insert the calibrated journal pin and tighten it with the nut (pos. 1), leaving the rod free to rotate around the calibrated
journal pin. Insert the counternut and tighten it against the nut then tighten both the nut and counternut into each other so that
they can't come loose.
Clean the gear unit (pos. 3) and machine shafts carefully then lubricate with care.
Fit the gear unit onto the machine shaft following the steps outlined in section "GEAR UNIT INSTALLATION ON VARIOUS
TYPES OF MACHINE SHAFT: p. 19".
Fit the reaction rod with all components defined at the design stage (Belleville washers, elastic pads, etc. etc.) (pos. 4).
Secure the reaction rod to the machine structure (pos. 2) and tighten with anchor bolts (minimum recommended class 8.8) to
the torque value indicated in "Values Table Torque Setting Bolts p. 32" (see Fig. 3).
2
1
4
A

GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS
17Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
a - 3 - Machine shaft Seat
b - 1 - calibrated journal pin
ASSEMBLY WITH COUPLING
• Glean and degrease the internal surface of the gear unit and machine shafts.
• Lubricate the coupling housing (Fig.4 pto. A).
• If the coupling is new there is no need to disassemble it and grease it.
• When servicing the coupling, disassemble it and grease the zones marked “C” (see fig. 4).
• Fit the coupling in its seat on the gear unit shaft without tightening the bolts, positioning it as shown in “a” (see Fig. 4).
• If the gear unit works in the vertical plane with the relative output shaft facing downwards, make sure the joint cannot slip
off and fall; whatever the case, never tighten the bolts before fitting the shaft in its seat.
Fig. 3
Fig. 4
5
2
4
A
B
ØDC
ØDS
HS
a
S
d
A

18
GENERAL INSTRUCTIONS FOR SWINGING ANCHOR SYSTEMS
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
• Fit the gear unit on to the machine shaft or vice versa (excessive axial force shouldn't be necessary); there should be no
interference when assembling, so make sure the shaft and gear unit are properly aligned..
• Using a torque wrench, tighten all the bolts gradually working your way round them (sequentially, not switching from side to
side) until they have all been tightened to the torque value “Ma” shown in Table 1.
• Set the torque wrench to 3 - 5% above the setting given in table N° 1, then tighten the coupling bolts to the new setting.
Ma (Nm.) = bolt torque
• Set the torque wrench again to setting “Ma” shown in Table 1 then re-check the torque on the coupling bolts, taking care
not to tighten them any further. If this happens, repeat the torque sequence.
• When the coupling has been correctly fitted, visually inspect the assembly to make sure that the front surfaces of the inner
and outer rings are on the same plane (see Fig. 4 pto. S).
DISASSEMBLING THE COUPLING.
• Gradually loosen the anchor bolts, working your way round in a circle. Loosen each bolt by just a quarter of a turn to start
with to avoid bending and seizing.
• If the coupling rings don't spring apart naturally after the bolts have been unscrewed, transfer some of the bolts (two bolts
at 180° or 4 at 90°) into the internal ring extraction holes (see Fig. 5), giving them no more than one turn a time to tighten
them, alternating if there are 2 bolts and in a circle if there are 4.
GEAR UNIT DIM. A [MM] ØDC [MM] ØDS [MM] HS [MM] D [MM] MA [NM]
16 27 90 155 38 M10 70
18 27 100 170 43 M10 70
20 27 115 197 53 M12 121
23 35 130 215 53 M12 121
25 35 155 263 62 M14 193
on account of the high axial force, if the bolts are unscrewed completely in one or two turns, the two rings in the coupling may
spring violently apart, putting the operators in danger.
Fig. 5
NOTE:
We recommend you use 10.9 or 12.9 class bolts when the application is subject to strong jolts, frequent stops, changes
of direction or when 70% of the maximum permitted torque is exceeded.
CAUTION

19Dana IncorporatedIMM-0005EN Posiplan (MT-5215-0806)
GEAR UNIT INSTALLATION ON VARIOUS TYPES OF MACHINE SHAFT:
GEAR UNITS WITH “K” TYPE SHAFT
MACHINE SHAFT WITH SHOULDER:
Assembly:
align the axes of the gear unit female shaft (pos. 2) as much as possible with the machine male shaft (pos. 1), then bring the two
shafts together after aligning the connecting spline.
Slot them together without exerting too much pressure on each part.
To make sure the female gear unit shaft is tight against the machine shaft use a threaded rod (pos. 4) of an appropriate size.
Now insert the inner seeger retaining ring (pos. 5) then the backplate (pos. 3). Now when you tighten the threaded rod, the two
shafts will abut against each other (see Fig. 6).
Securing:
unscrew the threaded rod nut (pos. 4) and take it out of its seat. Replace the rod (pos. 4) with screw (pos. 6), torquing it down
fully to the torque value shown in "Values Table Torque Setting Bolts p. 32", using an intermediate threadlocker. Dana Incorpo-
rated recommends LOCTITE 601 (see Fig. 7).
Disassembly:
remove the anchor bolt (pos. 6), the backplate (pos. 3) and retaining ring (pos. 5) from their relative seats. Turn the backplate
over (pos. 3) and then return itto its seat in the gear unit female shaft(pos. 2) and secure it in positionwith the inner retaining ring
(pos. 5).
Insert 2 bolts (pos. 7) into the two threaded holes on the backplate (pos. 3) (and screw them until they touch the machine shaft
(pos. 1). Now give them alternately one full turn each (see Fig. 8).
Fig. 6
Fig. 7
12
5
3
4
3
6

20
GEAR UNITS WITH “K” TYPE SHAFT
Dana Incorporated IMM-0005EN Posiplan (MT-5215-0806)
MACHINE SHAFT WITH NO SHOULDER
Assembly:
align the axes of the gear unit female shaft (pos. 2) as much as possible with the machine male shaft (pos. 1), then bring the two
shafts together after aligning the connecting spline.
Slot them together without exerting too much pressure on each part.
To make sure the female gear unit shaft is tight against the machine shaft use a threaded rod (pos. 4) of an appropriate size.
Now insert the backplate (pos. 3) then the inner retaining ring (pos. 5) into their relative seats and tighten the threaded bar to
bring the two shafts tight against each other (see fig.9).
Securing:
unscrew the threaded rod (pos. 4) and take it out of its seat. Replace the rod (pos. 4) with screw (pos. 6), torquing it down fully
to the torque value shown in "Values Table Torque Setting Bolts p. 32", using an intermediate threadlocker. Dana Incorporated
recommends LOCTITE 601 (see Fig. 11).
Fig. 8
Fig. 9
Fig. 11
2
5
3
7
5
123
8
4
8
6