Manual of

Installation, Maintenance and

Storage of
Planetary Gear Reducers

PAGE 1 / 35
Brevini Latin American Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
1. INTRODUCTION
1.1. Manual Consultation
[Link] Standards
[Link] Observations
1.4 Revisions
2. TECHNICAL DATA
[Link] of the acronym
[Link] Position
3. SUPPLY CONDITIONS
4. PACKAGING, HANDLING, RECEIVING AND STORAGE
[Link]
[Link]
[Link]
[Link] of the reducer without packaging
[Link]
5. INSTALLATION
[Link] Standards
[Link] standards for flange-mounted reducers
[Link] standards for reducers with feet
[Link] standards for pendulum reducers
[Link] of the reaction arm on the reducer
5.4.2. Installation of the reducer with FS type output shaft
[Link] of the contraction disc of the reducer
[Link] of the reducer with FP type output shaft
5.4.5. Disassembly of the reducer with output shaft FP
[Link] of the "RPR" reducer
[Link] standards for accessories
5.5.1. Assembling the Engine
5.5.2. Assembly of Accessories
6. START OF BRAKE OPERATION
[Link] multi-disc brake
[Link] brake
[Link] brake
7. LUBRICATION
[Link] of gear reducers
7.2. Lubrication of multi-disc brakes
7.2.1. Filling and level
[Link] of grease
7.4 Tabela de lubrificantes
7.5. Expansion tank

PAGE 2 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
8. CONTROLS
[Link] for starting operation
[Link] sem carga
9. MAINTENANCE

[Link] ASSISTANCE

[Link]
Brevini Latino Americana thanks you for the trust placed in its products and hopes that the
the use of the reducer should be a source of satisfaction for its customers.

1.1. CONSULTATION OF THE MANUAL

The consultation of this manual provides users of the reducers with the necessary information.
for the correct installation, use, storage, and maintenance of them, respecting the
safety limits dictated by current regulations.
For a better understanding of this manual, we indicate below the terms used in
even
DANGEROUS AREA: Area close to a machine where the presence of an exposed person
constitutes a risk to its safety and health.
EXPOSED PERSON: Any person who is completely or partially in a zone
dangerous.
OPERATOR: Person responsible for installing, operating, regulating, and performing maintenance.
normal and cleaning of the reducer.

QUALIFIED TECHNICIAN: Specialized person designated to perform operations of

extraordinary maintenance or repairs that require special knowledge of
equipment, its operation, safety, and modes of intervention.
ATTENTION: Safety rules for the operator.
NOTES: There is a possibility of causing damage to the reducer and/or its components.
CAUTION: Additional information regarding the ongoing operation.
NOTE: Useful information.

[Link] TERMS
Brevini Latino Americana guarantees its Standard products for a period of 12 months from
delivery date or 6 months of operation limited to a maximum of 8 hours per day,
prevailing whatever occurs first.
The warranty is invalid if the problem arises from incorrect applications and not
suitable for the product if it is not put into operation within a maximum period of 6
months after delivery.

PAGE 3 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] OBSERVATIONS
It is advisable that all personnel be informed about the following arguments inherent to
safety during the use of the equipment.
Risk of accidents
Use of P.P.E. (Personal Protective Equipment).
General accident prevention rules provided by the directives and legislation of the country where it is.
he/she will install the equipment.

At the time of delivery, ensure that the reducer has not been damaged during the
transport and that all possible accessories are found.
-The operator, before starting work, should know the characteristics of the reducer and
must have read this manual completely.
The reducer must be used in an appropriate environment and for applications consistent with
as planned during the project.
The possible modifications or replacements of the reducer parts not authorized by the
Brevini Latino Americana can pose a danger to safety and exempts the manufacturer from
all civil and criminal responsibility, thus not enforcing its guarantee.

1.4 REVISIONS
No part of this manual may be reproduced by any means
employees, without the written permission of Brevini.

PAGE 4 / 35
Brevini Latin American Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brazil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
2. TECHNICAL DATA
Each reducer contains an identification plate and a statement from the manufacturer, as per
figure below.
The plaque contains the main technical information regarding the characteristics of
operation and constructs of the reducer, therefore it must be kept intact and visible.
Å Reduction relationship
Ç Serial number
É Type of reducer/type of output
Ñ Manufacturing date
Typeas an appetizer
Ü Weight of the reducer

[Link] of the acronym

ED 2090 Mister 20 FL350 B3

Family Size Exit Reduction Entry Form

Redutor Redutor Redutor Redutor Redutor Construtiva

PAGE 5 / 35
Brevini Latin America Ind. and Com. Ltd.
Avenue Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] Position
Horizontal Position Vertical Position

Drain Oil Level Relief / Filling Valve

Horizontal Position Vertical Position

PAGE 6 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 PAGE 7 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
3. SUPPLY CONDITIONS
The reducers are externally painted with blue synthetic epoxy base (RAL 5010), except for
pre-established agreements in contract. The protection is designed to withstand environments
normal industrial, including external ones, and allows for the application of other synthetic paints. In
specialized equipment in aggressive environmental conditions is required.
special paints.
As partes usinadas externas do redutor, como os externos dos eixos (macho/fêmea/oco),
supporting plans, centering diameters, etc., are protected with anti-corrosive oil (Tectyl).
The internal parts of the housing of the reducers and the kinematics are also protected with
antioxidant oil.
All reducers, except for different contractual agreements, are supplied without lubricant.
as indicated on the adhesive label attached to the reducer to highlight such procedure.

PAGE 8 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
4. PACKAGING, MOVEMENT, RECEIPT AND STORAGE
The reducers are shipped properly packaged and require care from the customer.
during handling. The handling of the unit is determined according to its capacity.
client, however, the necessary precautions must be taken when determining the
points for lifting the reducer in order to avoid damage. Although certain reducers
cylindrical surfaces should not be rolled or dragged on the ground because
this procedure may damage the plugs.

All handling must be carried out by experienced personnel always using

devices specifically designed for lifting loads, such as hoists, while observing the rules
recommended basic safety measures for operations of this nature. The components do not
they may not experience falls or impacts under any circumstances.

[Link]

ATTENTION: Brevini products are packaged and

shipped in boxes or on pallets.
All Brevini products, except for contractual agreements.
pre-established, are delivered in packaging
suitable for resisting industrial environments
normal.

[Link]
NOTE: The weight indicated on the identification plate does not take into account the accessories: brakes, flanges.
of the motor, wheel flanges, etc., therefore to know the total weight of the reducer along with the
accessories, consider an indicative extra weight of around 40 Kg for entry-level accessories,
for output accessories, a value of around 8% can be considered approximately of
weight of the reducer, always in relation to its size.

PAGE 9 / 35
Brevini Latin America Ind. and Com. Ltda
Avenue Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 For the handling of loads, use devices for
elevations adapted for the type of packaging and for the
adequate capacity indicated therein.

Do not tilt or turn upside down during the

elevation and transportation.

If the packaging is unloaded by forklift,

make sure the weight is balanced on the forks

If necessary, use wooden trays underneath the

packaging to facilitate lifting.

PAGE 10 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 If the packages are unloaded with a winch or
Talha to ensure that the load is balanced and to use
legally certified lifting accessories.
For packages transported on pallets, make sure that
the lifting accessories do not damage the reducer.

While lifting and positioning the packaging,

avoid violent impacts and falls.

4.3. Receipt

Upon receiving the reducer, ensure that the material is

corresponding to what is specified in the order. Also check
if the packaging and its contents have not been damaged
during transport.

Page 11 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 ATTENTION: The straps that secure the product on the
packaging is under tension, which may affect the operator
while the product is being unloaded.

The packaging should be opened as follows:

- cut the straps (warning: the ends may hit the operator).
Remove the screws (hexagonal head) from the outer packaging.
cut the internal tapes (caution: the ends may hit the operator).
remove the reducer from the pallet.
If the machine is damaged or has any missing parts, report it immediately.
to Brevini Latin America. Tel.: +19 452 9280 Fax.: +19 452 6627 e-mail:
brevini@[Link]

[Link] of the reducer without packaging

Attention before removing the reducer from the packaging, make sure to
make sure it is properly connected to the accessories
of lifting and that they do not come loose or
slip. Before moving the reducer, remove the
wooden blocks used to maintain stability of the
packaging during shipping.
Lift o reducer ensuring to maintain o
load balancing during operations

PAGE 12 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link]
If the product needs to be stored for a period longer than 2
months, the following must be done:
protect the shafts and centering diameters with grease or oil
anticorrosive
fill the reducer and the brake when existing, with suitable oil
see Chapter 7.
store the reducer in a well-ventilated area and at a temperature between
–5ºC a 40ºC
protect the packaging from dirt, moisture, and dust.

NOTE: If the storage extends beyond 6 months, the retainers may lose the
efficiency. A periodic check is recommended, running the internal gears through
input shaft. In the presence of negative friction brake, release the brake using a pump
hydraulic or similar (for opening pressure see item 8.1). It is recommended to replace the
entry seals when the reducer is put into operation.

Do not stack
Do not walk or place items on the packaging

Do not keep any other material inside the packaging

PAGE 13 / 35
Brevini Latin America Ind. and Com. Ltd.
Avenue Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 Keep the packaging away from moving areas.

It is advised to support the sets on wooden crossbars.

preventing any contact with the ground.

5. INSTALLATION
[Link] Standards
The installation of the reducer must be carried out with care and attention to the following points:
In the installation of the reducer, control the oil plugs, relief valve, and drain plug.
be in the correct position, which varies depending on the mounting position (see
item 2.2 - Mounting positions.
-If the reducer has a lamellar brake, control oil plugs, relief valve and plug.
the brake drain should be in the correct position, (see item 2.2 - Mounting positions).
The brakes in general should be timely connected to the specific circuits of
command and in the presence of hydraulic command brakes, these must be subjected to
to the "bleeding" operation as a hydraulic circuit.
When installing RPR or MDU series reducers, pay close attention not to
damage the possible grease tubes or those for oil drainage from the reducer
installed next to the reducer support), and orient them so that the
the grease gun and the occasional oil expansion tank should be easily accessible.
installation foresees protection for pipes and vessels.
The reducer is usually supplied with a flange for electric or hydraulic motor.
tire.
It is the customer's duty to install their own protections for the input and output shafts, thus
such as couplings, pulleys, belts, etc., according to the current safety standards in
country of use.

PAGE 14 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 For reducers installed in outdoor environments, use anti-corrosive paint, protect the
retainers and their tracks with water-repellent grease and properly protect the
same as the weather conditions.

NOTE: Brevini advises the application of oil on its products when they are
are installed.

5.2 Installation standards for flange-mounted reducers

They must be mounted on perfectly flat surfaces with precise and orthogonal machining.
regarding the driven axle. The mounting holes must be machined with tolerance
corresponding to the existing diameters in the reducer. In reducers with two diameters
It is important that both are used for assembly to ensure alignment.
correct. These recommendations are particularly important for installations subjected to
a cycle of severe work, or when there are high loads acting on the axis of
reducer output.
The mounting surfaces must be free of dust, grease, and protective coating, if
exist, from the mounting flange of the reducer. The reducers must be secured with screws with
adequate sizes and quality (minimum recommended class 8.8). The screws must be
carefully tightened according to specific value using torque wrench and table of
torques existing in item 8.1.

NOTE: For severe applications where there are intense shocks, frequent starts, reversals
in the sense of rotation, or when high radial loads are reached or when 70% of the torque is achieved
maximum allowable, it is recommended to use class 12.9 screws along with use
of elastic pins.
NOTE: In the case of orthogonal reducers with a male shaft at the input, it may occur in the
installation where the input shaft is misaligned with its ideal position. For
to resolve this situation, it is advisable:
in the case of using elastic couplings, check if the existing misalignment is compatible
with the acceptable alignment capacity of the elastic coupling.
if there is elastic coupling change the position of the motor

[Link] standards for reducers with feet

They must be installed on flat and rigid bases to avoid undue stress on the support afterwards.
the tightening of the fastening screws. In cases where the support surface is made of concrete, brick,
tile, etc., a steel plate must be installed between the reducer and the base. It is recommended that the
use of minimum class 8.8 screws with tightening as per item 8.1. Resulting vibrations from
Misalignments will significantly reduce the lifespan of the reducers.

PAGE.15 / 35
Brevini Latin American Ind. and Trade Ltda
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] standards for swinging reducers
It is necessary to ensure that the reaction arm has a small degree of freedom of movement.
(inside-outside, up-down), but without rotating. This fixation is suitable for drive shafts.
which can bend downwards, axes subject to axial stretching and axes that can
need to vary its axial position during operation. The position of the reaction arm
It should induce the minimum possible tension on the reducer and output shaft.
Special attention is required during the installation of this unit, so please follow the
instructions described below:

[Link] of the reaction arm on the reducer

Observe that the guide diameter of the reducer and the reaction arm are clean and that there is no
dents, brush strokes, varnish, etc.
Lubricate the couplings and insert the reaction arm into the guide diameter of the reducer.
Fix the reaction arm using screws of at least class 8.8.
- For severe applications where there are intense shocks, frequent starts, reversals in
sense of rotation, or high radial loads, or when 70% of maximum torque is reached
acceptable, it is recommended to use class 12.9 screws.
Check that the armature anchoring system does not block the reducer, but the
possibility of moving freely in space in order to absorb movements
transmitted by the axis.
- To fix the reducer, apply the torque values according to Item 8.1, ensuring that
the applied torque is compatible with the structure and fastening elements used.

[Link] of the reducer with FS type output shaft.

NOTE: The contraction discs are supplied ready for installation, so do not
They must be disassembled before the initial installation.
Tighten slightly three contraction disk screws arranged at 120º, but make sure that
the inner ring can still be rotated manually (excessive tightening can deform the
internal panel)
Insert the contraction disk on the reducer axis whose external surface should have been
previously lubricated.
Degrease the internal surface of the reducer shaft and the machine shaft.
Insert the reducer onto the machine shaft or vice versa (excessive axial force is not required).
Position the contraction disc so that its center line aligns with the center of
useful length of the machine axis (see fig. 1; for this operation).
Observe the dimension "a" that will vary according to the size of the contraction disk,
as indicated in Table 1.

PAGE 16 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
Use a torque wrench and gradually tighten all the disc screws in one direction
circular (not diametrically opposite) until all screws reach the torque value
as indicated in the table 1.
Check that the 2 rings are concentric and parallel, observing that the maximum error of
parallelism is between 0.25% and 0.35% of the outer diameter of the contraction disc
NOTE: Excessive tightening can permanently deform the inner ring, so please be cautious.
the torque indicated in table 1.

[Link] of the contraction disk of the reducer.

Gradually loosen the fastening screws in a circular manner. Initially each
the screw should be loosened only a quarter turn to prevent tilting and jamming
fastening elements.
Remove the reducer from the machine shaft. For certain sizes of reducer, there is a hole.
in its axis through which it is possible to pump oil at low pressure to obtain a
gradual removal. Remove the contraction disk from the reducer shaft.
All reducers must be carefully aligned with the motor and the driven machine.
even in cases where there are flexible couplings on the input and/or output shaft, or when
coupling is not used as in the case of female extruded output shaft. Use
appropriate tools for assembly and adjustment of couplings, pinions, or pulleys in
axles and avoid shocks or axial loads during installations. Make sure there is no
gaps between the motor and the reducer. The adaptations for the motor, as well as the output shafts of the
reducers in the extracted female version do not support axial or radial loads.

TABLE 1

Type Dimensions Screws

Disco [Link]. dxD H2 n Type Ma a
SD 62 M 50 62 x 110 29 10 M6 x 25 12 23
SD 100 M 75 100 x 170 43 12 M8 x 35 29 31
SD 125 M 90 125 x 215 52 12 M10 x 40 58 47
SD 140 M 100 140 x 230 58 10 M12 x 45 100 47
SD 165 M 120 165 x 290 68 8 M12 x 55 240 40
SD 175 M 130 175 x 300 68 8 M16 x 55 240 46
SD 185 M 140 185 x 330 85 10 M16 x 65 240 46
SD 185 H 140 185 x 330 112 15 M16 x 80 250 46
SD 220 H 165 220 x 370 134 20 M16 x 90 250 70
SD 240 H 180 240 x 405 144 15 M16 x 100 490 75
SD 280 H 220 280 x 460 172 20 M20 x 120 490 90
SD 340 H 260 340 x 570 200 20 M20 x 120 820 103
SD 390 H 300 390 x 660 212 24 M24 x 140 820 120
Ma = Tightening torque in N.m.

PAGE 17 / 35
Brevini Latino Americana Ind. and Com. Ltda
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] of reducer with FP type output shaft
Insert the retaining ring (pos.1), optional assembly (fig next to it).
insert the o-rings into their respective housings.
properly greased (pos.2 and 3) of the cover (pos.4).
Insert the cover (pos.4) onto the machine shaft.
insert the retaining ring (pos.5) and the key (pos.6) into their
respective accommodations in the machine axis.
mount the reaction arm (pos.7) on the reducer
lubricate both: the machine shaft and the hollow shaft of the reducer
mount the reducer on the machine axis (operation that must be
carried out without much effort).
-fit the lid (pos.4) and secure it to the reducer using the
sealing screws/washers (pos.8) (supplied accessories),
torqueing the screws in a circular direction (not towards)
opposite diameter). Assemble these screws with lock.
medium torque chemistry. Torque values see table 3 of item 8.1 (strength class 8.8).
install the other plugs with their respective sealing washers (pos.9)

5.4.5. Dismantling of reducer with FP type output shaft

remove the fixing screws of the reducer (pos.8)
Remove the plugs (pos.9), insert longer screws into these sockets.
screwing them in a circular direction (not in the diametrically opposite direction), until the
reducer must be extracted from the machine axis.

Attention: the sealing washers (pos.8 and 9) cannot be reused after

disassembly of the reducer for repairs or any other type of operation, these must
always be replaced by new ones.

5.4. Installation of the "RPR" type reducer

The reducer must be secured to a rigid structure, with a support surface free of
solder residues.
The centering and fixing diameters of the turning reducer must be clean.
The measurements described above are to ensure a perfect fit between the pinion and the
spin bearing.
Manufacturers usually mark three teeth of the turntable bearing in green.
identifying the point of greatest ovalization of the primitive diameter, for use in
positioning of the gearbox.

PAGE.18 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brazil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 Attention: We recommend contacting the bearing manufacturer directly if not
there should be the proper marking on the gear teeth in the position of greatest ovalization.
For Brevini reducers equipped with eccentricity, the clearance between the tooth faces
the pawl and the rotation bearing can be adjusted by rotating the reducer in its
accommodation.
The value of the clearance between the tooth faces and the rotation bearing is obtained by multiplying
the value of the module for two fixed values: 0.03 and 0.04.

Example: For module=20 simply multiply 20x0.03=0.6 and 20x0.04=0.8 to obtain

the two values, this means that the clearance between the tooth faces for perfect contact
must be between 0.6 and 0.8 mm.

Then the reducer should be positioned with its greatest eccentricity coinciding with the largest.
eccentricity point of the swivel bearing. Rotating the reducer in its housing can-
bringing it closer or moving it away from the spinning roll, thus increasing or decreasing
the gap between the faces of the geared teeth.

Check this clearance at different points of the rotation, torque the screws of
fastening (class of minimum resistance 8.8) with the torque values from table 3 of item 8.1.

[Link] standards for accessories

5.5.1. Engine Assembly
When requested, the reducers are supplied with the appropriate configuration for installation of
specific motor (electric, hydraulic, or pneumatic, etc.). A basic assembly kit
The motor consists of a flange and adapter shaft for the input of the reducer. The seal is installed in
flange must be free of dirt to ensure proper sealing.

When assembling the adapter flange to the engine, it is essential to lubricate the coupling with
a grease film. Carefully insert the motor shaft into the coupling while
align the engine flange with the adapter flange. After ensuring that the engine is
fully positioned and that the fixing screws are properly tightened

PAGE 19 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
according to the recommended torques in Item 8.1, proceed with a re-check of all the
fastenings and clearance to ensure a proper installation.

[Link] of Accessories
There are several accessories available for our reducers. If any are required for the
Application take the necessary precautions not to damage the striations (internal / external).

Once the installation is complete, ensure that the grooves are free of dust and
corrosion. It is essential to lubricate the splines with a layer of grease and tighten them.
correct all screws at the specified torque values according to Item 8.1.

For the assembly of pinions, pulleys, or couplings, use appropriate tools in order to
avoid getting cold; alternatively, heat to 80º - 100ºC.

[Link] OF BRAKE OPERATION

6.1. Negative Multi-Disc Brake
NOTE: The multidisc brake is used only as a parking brake or in a situation
especially like an emergency brake.
Connect the hydraulic circuit plugs to the brake pilot hole (see figure 2) of all
the reducers with these characteristics installed in the system.
Pressurize the hydraulic circuit and then bleed all the brakes. Slowly unscrew the plug.
of the brake piloting, and keep pressurized until the oil is expelled without any air.
So re-plug the plug.

Drain Oil Level Relief / Filling Valve Steering Braking

FIG 2

6.2. Disc Brake

Connect the brake line plug of the hydraulic circuit to the command hole of brake 'A' (see
figure no. 2) of the brake clamp present in the reducer, of all reducers with these
features installed in the system. Bleed the brakes after injecting oil into the circuit
(remove the air from the brake circuit).

PAGE 20 / 35
Brevini Latin America Ind. and Com. Ltd.
Avenue Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 FIG 3

At least two people are needed to carry out this operation.

NOTE: For the withdrawal operation, it is recommended, after having removed the protection from
borracha da válvula "B", colocar uma mangueira de borracha de cerca de 20 cm para recolher o
oil in a container. (recommended operation to avoid environmental damage due to the oil being
highly polluting
Slowly unscrew (1 turn) the bleed valve 'B' and activate the brake control until the
oil without any air should be expelled from the valve. Immediately close the valve and deactivate the
brake piloting.
NOTE: If oil does not expel on the first brake piloting action, it is necessary to close the valve.
of bleeding and deactivating the brake operation. Then open the valve again and activate the
brake bleeding and continue in this manner until the oil is expelled.
Repeat this operation for all reducers with these characteristics installed in the system,
Then fill the brake circuit oil.

6.3. Drum Brake

NOTE: The brakes on reducers equipped with drum brakes are already adjusted.
Use a fork to connect the brake control system to a brake lever.
drum keeping the brake adjusted to zero.

PAGE 21 / 35
Brevini Latin American Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
7. LUBRICATION
7.1. Lubrication of gear reducers

NOTE: Brevini reducers are supplied without oil. The choice of lubricant must be
carried out according to the indication of the table of item 7.4.

The reducers are equipped with a level plug, filling, drain, and relief valve. The
the positions of these change according to the reducer configuration and installation position of
same.
Check the exact positions of the plugs and valves through item 2.2 Construction Form.
Unscrew the level and filling plugs and fill the reducer with oil until it reaches the point.
that the oil starts to come out through the level plug location.
Rotate the reducer axis to eliminate air pockets and re-adjust the various levels.
The first oil change should be done between 50 - 100 hours of work. Before
fill it again, arrange for internal cleaning using the recommended fluid
lubricant manufacturers. Subsequent changes should be made every 2000 - 2500
working hours or at least once a year. The oil change must be done hot
to prevent the formation of 'sludge'.
For conditions of intense use with high loads, shocks, harmful environment or others
In adverse conditions, it is recommended to perform exchanges at shorter intervals.
It is recommended to check the level at least once a month. In case it occurs
If the oil supplement is more than 10% of the total, check for leaks.
Never mix oils of different types, especially if one is mineral and the other is synthetic. In
case of applications with wide temperature ranges or extreme applications
We recommend the use of synthetic lubricating oils with EP additives. (Viscosity index
minimum 165, viscosity class VG 150 to VG 320). From the non-compliance with these indications
they may result in premature wear and/or failures of the reducer or its components. (see
table 7.4 for oil specifications.
In the RPR and MDU series, it is necessary to lubricate one of the existing bearings with grease.
output support, through the grease fitting located above the reducer mounting flange,
using a generic type grease with characteristics as per item 7.3

PAGE 22 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
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Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
7.2. Lubrication of multi-disc brakes
The Brevini multidisc brakes are supplied without oil.
The choice of lubricant must be made by the user following Brevini's guidelines.
To lubricate the multi-disk brake, Brevini Riduttori recommends using mineral lubricant.
heat and aging resistant, with a viscosity of ISO VG32, with an index of
viscosity equal to or greater than 95.
Hydraulic oils are generally satisfactory.

7.2.1. Filling and level

The multi-disc negative brakes are equipped with an oil level sight, relief valve/plug.
of filling and valve. Their position changes according to the configuration of
installation. (Figure 2)
Check the exact position of the plugs (figure 2).
Check the exact positions of the plugs and valves according to item 2.2 Construction Form.
Unscrew the level and filling plugs and fill the reducer with oil until the moment of
that the oil starts to come out through the level plug.
Rotate the reducer shaft to eliminate air pockets and re-control the various levels.

Disc Brake
Disc brakes do not require any lubrication. .

Drum Brake
With a grease pump, inject long-life grease using the grease fitting located at
brake housing, to lubricate the bearing of its axle.

[Link] of Grease
Type of soap: lithium stearate hydroxide 12 or equivalent
Consistency: NLGI No. 2
Base oil: mineral oil with viscosity of 100 to 320 cST at 40°C
Additive elements: Rust inhibitors
Drop point: -10°C maximum

PAGE 23 / 35
Brevini Latino Americana Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] Table

Temperature -20 to +5 +5 to +30 +30 to +50 -30 to +65

Environment (°C)

ISSO 3448 VG 100 VG 150 VG 320 VG 150-220

AGIP Blasia 100 Blasia 150 Blasia 320 Blasia S 220

ARAL Degol BG 100 Degol BG 150 Degol BG 320 Degol GS 220

BP MACH GR XP 100 GR XP 150 GR XP 320 Enersym HTX220

CASTROL Alpha Max 100 Alpha MAX 150 Alpha Max 320 Alphasyn PG 150

CHEVRON non leader gear non leader gear Non leader gear
Compound 100 Compound 150 Compound 320

ESSO Spartan EP 100 Spartan EP 150 Spartan EP 320 Excolub SLG

Q8 Goya 100 Goya 150 Goya 320 EL Greco 220

I.P. Mellana 100 Mellana 150 Mellana 320 Telesia Oil 150

MOBILE Mobilgear 627 Mobilgear 629 Mobilgear 632 Glygoyle 22

Glygoyle 30
SHC 630

SHELL Omala oil 100 Omala oil 150 Omala oil 320 Tivela Oil AS

TOTAL Carter EP 100 N Carter EP 150 Carter EP 320 N

KLÜBER Klüberoil! GEM Klüberoil! GEM Klüberoil! GEM Klübersynth! GH

1-100 1-150 1-320 6-220

ELF ["Reductelf SP 100","Reductelf SP 150","Reductelf SP 320"] Elf ORITS 125

MS
Elf Syntherma P
30
Check the complete table in the catalog.

PAGE 24 / 35
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7.5. Expansion Vessel
WARNING: Check that the expansion tank is positioned at the highest part of the reducer.

For high powers or high speeds in reducers installed in the vertical position it is
it is essential to ensure proper lubrication of the bearing located in the upper position
provide space for the expansion of the oil as the temperature increases
of operation. The continuous working temperature should not exceed 90ºC (194ºF).

The expansion tank is equipped with minimum and maximum level indicator plugs for
facilitate the verification of the oil level (SEE DIAGRAM 1 FIGURE A). At the top of the
the expansion tank has a relief valve that ensures proper ventilation of the
reducer. It is recommended to frequently check the valve to ensure that it
be free of obstructions so that no damage occurs to the reducer.

To facilitate the filling of oil in the reducer, an auxiliary piping can be used.
(SEE EXAMPLE IN DIAGRAM 2). When filling out, wait a certain amount of time until
that the oil passes through the entire reducer and reaches the minimum level. After filling, reinstall the
plug the sealing of the auxiliary piping and protect it.

In applications where the output speed is less than 1 rpm and the reducer is mounted in the position
horizontal, it is recommended to fill up to 75% of its capacity. This ensures the
lubrication of the highest points. Consult Brevini to see if this occurs with yours.
application. If desired, an expansion tank with visual control can be provided
from this oil level.

PAGE 25 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 PAGE 26 / 35
Brevini Latin America Ind. and Com. Ltd.
Avenue Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
8. CONTROLS
[Link] for starting operation
Before starting the machine cycle, you should check the following:
Check that the oil cylinder is in the correct position (See item 2.2).
Check that all oil levels are correct.
Check that all shoeshiners have grease.
Check if the operational work pressure (see Table 2) is sufficient to open
completely the multi-disc negative brake, thus avoiding overheating and any
premature wear of the brake discs.

TABLE 2

PRESSURE

TYPE OPENING ( bar ) MAX ( bar )

FL620/12 21 - 26 210
FL635/12 12 – 15 315
FL250 12 - 15 315
FL350 18 - 22 315
FL450 22 - 28 315
FL750 22 - 28 315
FL760 19 - 25 315
FL960 19 - 25 315

WARNING: Due to the type of brake, the working pressure should not fall below the minimum.
opening pressure of the same, avoiding its braking action.
ATTENTION: The reducers and any oil-free multidisk brake are provided. The customer is
responsible for filling such devices (see lubrication chapter) item 7.
Check the correct tightening of all screws (ISO metric thread) according to table 3

PAGE 27 / 35
Brevini Latin America Ind. and Com. Ltd.
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 TABLE 3

Torque values for tightening screws

dxp 4.8 5.8 8.8 10.9 12.9
mm KN Nm KN Nm KN Nm KN Nm KN Nm
3 x 0.5 1.2 0.9 1.5 1.1 2.3 1.8 3.4 2.6 4.0 3
4 x 0.7 2.1 1.6 2.7 2 4.1 3.1 6.0 4.5 7.0 5.3
5 x 0.8 3.5 3.2 4.4 4 6.7 6.1 9.8 8.9 11.5 10.4
6x1 4.9 5.5 6.1 6.8 9.4 10.4 13.8 15.3 16.1 17.9
7x1 7.3 9.3 9.0 11.5 13.7 17.2 20.2 25 23.6 30
9 x 1.25 9.3 13.6 11.5 16.8 17.2 25 25 37 30 44
8x1 9.9 14.5 12.2 18 18.9 27 28 40 32 47
10 x 1.5 14.5 26.6 18 33 27 50 40 73 47 86
10 x 1.25 15.8 28 19.5 35 30 53 43 78 51 91
12 x 1.75 21.3 46 26 56 40 86 50 127 69 148
12 x 1.25 23.8 50 29 62 45 95 65 139 77 163
14 x 2 29 73 36 90 55 137 80 201 94 235
14 x 1.5 32 79 40 96 61 150 90 220 105 257
16 x 2 40 113 50 141 76 214 111 314 130 369
16 x 1.5 43 121 54 150 82 229 121 336 141 393
10 x 2.5 49 157 60 194 95 306 135 435 158 509
18 x 1.5 57 178 70 220 110 345 157 491 184 575
20 x 2.5 63 222 77 275 122 432 173 615 203 719
20 x 1.5 72 248 89 307 140 482 199 687 233 804
22 x 2.5 78 305 97 376 152 502 216 843 253 987
22 x 1.5 88 337 109 416 172 654 245 932 266 1090
24 x 3 90 383 112 474 175 744 250 1080 292 1240
24 x 2 101 420 125 519 196 814 280 1160 327 1360
27 x 3 119 568 147 703 230 1100 328 1570 384 1840
27 x 2 131 615 162 760 225 1200 363 1700 425 1990
30 x 3.5 144 772 178 955 280 1500 300 2130 467 2500
30 x 2 165,850 204 1060 321 1670 457 2370 535 2380
d = diameter of the screw lead screw step
KN = axial preload Nm = tightening torque

PAGE 28 / 35
Brevini Latin America Ind. and Com. Ltd.
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[Link]
Make sure that the various plugs are in the correct positions for flanged reducers,
reducers with pendular mounting and reducers with feet checking item 2.2 of position
assembly. When inspecting the positions of the plugs, make sure that the relief valve is
positioned in the upper position, drain and magnetic plugs in the lower position, indicator of
level at the intermediate position for horizontal units, and above for vertical units. By
The reducers are supplied empty, fill them with the appropriate amount of oil.
lubricant (must have EP additive). Horizontally mounted units must be filled
up to halfway while mounted vertically must be completely filled and
to have an extension to the breath. However, there are also cases when the reducer is mounted
horizontally and the output speed is less than 1 rpm. See the expansion vessel section.
for more information or consult Brevini to see if the case occurs with your application.

For high powers or high speeds in gearboxes installed in the vertical position, it is
a reserve tank is available to accommodate the expansion of the oil (see 7.5 vessel of
expansion). If an oil circulation system is used, check all the tubes,
pump, filters, and heat exchanger regularly to ensure proper functioning.
Ensure that the relief valve is in good condition and that it is circulating clean water.
and fresh through the heat exchanger. The planetary reducer should not operate with oil at
temperature above 90ºC. (194ºF).

The correct direction of rotation of the motor must be checked. Remember that for gear reducers with
stationary housings the direction of rotation of the input and output shafts is the same,
while for those with a rotating casing (such as planetary gear reducers like wheels), the
the rotational direction of the input and output shaft are opposite.

When ready, start the engine movement slowly and, if possible, without load. In the case of
Electric motor without starting control is recommended to ensure that there is no load.
occurrence of loud noises or severe vibrations, the machine should be stopped immediately and
locate the source of the problem. The failure of any part of the system could destroy the reducer
internally if the operation is not interrupted quickly. contact immediately the
Brevini or its distributor.

8.2. Tests without Load

Check the levels after a brief period of operation without load (5 to 10 minutes)
of oil, eventually completing those that are necessary, control the torque of
all screws (reducer and reducer/machines)

Control the brakes by checking if they operate correctly when

activation/deactivation.

PAGE 29 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
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[Link]
9. MAINTENANCE
Premise: maintenance can be 'normal or extraordinary'

WARNING: all maintenance operations must be carried out under conditions of

security.

9.1 Normal maintenance:

Normal maintenance should be performed by the operator with the following operations:
after a running period of approximately 100 hours (rotation of
reducer) replace the reducer oil and possibly the multi-disc brake oil and wash the interior
of the group with liquid detergent.

check that there are no particles in the magnetic plug of the reducer and the multi-disc brake
in case of existence of this

Perform the oil change with the reducer heated to facilitate the exit.

Subsequent oil changes should occur every 2000 to 2500 hours.

functioning but not exceeding one year.

Do not mix different types of oils.

Check the oil levels periodically (approximately every month) and if it is

necessary to complete the level

ATTENTION: if during the oil level control of the reducers with multidisc brake and/or with
hydraulic motor, if an increase in levels is observed, it means there is an oil leak,
either the brake or hydraulic motor seals. In this case, contact the 'Assistance Service
Brevini technique.

It is advisable to document all maintenance performed.

9.2 Oil Change

Locate the drain plug through the diagrams in paragraph 2.2 'Constructive Form'.
of the oil according to the configuration of the reducer, as well as the multi-disc brake.
Remove the drain plug and the fill/relief valve to facilitate the exit.
of the reducer oil. Once emptied, replace the drain plug and repeat the same
operation with the multi-disc brake.
In the MDU series, starting from size '550', there is a tube for the oil drainage of the
reducer, which should be carried out using a suction pump.
-Wash the reducer internally with a detergent liquid suitable for this purpose and
recommended by a lubricant manufacturer, if the reducer is equipped with a brake
multidisco, repeat the same operation with the brake as follows: Introduce the liquid
detergent in the reducer and in the multi-disc brake, replace the drain plug, rotate for

PAGE 30 / 35
Brevini Latin American Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
 a few minutes on a low spin, and then completely drain the detergent liquid from
brake and of the reducer.
For oil filling check item 7 Lubrication.

9.3 Extraordinary maintenance

Brevini prohibits the opening of the reducer for any operation not indicated in
ordinary maintenance. Brevini assumes no responsibility for all those
operations performed and not included in regular maintenance that caused damage to
people or equipment. In case of need, contact the Brevini Assistance Center
closer.

PAGE.31 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
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[Link]
10. MAINTENANCE OF BRAKES
10.1 Procedure for replacing the discs or seals of the multi-disc brakes.

Brevini prohibits the execution of these operations on the brakes, therefore in the face of a situation of
little braking action, go to a Brevini Assistance Center.

PAGE.32 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
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[Link]
11. INCONVENIENCES AND CORRESPONDING SOLUTIONS:

In case of irregular operation, consult the following table. In the case of anomalies
if the problem persists, contact the Brevini Assistance Center.
ANOMALY POSSIBLE CAUSE SOLUTION

1) Incorrect mounting of the engine Check the coupling between

the reducer and the motor
As o motor in me
functioning the axis of Internal anomaly Get in touch with the
output does not spin. Brevini Service Center

3) Locked brake Check the hydraulic circuit

Very high level Lower the oil level

Oil loss during the 2) Incorrect position of the valve Check the position of the valve
functioning of relief. of relief.

Possible wear to get in touch with the

multidisc brake seals or Brevini Service Center
hydraulic motor

Blocked relief valve Unclog and clean the valve

Reinforcement of seals Clean the area and check

Oil loss in seals due to storage after a few days
prolonged.

3) Wear or damage of Contact the

seals Brevini Service Center

Excessive noise Internal anomaly Get in touch with the

Brevini Service Center

1) Reducer no installed Check as fixations e

correctly. coaxiality.

Weak assembly structure. Reinforce the structure

PAGE.33 / 35
Brevini Latin America Ind. and Com. Ltd.
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Excessive vibrations Internal anomaly Get in touch with the
Centro de Atendimento Brevini

Lack of ventilation Remove the protections from

equipment
Excessive heating
2) High thermal power Insert recirculation system
of oil.

There is no pressure on the brake. Check hydraulic circuit

Internal anomaly Get in touch with the

The multi-disc brake does not release. Brevini Service Center

3) Lack of pressure in the circuit Check the hydraulic circuit

1) Residual pressure in the circuit Check the hydraulic circuit

hydraulic
Multi-disc brake does not brake

1) Without pressure to brake Check the hydraulic system

Multi-disc brake does not stop
Worn brakes Get in touch with the
Brevini Service Center

PAGE 34 / 35
Brevini Latin American Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]
[Link] ASSISTANCE
Brevini Latin America Industry and Commerce Ltd.

Av. Mal. Arthur Costa e Silva, 963 - Jd. Glória

13487-230 - Limeira - SP - Brasil

Tel: (19) 3446 8600 / Fax: (19) 3446 8601

e-mail: brevini@[Link]

PAGE 35 / 35
Brevini Latin America Ind. and Com. Ltd.
Av. Mal. Arthur da Costa e Silva, 963 - Jd Glória
13487-220 - Limeira - SP - Brasil
Tel: +55 (19) 3446 8600 - Fax: +55 (19) 3446 8601
[Link]