EPPINGER BT Series User manual

Doc. No. : 1002
Version 1 dated 18/10/2018
Page 1/11
Assembly instructions
BT / BM / BF Gearboxes

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
Page 2/11
Table of contents
1Safety instructions ............................................................................. 3
2General.............................................................................................. 3
2.1 Information on the documentation .......................................................... 3
2.2 Target group.............................................................................................. 4
2.3 Scope ......................................................................................................... 4
2.4 Intended use.............................................................................................. 4
2.5 Contact ...................................................................................................... 4
3Handling and Transport...................................................................... 5
4Storage .............................................................................................. 6
5Assembly ........................................................................................... 6
5.1 Mounting of the gearbox .......................................................................... 7
5.2 Assembly of the shafts .............................................................................. 7
5.3Assembly of the motor for the BF series................................................... 7
6Commissioning................................................................................... 8
7Operation .......................................................................................... 8
8Maintenance...................................................................................... 9
9Decommissioning............................................................................. 11
9.1 Dismantling.............................................................................................. 11
9.2 Disposal ................................................................................................... 11

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
Page 3/11
1Safety instructions
A distinction is made between different levels of safety instructions. Table 1 below
shows the definitions of symbols and signal words.
Symbol
Signal word
Definition
DANGER!
Immediately imminent danger.
Death or extremely serious injury, crippling.
WARNING!
Possibly dangerous situation.
Death or extremely serious injuries may result.
CAUTION!
Less dangerous situation.
Minor or moderate injuries may result.
NOTICE
Potentially damaging situation.
Possible damage to product and/or machine.
INFO
Tips and other useful or important information and
advice.
No dangerous or harmful consequences for persons
or property.
Table 1: Classification of notices
Symbol
Signal word
Definition
Environmental
hazard
Pollution risk for the environment
Table 2: Other symbols
2General
2.1 Information on the documentation
These assembly instructions have to be read carefully before assembling, commis-
sioning and maintaining the product. The document must be kept in a suitable place
for future reference and must be available for any assembly, maintenance or disman-
tling work.

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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2.2 Target group
This documentation is intended for qualified trained personnel who are familiar with
mechanical assembly work. Assembly, commissioning and maintenance may only be
carried out by accordingly qualified personnel. Technical training or safety instruction
is required.
2.3 Scope
The scope of these instructions covers the following products of the company EGT
Eppinger Getriebe Technologie GmbH:
•BT Bevel gearboxes
•BM Bevel gearboxes
•BF Bevel gearboxes with motor flange
All mounting parts necessary for the assembly, installation, operation and mainte-
nance, which are included in the scope of supply of these gearboxes, are also within
the scope of this document.
2.4 Intended use
Eppinger gearboxes are machine elements for converting or diverting torques and
rotational speeds within the respectively specified performance range. Any operation
outside the specified performance characteristics or other than the specified use is
not permitted. The permissible torques and rotational speeds of the gearboxes must
not be exceeded. The forces affecting on the gearbox shafts have to be limited to the
maximum permissible values.
Unauthorised modifications or alterations to the product are not permitted.
According to the EC Machinery Directive 2006/42/EC, gearboxes are referred to as
machine components and are therefore assemblies that do not fall within the scope
of the Machinery Directive 2006/42/EC. Therefore, gearboxes are components to be
installed in machines. The commissioning is forbidden until by or after the integration
into the end product, the requirements of the machine directives are met.
2.5 Contact
EGT EPPINGER Getriebe Technologie GmbH
Breitwiesenweg 2-8

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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73770 Denkendorf/Germany
+49 (0) 711 / 934 934-626
[email protected]
http://www.eppinger-gears.com
3Handling and Transport
During handling and transport, suitable lifting equip-
ment must be used depending on the weight of the
gearbox. The permissible lifting capacities and other
specifications of the hoist manufacturer must be ob-
served.
Suitable suspension points have to be gathered from
Figure 1. All BT, BM and BF series gearboxes are
equipped with metric threads in the housing at these
points. The thread sizes can be gathered from the re-
spective data sheets. If ring bolts are used, a suitable
spreader beam may have to be used.
DANGER!
Death or extremely serious injury / crippling caused by falling loads. During
transport, never stay under suspended loads.
The weights given in Table 3 apply to gearboxes with solid output shafts on both
sides.
Figure 1: Suspension points

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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Gearbox
Weight
about
Gearbox
Weight
about
Gearbox
Weight
about
BT50
1.5 kg
-
-
BF50
2.0 kg
BT75
5.2 kg
BM75
5.5 kg
BF75
6.0 kg
BT90
8.5 kg
BM90
9 kg
BF90
10 kg
BT110
14 kg
BM110
16 kg
BF110
16 kg
BT140
26 kg
BM140
32 kg
BF140
32 kg
BT170
42 kg
BM170
48 kg
BF170
47 kg
BT210
72 kg
-
-
-
-
BT240
105 kg
-
-
-
-
BT280
160 kg
-
-
-
-
Table 3: Weights
4Storage
The gearboxes have to be stored protected from dust, dirt and moisture. The tem-
perature has to be between -5°C and +40°C.
5Assembly
CAUTION!
Assembly work may only be carried out by accordingly qualified trained person-
nel.First of all, check the gearbox for external damage.
CAUTION!
A damaged gearbox must not be operated.
Before installing the gearbox, always switch off the machine and secure it against a
restart. In addition is has to be ensured that the machine cannot move.

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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DANGER!
Death or extremely serious injury / crippling caused by moving machine elements
when accidentally switched on or by accidentally releasing stressed components
during assembly.
Before installation, check the direction of rotation of the gearbox. The direction of
rotation of the gearbox can be gathered from the data sheet.
5.1 Mounting of the gearbox
The gearbox has to be securely screwed to the application. Special attention has to
be paid to a flat support.
All existing mounting holes must always be used on the selected screw-on side. At
this, the screw tightening torque depends on the strength class of the screw as well
as the material of the bearing face respectively the internal thread.
5.2 Assembly of the shafts
The torque transmission takes place via a key. The shaft is suitable for mounting cou-
plings or for a direct mounting of transmission elements such as gearwheels or belt
wheels onto the shaft.
The gear shaft must be clean and free of grease or oil.
For the chosen transmission principle, the existing specification of the manufacturer
of the coupling or the clamping device must be observed.
NOTICE
Damages of the gearbox caused by large axial loads during the assembly.
When pressing components onto the shaft, do not support the force via the gear-
box housing.
The supporting length of the key must be suitable for the torque to be transmitted.
5.3 Assembly of the motor for the BF series
The torque transmission of the motor also takes place via a key. The hollow input
shaft of the gearbox as well as the solid shaft of the motor must be clean and free of
grease or oil.

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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After the motor has been inserted until the motor plate is in
contact with the gearbox flange, screw the motor to the
gearbox flange. Take care of the thread reach of the bolts.
The thread reach of the bolt shall be twice the length of the
nominal diameter of the bolt. (Figure 2)
6Commissioning
CAUTION!
The commissioning may only be carried out by accordingly qualified trained per-
sonnel.
Before commissioning, all mechanical mounting parts and their fastening must be
checked. Check the screw tightening torques. Commissioning may only take place if
the machine complies with the provisions of the EC Machinery Directive. The moni-
toring and protective devices of the machine must not be put out of operation. In
addition to EMERGENCY STOP buttons, EMERGENCY STOP command devices, covers
and hoods, this also includes other protective devices such as sensors, light barriers
and acoustic or optical emergency signals. The security of the gearbox can only be
assured by the end product. Therefore, any commissioning with overridden protec-
tion equipment of the machine is not permitted.
DANGER!
Death or extremely serious injury / crippling caused by equipment in operation
without suitable safety or protective devices by the surrounding end product.
7Operation
CAUTION!
The gearbox may only be operated by accordingly qualified trained personnel.
The gearbox may only be operated with active protective and monitoring equipment
of the machine.
Figure 2: Length of the
bolt

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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DANGER!
Death or extremely serious injury / crippling caused by equipment in operation
without suitable safety or protective devices by the surrounding end product.
WARNING!
Burns at hot surfaces.
During operation, the surface of the gearbox can reach high temperatures. It must
be ensured that there is no unintentional contact with the surface of the gearbox.
During the operation, the gearbox should be observed.
Leakage, unusual temperature rises or an increase in the noise respectively vibration
indicate a fault which has to be repaired. If one of these criteria should occur, the
plant has to be shut down immediately. If the fault cannot be eliminated, contact EGT
Eppinger
(chapter 2.5).
8Maintenance
CAUTION!
Maintenance may only be carried out by accordingly qualified trained personnel.
Gearboxes from size 140 are equipped with screw plugs to allow an oil change.
Smaller gearboxes are lubricated for life and they are therefore designed without any
screw plugs.
The quantities of oil and the intervals of the oil changes can be gathered from Table
4. The recommended intervals for a change have to be observed.
For special gearboxes and gearboxes with operating conditions outside the specifica-
tion, any separately communicated maintenance intervals and specifications apply.
Gearbox
Oil quantity
Change interval
BT/BM/BF 140
0.35 L
15 000 h
BT/BM/BF 170
0.8 L
15 000 h

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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BT210
1.5 L
15 000 h
BT240
2.0 L
15 000 h
BT280
2.8 L
15 000 h
Table 4: Oil quantities and maintenance intervals
Fully synthetic oil Mobil SHC Gear 150 is used as the standard lubricant. During the
oil change, choose either the same lubricant or a lubricant acc. to the following spec-
ification:
•Fully synthetic lubricant
•Viscosity class ISO VG150
•Minimum requirements according to DIN 51517-3:2018-09 respectively
ANSI/AGMA 9005-F16
NOTICE
Damages to the gearbox by a reduced lubricity.
Different lubricants must not be mixed. This may result in a reduced lubrication
effect and a damaging of the gearbox.
To change the oil, open the screw plugs on one side of the gearbox and empty the
gearbox completely. For a complete draining, it might be necessary to move the gear-
box.
DANGER!
Risk of burns during the oil change by hot gearbox oil.
CAUTION!
Skin irritation by intensive contact with synthetic oil.
After the complete draining all but the topmost of screw plugs can be closed again.
The required quantity of oil according to Table 4 can be filled via this opening.
The required quantity of oil must not be exceeded or undercut.

Assembly instructions (Original)
BT / BM / BF Gearboxes
Doc. No. : 1002
Version 1 dated 18/10/2018
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NOTICE
Damages to the gearbox due to the wrong quantity of lubricant.
Insufficient lubricant can result in a damaging of the gearbox.
Too much lubricant can result in an excessive heating.
Fill in each time the specified quantity of lubricant.
After the filling of the lubricant, close the screw plug again.
The drained oil has to be disposed of acc. to chapter 9.2.
9Decommissioning
CAUTION!
Dismantling and disposal may only be carried out by accordingly qualified trained
personnel.
9.1 Dismantling
Before dismantling the gearbox, always switch off the machine and secure it against
a restart. In addition is has to ensured that the machine cannot move.
DANGER!
Death or extremely serious injury / crippling caused by moving machine elements
when accidentally switched on or by accidentally releasing stressed components
during dismantling.
9.2 Disposal
ENVIRONMENTAL HAZARD!
Environmental compatibility, health risks, disposal regulations and the local possi-
bilities of proper disposal must be observed.
Any and all operating materials, in particular oils, fats and lubricants are to be dis-
posed of according to the national and regional applicable regulations.
CAUTION!
Skin irritation by intensive contact with synthetic oil.