Operating Manual

Helical Gearbox ANOX - 110

Part Number: G 046630X

Gearbox Type: 1 - stage helical gearbox

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 Operating Manual
Contents

Contents

1 Introduction 1–1

1.1 The Gearbox .......................................................................................................... 1–1

1.2 Legal Provisions .......................................................................................................... 1–1

1.3 The Operating Manual .......................................................................................................... 1–2

2 Safety Instructions 2–1

2.1 General Safety Instructions .......................................................................................................... 2–1

2.2 Safety Instructions for Transport .................................................................................................... 2–3

2.3 Safety Instructions for Assembly .................................................................................................... 2–4

2.4 Safety Instructions for Starting - up ................................................................................................ 2–4

2.5 Safety Instructions for Maintenance ............................................................................................... 2–5

2.6 Safety Instructions for Waste Disposal........................................................................................... 2–5

3 Technical Description 3–1

3.1 Scope of Supply .......................................................................................................... 3–1

3.2 State as Supplied .......................................................................................................... 3–1

3.3 Rating Plate .......................................................................................................... 3–1

3.4 Designated Use .......................................................................................................... 3–2

3.5 Design and Principle of Operation.................................................................................................. 3–2

3.6 Limits of Application .......................................................................................................... 3–3

3.7 Quality Assurance .......................................................................................................... 3–3

3.8 Technical Details .......................................................................................................... 3–4

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Contents

4 Transport and Storage 4–1

4.1 Transport of the Gearbox .......................................................................................................... 4–1

4.2 Storage of the Gearbox .......................................................................................................... 4–2

5 Assembly and Starting - up 5–1

5.1 Safety Instructions .......................................................................................................... 5–1

5.2 Assembly .......................................................................................................... 5–1

5.3 Starting - up .......................................................................................................... 5–4

6 Maintenance 6–1

6.1 Safety Instructions .......................................................................................................... 6–1

6.2 Maintenance Table .......................................................................................................... 6–3

6.3 Changing the Gear Oil .......................................................................................................... 6–4

7 Drawings and Tables 7–1

7.1 Dimensional Drawings .......................................................................................................... 7–1

7.2 Spare Parts Drawings and - list ...................................................................................................... 7–2

7.3 Table of Lubricants .......................................................................................................... 7–8

7.4 Use of Loctite .......................................................................................................... 7–9

8 Annex 8–1

8.1 Service .......................................................................................................... 8–1

8.2 Company Address .......................................................................................................... 8–1

8.3 Agencies .......................................................................................................... 8–2

8.4 Manufacturer’s Declaration .......................................................................................................... 8–3

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Introduction

1 Introduction

1.1 The Gearbox

Identification
Part Number: G 046630X
Gearbox Type: 1 - stage helical gearbox ANOX - 110
Manufacturer
EICKHOFF Maschinenfabrik GmbH
Hunscheidtstr. 176
D-44789 Bochum

Proper Use
The gearbox is designed exclusively for proper use as defined in this operating manual (see chapter
3.4 Designated Use).
Improper Use
The gearbox must not be used for applications other than provided for in the chapter on Proper Use.
Any other use is classified as improper use and may lead to:

injury to persons or death

damage to the installation

damage to other material property

1.2 Legal Provisions

Liability
The information, details and notes contained in this operating manual reflect the latest state on the day
of issue. Technical modifications are reserved within the bounds of the further development of the
gearbox. No claims shall therefore be pushed for already delivered gearboxes on the grounds of
specifications, illustrations or descriptions contained in this operating manual.
No liability is assumed for damages or functional disorders caused by:

Disregard of the operating manual

Operator's mistakes

Inexpert work on and with the gearbox

Use of other than genuine OEM spare parts or accessories

Unauthorized conversions or modifications of the gearbox by the user or his/her
personnel

EICKHOFF Maschinenfabrik GmbH accept liability for faults and omissions within the bounds of the
warranty obligations entered into according to the principal contract. Claims for damages, from
whatever legal grounds they may be deduced, are excluded therefrom.

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 Operating Manual
Introduction

Warranty
Warranty claims shall be brought to the notice of EICKHOFF Maschinenfabrik GmbH immediately after
the fault oder defect has been located, by indicating the part number, gearbox type and serial number.
Wear parts are excepted from the warranty. The following actions will invalidate the warranty:

Improper use of the gearbox

Inexpert work on and with the gearbox

Use of inadmissible operating material

Use of other than genuine OEM spare and wear parts

Opening of the gearbox during the warranty period

Draining oil from the gearbox in the case of damage

Copyright
This operating manual and all information contained therein are protected by copyright. Duplication
(including extracts) or conveying to third parties, disclosure or exploitation of its contents are not
permissible without the explicit consent of EICKHOFF Maschinenfabrik GmbH.
© Copyright 2000 by EICKHOFF Maschinenfabrik GmbH

1.3 The Operating Manual

The details and notes contained in the present operating manual shall enable the active personnel to
work safely, properly and efficiently on and with the gearbox. It is only when the contents of the
operating manual is understood and observed that

dangers are avoided

repair cost and downtimes are kept to a minimum and

reliability and service life of the gearbox are increased.

For easy reference, the following paragraphs explain the systematics and rules as well as the textual
and pictorial definitions applied in this manual.

Definition of Terms
This operating manual uses a number of important terms which are defined below:
Gearbox
The term "gearbox" as used in this manual shall mean the complete gearbox (see chapter 3.1 Scope
of Supply).
EICKHOFF
Eickhoff Maschinenfabrik GmbH is the manufacturer of the gearbox and will be called EICKHOFF
hereinafter.
User
The user shall be every natural or legal person who operates the gearbox or gives instructions to
operate the gearbox on his/her behalf.

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 Operating Manual
Introduction

Operating Personnel
Operating personnel shall be persons who have been charged with and instructed in
the operation of the gearbox. The operating personnel is authorized to carry out
simple maintenance such as cleaning the gearbox on the outside.

Persons shall be deemed instructed when they have been

informed of the tasks assigned to them and have received corresponding
training, as necessary.

warned of the potential dangers arising in the case of inexpert handling

made familiar with the necessary safety devices, safety precautions, accident
prevention regulations, pertinent rules and service conditions.

For the required instruction duties and authority, see chapter 2.1 General Safety Instructions.
Skilled Personnel
Skilled personnel shall be persons having

qualifications as machine fitters (recognized occupation: industrial mechanic) or
equivalent qualifications and

the ability to assess and perform, in a professional way, the tasks assigned to
them owing to their professional training, knowledge and experience.

The skilled personnel shall be familiar with the accident prevention regulations, pertinent rules and
service conditions.
EICKHOFF Maschinenfabrik GmbH Personnel
EICKHOFF personnel shall be skilled personnel employed by EICKHOFF.
Remaining Hazards
Remaining hazards shall be the latent risks arising from the use of the gearbox.

Example:
Danger of burning parts of one's body on hot components after the gearbox has been
switched off.

Protective Clothing
Protective clothing shall be the personal protective gear that protects the body against the dangers
arising at work. The protective clothing must comply with the requirements of the Equipment Safety
Act.
The circumstances under which protective clothing must and shall be worn are set out in the
applicable local accident prevention regulations.

Pictorial Representations and Textual Displays

The following pictograms and symbols are used in this operating manual to give salience to important
information.

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Introduction

General Danger
Makes reference to safety instructions which must by all means be observed and to
which no specific pictogram (e.g. one of the following) can be assigned.

High Electric Voltage

Warns of the danger of electric shock

Hot Components
Warns of the danger of burning parts of one's body when hot system components
are touched.

Ecologically Harmful Substances

Warns of the dangers caused by chemical substances unless the said substances are
disposed of in accordance with the applicable environmental rules and regulations.

Safety Related Note

Makes reference to statements on how to work safely on and with the gearbox.

Supplementary Information
Makes reference to practical hints and useful information.

Three different symbols are used in this operating manual:

 This symbol indicates individual work instructions which must be executed

precisely in the given order.

This symbol indicates enumerations, the contents of which is of equal priority.
 This symbol indicates enumerations of subsidiary points which are sub-
ordinate to the enumerations and the contents of which is again of equal
priority.

Structure and Contents of the Safety Instructions

All safety instructions contained in this operating manual are of uniform structure.
Essential Elements of a Safety Instruction
Each safety instruction is composed of a number of essential elements:

a pictogram

a signal word indicating the degree of the danger

a statement on the type of danger and

a statement on how to avert the danger.

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 Operating Manual
Introduction

The following signal words indicate the degree of the danger:

Danger
warns of an imminent danger to life and health of human beings.

Possible consequences: death or serious injuries

Warning
warns of a potential danger to life and health of human beings.

Possible consequences: death or serious injuries

Attention
indicates a potential danger to persons or material property.

Possible consequences: Slight injuries to persons or damages to material property.

Note
indicates a potentially hazardous situation for material property or the environment.

Possible consequences:

The gearbox itself is damaged.

Material property surrounding the gearbox is damaged

The environment is damaged

Hint
indicates supplementary information on how to make work easier and more efficient
(practical hints).

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Safety Instructions

2 Safety Instructions

2.1 General Safety Instructions

The gearbox has been built in accordance with the state-of-the-art standards at the time of ordering
and is deemed operationally safe in general.
Nevertheless, the use of the gearbox may constitute a risk when

unauthorized and non-instructed personnel is working on and with the gearbox
or

the gearbox is subject to improper use.

In such a case the following are at risk:

persons

the gearbox and

other material property of the user

Safety of the Gearbox

The following must be observed when working on and with the gearbox:

the currently valid rules and regulations (e.g. VDE standards)

the applicable accident prevention regulations (UVV)

the pertinent directives

the currently valid environmental protection laws

The gearbox must be used in a perfect condition only. This includes the prerequisite that safety
devices of the gearbox are in place and fully functional. In the event of functional disorders or defects
the gearbox must be immediately withdrawn from service and the said malfunction reported to the
user's authorized supervisor.
The gearbox must not be restarted until the perfect function of the gearbox is reestablished.
The safety devices must neither be removed nor deactivated. Where safety devices have to be
removed for maintenance after all, they must be refitted immediately upon completion of the work. All
safety devices must be checked for proper operation before the gearbox is started.

Note
Additions to and / or modifications and conversions of the gearbox which may affect
safety are prohibited in general unless EICKHOFF's written consent has been obtained.
The same applies to the installation and calibration of safety devices and to welding
load bearing components.

Genuine O.E.M. spares shall be used exclusively for changes of gearbox components. Only O.E.M.
spares keep the gearbox fully functional and safe.

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Safety Instructions

Operating Manual
The present operating manual primarily aims at ensuring safety-conscious working on and with the
gearbox. It contains safety instructions which must by all means be observed.
Besides the general safety instructions contained in this chapter the specific safety instructions set out
in the other chapters must be observed as well. These specific safety instructions are related to
specific work instructions and warn of an imminent danger.

The operating manual must

be read and understood by all persons working on and with the gearbox before
starting work

always be at hand at the place of use of the gearbox and stowed at a
designated location

always be complete and kept in a legible condition.

Should this operating manual or parts thereof not be fully understood, work shall not be started. Ask
the skilled personnel of

the user or

EICKHOFF
before you risk exposing yourself to a potentially hazardous situation.

Duties of the User

The user has to fulfil a number of duties towards his/her personnel.

The user is bound

to supplement the operating manual with instructions containing the national

accident prevention regulations and environmental protection laws

to familiarize the personnel with all relevant regulations, directives and laws, as
necessary

to verify that all relevant regulations, directives and laws are observed

to have the personnel instructed in the proper way of working on and with the
gearbox

to clearly define the responsibilities for assembly, starting-up and maintenance
of the gearbox

to verify that the defined responsibilities are actually respected

to verify at regular intervals that his/her personnel operates the gearbox in a
safety and danger conscious manner in accordance with the operating manual
and

to make sure that the personnel has read and understood the operating manual,
and the chapter on Safety Instructions in particular. The user of the gearbox
should seek a written confirmation to this effect from the personnel.

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Safety Instructions

Active Personnel
Only authorized and instructed personnel shall be allowed to work on and with the gearbox.
Unauthorized persons must be prohibited from operating the gearbox. The following work must be
performed by skilled personnel only:

Assembly

Starting-up

Maintenance

The responsible superior shall instruct the operating personnel in safety at work matters at regular
periods not exceeding one year. The completed instruction course shall be placed on record and
signed by the instructed personnel.
The operating personnel is bound to report any changes in the operating characteristics of the
gearbox immediately to the responsible superior. Compliance with this requirement is absolutely
imperative in cases where the safety of the gearbox is no longer ensured.
The personnel working on and with the gearbox must have long hair tied back or otherwise secured.
Garments must be close-fitting, and jewellery - such as rings - must not be worn. The personnel must
use their personal protective gear as necessary and as prescribed by the applicable rules.

2.2 Safety Instructions for Transport

Warning
Danger of falling transport objects

The transport of the gearbox must be carried out by skilled personnel only.

Use only transport equipment and transport aids which
 comply with the safety requirements and
 are designed for the respective loads.

The gearbox must be lifted and transported exclusively at the marked
attachment points provided for this purpose.

Before initiating transport to the customer's site, it must be ensured that all
transport routes are clear of obstacles.

Note
Damages to the gearbox due to fluctuations of temperature
Do not expose the gearbox to wide fluctuations of temperature during transport in
order to avoid condensing. Protect the gearbox against humidity using tarpaulins for
transport.

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Safety Instructions

2.3 Safety Instructions for Assembly

Attention
Danger caused by inexpert work on the gearbox
Assembly, installation and test run (commissioning) of the gearbox must be carried out
by skilled personnel only.

Danger
Danger caused by high electric voltages
Assembly and installation of the electrical components and their testing must be
carried out by skilled personnel (electrical engineers) only.

Note
Before starting up the gearbox, check all lines and bolted connections for tight fit,
leakage and externally discernible damages.

2.4 Safety Instructions for Starting - up

Warning
Danger caused by inexpert work on and with the gearboxDanger caused by improper
use of the gearbox

Starting up of the gearbox must be carried out by authorized and instructed
skilled personnel only.

The gearbox must be used in a perfect condition only. All safety devices of the
gearbox must be in place and fully functional. In the event of defects or
functional disorders, the gearbox (or the system in which the gearbox is
integrated) must be immediately withdrawn from service and secured against
restarting.

The gearbox (or the system) must not be put into service until all defects or
functional disorders are rectified and the gearbox is fully functional.

Attention
Danger to the gearbox caused by strewn tools or other objects
See for yourself that no tools or other objects, which are foreign to the system, are
within the functional reach of the safety devices of the gearbox.

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Safety Instructions

Warning
Danger caused by the starting gearbox
Before starting up the gearbox make sure that no persons are exposed to danger
caused by the starting gearbox.

2.5 Safety Instructions for Maintenance

Danger
Danger caused by inexpert maintenance of the gearbox

Maintenance of the gearbox must be carried out by skilled personnel only.

The maintenance work and intervals specified in this operating manual must
be strictly observed so that the gearbox is maintained in its operationally
safe condition and provides a long service life.

Switch off the system in which the gearbox is integrated, as prescribed and
secure it against restarting.

Do not remove any safety devices from the gearbox. Where safety devices
need to be removed for maintenance, they must be refitted upon completion
of the work and checked for proper operation.

Bolted connections separated for maintenance must always be firmly
retightened and secured with Loctite.

Note
Damages to the gearbox due to inexpert cleaning

Do not use any aggressive detergents.

Use only non-fraying cleaning rags.

Clean the gearbox from oil and contamination before starting maintenance.

Do not clean the oil filling area or the elastic shaft seals by means of a
high pressure cleaner.

2.6 Safety Instructions for Waste Disposal

Note
Danger to the environment caused by inexpert waste disposal

Keep proper collecting pans and receptacles ready to hand to collect
any leaking operating fluid or spillage (such as gear oil).

All operating fluids, consumables and replacement parts must be disposed
of in a safe and environmentally protective manner in accordance with the
applicable environmental rules and regulations.

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Technical Description

3 Technical Description

3.1 Scope of Supply

Depending upon the order specifications, the gearbox is either a single unit or comprises a number of
components which are not yet mounted to the gearbox upon delivery. The existing scope of supply
comprises:

1 - stage helical gearbox including shear pin coupling.
The supplied gearbox shall be checked for completeness upon receipt. Any transport damages and/or
missing components shall be reported immediately in writing.

3.2 State as Supplied

State of the gearbox as supplied:

The gearbox is supplied ready for operation, but without oil and without the
external add-on pieces being mounted.

The gearbox has been coated with a preservative prior to delivery. This
preservation is adequate for a storage period not exceeding 12 months from
readiness for despatch and transport, subject to indoor storage.

Labyrinth seals are already filled with grease ex works.

The gear housing and the housing parts are coated, internally and externally,
with paint.

Vent holes, oil filling holes, oil drain holes, the oil level indicator and any
lubricating points are identified in colour.

The shaft extensions and the hollow shaft holes are coated with anti-rust paint.
The anti-rust paint is saltwater-proof and tropicalized for one year.

3.3 Rating Plate

The gearbox type and the serial No. indicated on the rating plate and the part number stated in this
operating manual (see chapter 1 Introduction) should always be quoted in the case of enquiries. The
rating plate is securely fixed to the gearbox and contains the following details:

Gearbox type with part number and type designation

Model (column to the right of the type designation)

Serial No. (No.)

Power (P)

Operating torque (T2)

Ratio (i)

Input speed (n1) / Output speed (n2)

Oil quantity

Oil type

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Technical Description

3.4 Designated Use

The gearbox is designed exclusively for power transmission between the electric motor and the drive
shaft of the generator. The rotational speed of the motor is reduced to the required speed of the drive
shaft.
Any other use or any use beyond the above limits is classified as improper use, in which case
EICKHOFF shall not be held liable for resultant damages of any kind whatsoever.
Proper use also takes it for granted that all instructions and details of the present operating manual be
observed.

3.5 Design and Principle of Operation

Design
The design of the drive unit and the referring part numbers are shown on the spare parts drawings.The
input and the output shafts are equipped with parallel keys.

Casing
The casing is a three-piece casting made of high grade Meehanite cast iron.

Gears
The gearbox reduces the speed by means of one stage.
The pinion shaft and wheels are made of case hardening steel and the tooth flanks are ground.
The gear teeth can be inspected through the openings of the inspection hole covers while the gearbox
is stopped.

Bearing Assembly
All shafts are supported in well dimensioned taper roller bearings.

Lubrication
The gearbox is lubricated by forced feed lubrication.
Attention:
The oil level has to be checked before putting the gearbox into operation.

Seals
The shaft exits are sealed by shaft seal rings and additionally by grease-filled grooved seals.

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Technical Description

Coupling
Before starting into operation the coupling must be lubricated according to the
Coupling Manual "Installation and maintenance instructions for MTBR - couplings".

3.6 Limits of Application

The temperature rise of the gearbox varies as a function of the operating conditions. At ambient
temperatures ranging from 0°C to 30°C, the normal continuous temperatures of the oil bath will be
between 50°C and 90°C.
For roller bearing gearboxes with mineral oil lubrication, the continuous temperature of the oil bath
must not exceed 100°C as a maximum. If higher temperatures are encountered which are, for
example, due to elevated ambient temperatures or heat generated by external sources, special pre-
cautions must be taken. In such cases synthetic lubricants may be used, but consult EICKHOFF first to
have their compatibility with the provided sealings and paintings confirmed.
Ambient temperatures of less than -10°C require the use of controlled heaters and / or proper
lubricants.
The thermal capacity and the operating range of the gearbox are based on the operating details
specified in chapter 3.8 Technical Details.
We recommend that you should consult EICKHOFF before using the gearbox outside its contractual
limits of application or under different operating conditions.

3.7 Quality Assurance

The EICKHOFF quality system is audited in accordance with DIN ISO 9001 - design/development,
production, installation and servicing - and in accordance with the European Standard EN 29001 and
the British Standards BS 5750.1.
The Certificate (Registration No. 2298-08) has been awarded to EICKHOFF by Deutsche Gesellschaft
zur Zertifizierung von Qualitätssicherungssystemen mbH – DQS (German Association for the
Certification of Quality Systems).

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Technical Description

3.8 Technical Details

Designated use Drive for a alternator

Identification Gearbox design 1 - stage helical gearbox

Gearbox type ANOX – 110
Part number G 46630X
Size Dimensions see chapter 7.1 Dimensional
Drawing
(for the packing dimensions see
chapter 7.2 Spare Parts Drawings)
Weight 2 000 kg
Drive Drive motor Thermal engine
Nominal power 2 800 kW
Torques Operating output torque 17 800 Nm
Nominal output torque 90 500 Nm
Rotational speeds input speed 1 795 r.p.m.
output speed 1 500 r.p.m.
Direction of rotation (when looking Clockwise
at the shaft end face of the shafts)
Ratio 1.1961 : 1

Lubrication Type of lubrication Forced feed lubrication

Oil quantity Approx. 160 l
Oil type ISO viscosity class synth. oil ISO VG 220
Designation acc. to DIN 51517 synth. oil CLP - HC 220
Designation acc. to ISO 3496 synth. oil CC – 320
The rating plate of the gearbox indicates the designation according to
the DIN standard.
Operating conditions Ambient temperature up to + 40 °C
Duty cycle 24h / day
Oil cooling system Cooling water quantity 3 600 l/h
Cooling water pressure max. 10 bar
Primer and paint Acc. to specification

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Transport and Storage

4. Transport and Storage

4.1. Transport of the Gearbox

Warning
Danger of falling transport objects
• The transport of the gearbox must be carried out by skilled personnel only.
• Use only transport equipment and transport aids which comply with the perti-
nent safety requirements and provide an adequate load carrying capacity.
• The gearbox must be lifted and transported exclusively at the marked attach-
ment points provided for this purpose.
• Secure the gearbox against toppling and slipping using adequate transport aids.

Warning
Danger to the health or safety of persons caused by falling objects
Standing or working under suspended loads is strictly prohibited.

Note
Damages to the gearbox
Under no circumstance must the gearbox be lifted and transported on its shafts. For
lifting the gearbox, use the lifting eyes, lifting cams or 3 - D load rings fitted to the
housing, or lifting cables which are to be tied round the housing. See the spare parts
drawings (chapter 7.2 Spare Parts Drawings) for the permissible attachment points.

Note
Damages to the gearbox due to fluctuations of temperature
Do not expose the gearbox to wide fluctuations of temperature during transport in or-
der to avoid condensing. Protect the gearbox against humidity using tarpaulins for
transport.

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Transport and Storage

4.2 Storage of the Gearbox

Note
Damages due to inexpert storage
• Take due note of the state of the gearbox as supplied with a view to storage
(see chapter 3.2 State as Supplied).
• Store the gearbox in a vibration-free place as otherwise damages to the bear-
ings could occur.

Storage Conditions
The gearbox must be stored indoors in general. Where the actual storage period exceeds the period
stated in chapter 3.2 State as Supplied, long-term preservation must be applied.
Where storage extends over a period of several years, further preservations may become necessary
depending on the state of the gearbox.
After very long storage periods - but after 5 years at the latest - a general inspection must be con-
ducted before starting up the gearbox.

Temporary Storage / Withdrawal from Service

If the gearbox is withdrawn from service for a period of more than 3 months after it has already been
working within the system, it must be completely filled with gear oil.
The breather must be removed and the opening must be closed using a suitable plug with seal ring.
Check the oil level at regular 1-month intervals and turn the gearbox by hand as far as practicable.
When withdrawal from service lasted for more than 1 year, the gear oil must be changed before the
gearbox may be put into service again.

Note
Damages to the gearbox
Install the breather and reduce the oil level to normal before re-commissioning the
gearbox

Inspection
The said general inspection can be conducted by EICKHOFF, upon request, either at their works or -
where the gearbox is still integrated in the system - at the user's site.

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Assembly and Starting - up

5 Assembly and Starting - up

5.1 Safety Instructions

Attention
Danger caused by inexpert work on the gearbox
Assembly, installation and test run (commissioning) of the gearbox must be carried
out by skilled personnel only.

Danger
Danger caused by high electric voltages
Assembly and installation of the electrical components and their testing must be
carried out by skilled personnel (electrical engineers) only.

Note
Before starting up the gearbox, check all lines and bolted connections for

tight fit

leakage and

externally discernible damages.

5.2 Assembly
Prerequisites for Assembly
A number of prerequisites must be satisfied for the assembly of the gearbox:

Adequate transport equipment and transport aids must be on hand for

transporting the gearbox. The transport routes to the place of installation of the
gearbox must be clear of obstacles. See also the details contained in chapter
4 Transport and Storage.

Gearboxes other than shaft-mounted versions are mounted on foundations. The

foundation must be level, rigid and torsionally stiff. Any distortion of the
foundation must be removed

The place of installation of the gearbox must be clean and dry.

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Assembly and Starting - up

Mounting the gearbox

Hint
When mounting the gearbox be careful

to keep the holes for venting, oil filling and draining as well as the oil level
indicator easily accessible.

not to impede the air flow on the suction and pressure sides for fan - cooled
gearboxes.

 Put the gearbox onto the properly designed foundation. Make sure that the
contact surface of the housing foot rests completely on the foundation.
 Mount the gearbox with its housing foot on the foundation using the foot bolts.
For the size and tightening torque of the foot bolts, see the dimensioned
drawing contained in chapter 7.1 Dimensioned Drawing.
Only where external forces are acting (e.g. radial forces in the case of belt drives):

 Secure the gearbox against axial displacement by means of pins or stops.

For shaft - mounted and hollow shaft gearboxes only:

Note
A rigid attachment of the gearbox is not permissible as this could cause damage to the
gearbox bearings or the machine shaft. Use the torque arm to compensate for the
reaction torque.

 Mount the torque arm of the gearbox to ensure a flexible compensation of the
reaction torque.

Aligning the Gearbox

Note
Additional loads due to misalignment reduce the lifetime and may lead to the
premature failure of the gearbox. Oblique gearbox positions are only permitted with
the explicit prior consent of EICKHOFF.

 Align the gearbox without angular displacement to ensure smooth and low-
vibration operation.

Hint
For the permissible angular and axial displacement tolerances of the ancillary units
included in the scope of supply, such as couplings, see the details of the respective
manufacturers.

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Assembly and Starting - up

Mounting the Shaft Connections

The torque is transmitted via couplings, shrink disks, parallel keys, flanges or other connecting
elements depending upon the order specifications and the gearbox type.
For parallel key connections:
 Grease the shaft and hole before establishing the connection where parallel key
connections are provided.

For flange connections:

 Tighten the bolts firmly where flange connections are provided. For the size and
tightening torque of the bolts see the dimensioned drawing contained in chapter
7.1 Dimensioned Drawing.

For frictional connections (such as shrink disks):

 Observe the corresponding assembly instructions of the manufacturer where
frictional connections are provided.

Mounting the Ancillary Units

Hint
For the assembly of ancillary units, see the assembly and operating instructions of the
manufacturer.

 Mount the components supplied as loose items to the gearbox in accordance

with the submitted drawings.
 Clean the components supplied prior to assembly.

For Couplings, Hubs, Flanges ... :

Note
Under no circumstance must the rust preventative be rubbed off the shaft extensions
or centre holes with emery.

 Remove the rust preventative from the shaft extensions and centre holes using
a solvant before mounting the connecting elements.

 Mount the connecting elements exclusively using the front side threaded holes
(to DIN 332) in the shaft ends.

For Backstops:
For gearboxes with mounted backstop, care must be taken to ensure that the motor and the gearbox
rotate in the same direction.

G 046630X 19.12.2006 5–3

 Operating Manual
Assembly and Starting - up

For Forced Lubrication Systems:

Gearboxes with forced lubrication systems have the oil pump directly flanged on to the gearbox. Oil
pumps with electrical motors of their own are used in specific applications (see spare parts drawing
contained in chapter 7.2 Spare Parts Drawings).
For Oil Heaters:
Where the order specifies an oil heater for the gearbox, the required connections have to be
established by the user in accordance with the manufacturer's instructions.
Electrical heating elements with heating cartridges below the oil level are used as an oil heater. The
heating temperature is controlled and/or monitored by thermostats which are either integrated in the
heating element or positioned separately in the oil sump.
For Oil Coolers:
Where the order specifies integrated coolers or separate oil coolers for the gearbox, the water ports
(for fresh water which is low in calcium carbonate) must be connected according to the manufacturer's
instructions.

After Assembly
 Check the corrosion preventative and the paint of the gearbox for damages and
retouch where necessary.
 Mount a proper guard to the gearbox when the latter is exposed to heavy
contamination, dust, water, heat effects or other unfavourable environmental
effects.

5.3 Starting - up
Prior to Commissioning
The gearbox is supplied without oil but with a preservative. The preservative need not be removed
prior to commissioning as it dissolves in oil at operating temperature.
 Fill the gearbox with the specified oil (see chapter 6.3 Changing the Gear Oil).
 The greasing points of the gearbox are already packed with the specified
grease quantity and quality ex works (see chapter 7.4 Table of Lubricants).
 Make sure that the gearbox is only run in the permissible direction of rotation.
 Check the gearbox for proper assembly.
 Secure rotating parts (such as couplings, shafts, brakes)
 Before pressurizing the hydraulic motor make sure that the multiple disk holding
brake, if any, is vented hydraulically.

For Forced Lubrication Systems:

Hint
For adjusting the monitoring and control devices, see the operating instructions of the
manufacturer.

G 046630X 19.12.2006 5–4

 Operating Manual
Assembly and Starting - up

 For oil pumps with electrical motors of their own: Start the pump motor prior to
starting the main motor to ensure an adequate lubrication of the gearbox.
 Take care that an adequate oil pressure from 0.5 to 4 bar is applied at operating
temperature. A pressure gauge, contact making pressure gauge, pressure
monitor or flow switch is provided for monitoring depending upon the order
specifications.

For Oil Coolers:

 Take care that the water pressure does not exceed the pressure specified in
chapter 3.8 Technical Details.

For Oil Heaters:

 Warm up the gear oil to not less than +5°C at lower ambient temperatures. This
also applies to additional oil tanks, if any.

During the Running - in Period

 Increase the load of the gearbox gradually until the full load is reached after a
number of hours.
 Check the oil and bearing temperatures permanently during the running - in
period.

G 046630X 19.12.2006 5–5

 Operating Manual
Safety Instructions

6 Maintenance

6.1 Safety Instructions

Danger
Danger caused by inexpert work on and with the gearbox

Maintenance of the gearbox must be carried out by authorized skilled personnel
only.

Do not remove any safety devices (such as guards for rotating parts) from the
gearbox which serve for the prevention or elimination of dangers. Where safety
devices have to be removed for maintenance after all, they must be refitted
immediately upon completion of the work and checked for proper operation.

Bolted connections separated for maintenance must always be firmly
retightened and secured with Loctite.

Attention
Danger to the gearbox caused by strewn tools or other objects
Following maintenance see for yourself that no tools or other objects, which are
foreign to the system, are within the functional reach of the safety devices of the
gearbox.

Attention
Damages to the gearbox due to contamination
Proper operation and the service life of the gearbox as a whole are affected when
contaminants penetrate into the oil circuit. Therefore pay attention during maintenance
of the gearbox that no fibres of cleaning rags, sand or foreign material enter the
oil circuit.

Note
Damages to the gearbox due to inexpert cleaning

Clean the gearbox from oil or contamination before starting maintenance.

Do not use any aggressive detergents.

Use only non - fraying cleaning rags.

Do not clean the oil filling area or the elastic shaft seals by means of a high
pressure cleaner.

G 046630X 19.12.2006 6–1

 Operating Manual
Safety Instructions

Note
Make sure throughout the maintenance that

all bolts and nuts are tightened to the specified torques and secured with
Loctite "LV" and

internal bolts are secured with Loctite "SV".

The bolts must be cleaned and reinserted with Loctite (see chapter 7.5 Use of Loctite)
after every disassembly.

Hint
Genuine O.E.M. spares as itemized in the pertinent spare parts list shall be used
exclusively for component changes (see chapter 7.3 Spare Parts Lists).

Hint
Do not open the gearbox during the warranty period without the explicit prior
consent of EICKHOFF. Unauthorized repairs which are carried out within this period
will invalidate the warranty.

Note
Danger to the environment caused by inexpert waste disposal
All operating fluids, consumables and replacement parts must be disposed of in a
safe and environmentally protective manner in accordance with the applicable
environmental rules and regulations.

G 046630X 19.12.2006 6–2

 Operating Manual
Safety Instructions

6.2 Maintenance Table

Inspection Interval
weekly monthly during the every 1 - 2
oil change years
Lubrication Oil temperature

system Oil level

Oil pressure

Oil filter

Internal condition and function

Gearbox Bearing temperature

Leakages

Noise

Vibrations

Mounting of units

Breather

External condition

Tooth flank condition

Internal condition and

function
Maintenance Interval
weekly monthly during the every
oil change 1 - 2 years
Change oil filter insert

Change gear oil see chapter 6.3 Changing the Gear Oil
Change grease of gearbox see chapter 6.4 Changing the Grease Packing of the
Regrease grease lubricated Gearbox and of the Rolling Bearings
rolling bearings
Clean screw plug magnets

Clean interior of the gearbox

Clean oil circulating system

G 046630X 19.12.2006 6–3

 Operating Manual
Safety Instructions

6.3 Changing the Gear Oil

Using Mineral Oil :

Recommended Intervals for Mineral Oil Changes

First oil change after 300 – 500 hours of operation or after one month
at the latest
All further oil changes after 12 months
Guidelines for further oil changes as a function of the up to 70 °C every 8 000 hours of operation
operating temperature
up to 80 °C every 5 000 hours of operation
up to 90 °C every 3 000 hours of operation
up to 100 °C every 2 000 hours of operation

The gear oil must be drained completely and replaced by new oil on the expiry of the oil change
interval.
The table of lubricants contained in chapter 7.4 Table of Lubricants details a number of different gear
oils as recommended by the respective producers. Equivalent premium oils of other producers may be
used as well.

Using Synthetic Oil :

When using synthetic oil according to chapter 3.8 Technical Details you may follow the
Recommended Intervals for Mineral Oil Changes (see table above).
A regular oil sample analysis (six month interval at the latest) may extend the oil change intervals
depending on the result of the analysis.

Oil Change Procedure :

Depending on the design of the gearbox, the oil is filled either through

the hole of the breather or

the hole(s) of the marked vent screw(s) or

the hole of the inspection hole cover

Attention
Danger of burning parts of one's body on hot components or operating fluids
The oil bath temperatures attained may be as high as 90°C with the consequence
that also the gearbox components may be subject to a strong rise in temperature.
Wear safety gloves where necessary when implementing the oil change.

G 046630X 19.12.2006 6–4

 Operating Manual
Safety Instructions

Attention
Damages to the gearbox due to contamination
Proper operation and the service life of the gearbox as a whole are affected
when contaminants penetrate into the oil circuit. Therefore pay attention during
maintenance of the gearbox that no fibres of cleaning rags, sand or foreign material
enter the oil circuit.

 Remove the vent screw from the gearbox.

 Put an amply dimensioned collecting pan under the oil drain plug of the gearbox
(for the oil volume see chapter 3.8 Technical Details).

Hint
When unscrewing, you should firmly hold onto the oil drain plug with seal to prevent
the oil drain plug from falling into the collecting pan.

 Unscrew the oil drain plug with seal from the gear housing.
 Drain the oil at operating temperature.
 Clean the magnets of the oil drain plug and vent screw after having drained the
gear oil.
 Screw the oil drain plug into the gearbox.

Hint
The correct oil level is reached with the gearbox being stopped and in the
horizontal mounting position, when the oil level has risen up to the mark of the
oil level indicator, up to the lower edge of the oil level hole or up to a point
between the marks on the dip rod. Consult EICKHOFF before selecting another
mounting position. If the acknowledgement of order confirms an oblique
mounting position of the gearbox, the check marks will be provided accordingly
on the oil level indicator.

 Fill the gearbox with the oil specified on the gearbox rating plate (see also
chapter 3.8 Technical Details). Observe the oil level indicator during filling. If the
actual oil level is above the specified level, the oil will heat up additionally and
show a tendency towards foaming.

 Screw the vent screw into the gearbox.

Note
If you remove the inspection hole cover for the oil filling, do not forget to reinsert it
with a new jointing compound.

G 046630X 19.12.2006 6–5

 Operating Manual
Safety Instructions

Note
Danger to the environment caused by inexpert waste disposal
All operating fluids, consumables and replacement parts must be disposed of in a
safe and environmentally protective manner in accordance with the applicable
environmental rules and regulations.

G 046630X 19.12.2006 6–6

 Operating Manual
Drawings and Tables

7 Drawings and Tables

7.1 Dimensional Drawings

010134 G2 B Dimension Sheet

G 046630X 19.12.2006 7–1

 Operating Manual
Drawings and Tables

7.2 Spare Parts Drawings and - list

G 046630X Helical Gearbox

G 045656 Filter

G 052851 Shear Pin Coupling MTNBR - 230

G 046630X 19.12.2006 7–2

 Operating Manual
Drawings and Tables

ERSATZTEILLISTE
SPARE PARTS LIST
G 046630X STIRNRADGETRIEBE ANOX - 110 I = 1.1961 : 1
SPUR WHEEL GEARBOX
Teilzeichen Menge ME Benennung Zusatzbenennung
PART NUMBER QTY DESIGNATION DESIGNATION ADDITION
G 025279 2 St DECKEL 0125X0180X013
COVER
G 025280 2 St DICHTUNG 0125X180X01,5X0085X0140
SEAL
G 035077 4 St OELWANNE
OIL PAN
G 035078 4 St DICHTUNG 083518
SEAL
G 035739 1 St VERSCHLUSSDECKEL 0309/345X38,0
CLOSING COVER
G 036094 1 St LAUFBUCHSE 0200/220X0081
BUSH
G 036094 1 St LAUFBUCHSE 0200/220X0081
BUSH
G 043711 1 St DURCHGANGSDECKEL 0080/310/345X38
THROUGH-COVER
G 043740 1 St KUPPLUNGSMUFFE 0024/060X53-30
COUPLING SLEEVE
G 043749 1 St PUMPE KF 40 RF2 - D15 KRACHT
PUMP
G 045655Z 1 St GETRIEBEGEHAEUSE FUER ANO-110
GEARBOX CASING
G 045739 1 St DURCHGANGSDECKEL 0222/310/345X36 8XDU18
THROUGH-COVER
G 045739 1 St DURCHGANGSDECKEL 0222/310/345X36 8XDU18
THROUGH-COVER
G 045744 1 St BUCHSE 0205/245X0049
BUSH
G 045746 1 St BUCHSE 0205/245X0045
BUSH
G 046634W 1 St ANTRIEBSWELLE MIT STIRNRAD
INPUT SHAFT
G 046635Y 1 St OELLEITUNG FUER ANOX - 110 OZ
OIL CONDUITE
G 046637W 1 St ABTRIEBSWELLE M.STIRNRAD
OUTPUT SHAFT

G 046630X 19.12.2006 7–3

 Operating Manual
Drawings and Tables

ERSATZTEILLISTE
SPARE PARTS LIST
G 046630X STIRNRADGETRIEBE ANOX - 110 I = 1.1961 : 1
SPUR WHEEL GEARBOX
Teilzeichen Menge ME Benennung Zusatzbenennung
PART NUMBER QTY DESIGNATION DESIGNATION ADDITION
L 000502 4 St SECHSKANTSCHRAUBE M008 X025 DIN00933 8.8
HEXAGON SCREW
L 000502 16 St SECHSKANTSCHRAUBE M008 X025 DIN00933 8.8
HEXAGON SCREW
L 000513 8 St SECHSKANTSCHRAUBE M008 X012 DIN00933 8.8
HEXAGON SCREW
L 001395 2 St VERSCHLUSSCHRAUBE G2A DIN00908 ST-
CLOSING SCREW PHR
L 001705 4 St KERBNAGEL 0003 X006 ISO 8746 ST-
GROOVED DRIVE STUD A3A
L 004908 1 St ZYLINDERSCHRAUBE M012 X025 DIN06912 8.8
CYLINDRICAL SCREW
L 004908 1 St ZYLINDERSCHRAUBE M012 X025 DIN06912 8.8
CYLINDRICAL SCREW
L 005425 8 St SECHSKANTSCHRAUBE M016 X040 DIN00933 8.8
HEXAGON SCREW
L 005425 8 St SECHSKANTSCHRAUBE M016 X040 DIN00933 8.8
HEXAGON SCREW
L 005425 8 St SECHSKANTSCHRAUBE M016 X040 DIN00933 8.8
HEXAGON SCREW
L 005425 8 St SECHSKANTSCHRAUBE M016 X040 DIN00933 8.8
HEXAGON SCREW
L 010481 1 St GEWINDESTIFT M006 X016 DIN00916 45H
THREADED PIN
L 052302 2 St KEGELROLLENLAGER 200X310X70 32040 X
TAPER ROLLER BEARING
L 052302 2 St KEGELROLLENLAGER 200X310X70 32040 X
TAPER ROLLER BEARING
N 002948 B 1 St LEISTUNGSSCHILD 0074X105X1 ENGLISCH
RATING PLATE CUZN 37
N 004958 1 St BELUEFTUNGSFILTER G003/4A DIV.
BREATHER FILTER
N 006347 2 St DICHTRING A060X068X2.5 DIN07603
SEAL RING CU
N 006378 1 St DICHTRING A027X032X2 DIN07603
SEAL RING CU

G 046630X 19.12.2006 7–4

 Operating Manual
Drawings and Tables

ERSATZTEILLISTE
SPARE PARTS LIST
G 046630X STIRNRADGETRIEBE ANOX - 110 I = 1.1961 : 1
SPUR WHEEL GEARBOX
Teilzeichen Menge ME Benennung Zusatzbenennung
PART NUMBER QTY DESIGNATION DESIGNATION ADDITION
N 007869 1 St O-RING 199.2X5.7 NB 70
O-RING
N 007869 1 St O-RING 199.2X5.7 NB 70
O-RING
N 007966ZA 1 St OELSTANDSAUGE G1A X009 CUZN
OIL LEVEL GLASS
N 008953 1 St WELLENDICHTRING 220X250X15 AUSF.BA UM
SHAFT SEAL RING FP
N 008953 1 St WELLENDICHTRING 220X250X15 AUSF.BA UM
SHAFT SEAL RING FP
N 011329 1 St PASSFEDER D045X025X270 DIN06885
PARALLEL KEY 1.7225QT
N 011329 1 St PASSFEDER D045X025X270 DIN06885
PARALLEL KEY 1.7225QT
110305201215 1900 mm ROHR 012 X001.5 DIN02391
PIPE 1.0255
110305202215 1300 mm ROHR 022 X001.5 DIN02391
PIPE 1.0255
110305202820 1000 mm ROHR 028 X002 DIN02391
PIPE 1.0255
G 028934 1 St DRUCKSCHALTER 0166-40103-1-003 MEMBRAN
PRESSURE SWITCH 0,8 BAR
G 028936 1 St SCHUTZKAPPE
PROTECTION CAP
G 044137 1 St MANOMETER 0010,0-063-G 1/4A
MANOMETER EDELSTAHL
G 045656 1 St LEITUNGSFILTER TYP AGS-100 G1" PARKER
LINE FILTER
G 045740 1 St OELKUEHLER EKM 1024 T
OIL COOLER
L 000335 1 St SCHEIBE 0027 DIN01440 ST
DISC
L 000619 4 St SCHEIBE B10.5-140HV DIN00125 ST
DISC
L 000827 3 St KERBSTIFT 0005 X028 DIN01471 ST
GROOVED PIN

G 046630X 19.12.2006 7–5

 Operating Manual
Drawings and Tables

ERSATZTEILLISTE
SPARE PARTS LIST
G 046630X STIRNRADGETRIEBE ANOX - 110 I = 1.1961 : 1
SPUR WHEEL GEARBOX
Teilzeichen Menge ME Benennung Zusatzbenennung
PART NUMBER QTY DESIGNATION DESIGNATION ADDITION
L 002017 1 St VERSCHRAUBUNG DL28 DIN02353 ST-
SCREW JOINT GER.
L 002229 1 St VERSCHRAUBUNG KL12 DIN02353 ST
SCREW JOINT
L 002232 1 St VERSCHRAUBUNG KL22 DIN02353 ST
SCREW JOINT
L 002232 1 St VERSCHRAUBUNG KL22 DIN02353 ST
SCREW JOINT
L 002232 1 St VERSCHRAUBUNG KL22 DIN02353 ST
SCREW JOINT
L 002233 2 St VERSCHRAUBUNG KL28 DIN02353 ST
SCREW JOINT
L 002233 1 St VERSCHRAUBUNG KL28 DIN02353 ST
SCREW JOINT
L 002256 1 St VERSCHRAUBUNG QL22 DIN02353 ST
SCREW JOINT
L 002256 1 St VERSCHRAUBUNG QL22 DIN02353 ST
SCREW JOINT
L 002341 1 St REDUZIERSTUTZEN RI 1 1/2X3/4 ST
REDUCING JOINT
L 002342 1 St REDUZIERSTUTZEN RI 1 1/2 X 1 ST
REDUCING JOINT
L 002516 1 St VERSCHRAUBUNG MAVE 12-LR G1/4 ST
SCREW JOINT
L 002516 1 St VERSCHRAUBUNG MAVE 12-LR G1/4 ST
SCREW JOINT
L 005086 2 St SECHSKANTMUTTER M010 DIN00934 8
HEXAGON NUT
L 005372 3 St SECHSKANTSCHRAUBE M010 X025 DIN00933 8.8
HEXAGON SCREW
L 005374 4 St SECHSKANTSCHRAUBE M010 X035 DIN00933 8.8
HEXAGON SCREW
L 008807 1 St VERSCHRAUBUNG EW22-PL ------- ST
SCREW JOINT
L 008807 2 St VERSCHRAUBUNG EW22-PL ------- ST
SCREW JOINT

G 046630X 19.12.2006 7–6

 Operating Manual
Drawings and Tables

ERSATZTEILLISTE
SPARE PARTS LIST
G 046630X STIRNRADGETRIEBE ANOX - 110 I = 1.1961 : 1
SPUR WHEEL GEARBOX
Teilzeichen Menge ME Benennung Zusatzbenennung
PART NUMBER QTY DESIGNATION DESIGNATION ADDITION
L 008827 2 St VERSCHRAUBUNG EW22-PLR-ED G3/4A ST
SCREW JOINT
L 008828 1 St VERSCHRAUBUNG EW28-PLR-ED G1A ST
SCREW JOINT
L 008828 2 St VERSCHRAUBUNG EW28-PLR-ED G1A ST
SCREW JOINT
L 008887 1 St VERSCHRAUBUNG ET22-PLR-ED G3/4A ST
SCREW JOINT
L 008887 1 St VERSCHRAUBUNG ET22-PLR-ED G3/4A ST
SCREW JOINT
L 009903 3 St ROHRSCHELLE 0013 DIN01592 ST
PIPE CLAMP
L 012054 2 St VERSCHRAUBUNG ROV 12-PL ST
SCREW JOINT
L 012054 1 St VERSCHRAUBUNG ROV 12-PL ST
SCREW JOINT
L 014139 1 St REDUZIERANSCHLUSS RED22/12-PL M30X2 ST
REDUCING CONNECTION
L 014139 1 St REDUZIERANSCHLUSS RED22/12-PL M30X2 ST
REDUCING CONNECTION
L 014139 2 St REDUZIERANSCHLUSS RED22/12-PL M30X2 ST
REDUCING CONNECTION
L 014139 1 St REDUZIERANSCHLUSS RED22/12-PL M30X2 ST
REDUCING CONNECTION
L 014164 2 St REDUZIERANSCHLUSS RED42/28-PL M52X2 ST
REDUCING CONNECTION
L 014228 1 St VERSCHRAUBUNG EGE28-PLR-ED G1A ST
SCREW JOINT
L 014765 2 St SAE-FLANSCHVERBDG. GFS36/42-PL NENNGR.1 1/2
SAE SCREW JOINT
N 001192 3 St PASSFEDER A020X012X065 DIN06885
PARALLEL KEY 1.0503+C
N 010521 1 St SCHLAUCHLEITUNG(L) 25DNX1150 2ST-FA DIV.
HOSE (LIGHT SERIES)

G 046630X 19.12.2006 7–7

Installation and maintenance instructions for MTBR-MTNBR couplings in
case of external screw at flange-hub

1
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

INSTRUCTIONS

These instructions refer to the MTBR-MTNBR shear pin type coupling in case screws that
join coupling’s inner shaft and flange-hub have been assembled outside. See this
drawing below for different coupling parts as well as for the different terms used.

Contents

1.- General Instructions

2.- Installation
2a. First step: Preparation for assembly.
2b.Second step: Assembly on site.
3.- Alignment.
4.- Lubrication.
5.- Final assembly.
6.- Coupling removal
7.- Replacement of the shear pins
8.- Maintenance
9.- General Recommendations.

1.- General Instructions

Prior to installation, inspect the coupling for any signs of possible damage during shipment.
Check that all the parts are on hand and that they are as ordered. Warning : Use only parts
from the original supplier.

Components should be supported during handling to avoid damage and should be

wrapped for protection.

Read all the installation instructions and review the procedure before the actual coupling
installation.

Always use caution when working on rotating equipment . Be sure to lock out the
starting switch of the prime mover so that the equipment cannot be started until work is
completed , checked, and personnel are safely away.

2
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

Different coupling sizes are installed:

Jaure coupling size

MTBR-145
MTBR-165
MTBR-185
MTBR-205
MTBR-230

2.- Installation of the coupling

The coupling is supplied fully assembled and it has to be disassembled and prepared for
assembly on the gearbox, as follows :

2a. First step: Preparation for assembly.

1.- The coupling is supplied completely assembled with protecting grease on the gear mesh.
This grease must be removed.

2.- Remove firstly the screws 15. Then remove screws 18,19 and cover 29 (after
removing screws 21). Finally, remove items 43, 42, 9, 41 and 8.
3
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

3.- Remove the screws item 25, 26

Coupling size Thread size (metric sizes)

MTBR 145 M8
Rest of sizes M10

2b.Second step: Assembly on site.

1.- Check that the hub bores and shafts are free from nicks and burrs. Make sure that the bore
and shaft are clean, and have the correct dimensions.

2.- Install the rigid hub item 5 on the corresponding shaft. For this purpose heat the hubs
prior to installation. For an interference fit ISO H7/m6 (0.005inch/inch),at least 110ºC
(230 ºF) is required. Install the hub item 5 and make sure that the shaft is flush with
counterbore of the hub item 5.

3.- Install stub shaft item 6 to the hub item 5, and tighten the screws item 25 with their
corresponding lock washers item 26 to the specified tightening torque using a torque
wrench.

Item 25 Tightening torque values

Coupling size Tightening torque Tightening

in Nm torque in lb-in
MTBR-145 46 400
MTBR-165 79 700
MTBR-185 79 700
MTBR-205 193 1700
MTBR-230 193 1700

4.- Place the shear pins item 8 in the hubs item 4 and item 5. Join the shear pins by
means of the place wire supplied. Install the retainer rings item 27 in order to lock the
shear pins in place.

5.- Place the cover item 7 on the gearbox shaft prior to the installation the gearbox hub
item 1

6.- Heat the gearbox hub item 1. Do not use an open flame burner. Install the hub item 1
on the shaft with the longest chamfer hub end towards the gearbox bearing. Hub face

4
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

has to be flush with shaft end. Place ring item 17 on the hub only after it cools down in
order to avoid damage of the seal item 15.

7.- Allow the hub cools down before installing the sleeve item 2

8.- Install the sleeve item 3 on hubs item 4 and item 29.

9.- Install machines in place.

3.- Alignment

The better the alignment the longer the coupling life. This is true except that a slight angular
misalignment (0.05º) is always advisable in order to have good lubrication conditions. Despite
this image, in this case you must use the following surfaces to make the alignment: For the left
side hub (nº 1), the same place must be used. For the right side one, instead of the hub, the
external diameter of part number 5 or 4 must be used, as there is no place to use number 36. It
is absolutely valid to do it this way.

a) Check the angular alignment

Place a dial indicator and measure the distance Y-Z where Y is the maximum reading
and Z is the minimum reading as shown in the drawing. The existing Y-Z should be less
than the Y-Z value mentioned in the tables below.

b) Check the offset alignment

Attach a dial indicator bracket to hub item 4 with dial indicator probe contacting the opposite hub
item 1 alignment surface. Rotate the hub on which the dial indicator is attached, and take
readings at 4 points 90º apart. The offset should be less than X value mentioned in the tables
below.

5
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

Values valid for speeds between 1000-2000 rpm
Coupling Size Xmax in Xmax in Y-Z max Y-Z max
mm inch. in mm in inch

MTBR-145/165/185 0.15 0.006 0.20 0.008

MTBR-205/230

4.- Lubrication.

Once the coupling has been aligned it has to be lubricated. The coupling must be
lubricated before operation. Couplings are supplied originally with protective grease
but not with lubricating grease. Remove this protective grease and use the proper ones
mentioned below.

Lubrication has to be performed both at the gear-mesh as well at the bearings. Different
quantities and grease qualities are needed at each place.

a) Lubrication of the gear-mesh:

Before bolting the sleeves , approx. 70% of the grease quantity shall be hand packed
between the hub and sleeve teeth and surrounding area. After tightening the sleeve bolts
the remaining 30% of the grease shall be pumped into the sleeve lubrication holes item
14. For this purpose both lubes at 180º must be removed in order to vent the interior ; an
air lock can result in incomplete filling or in damage of the seals. After lubrication ,
tigthen the lube plugs to the specified torque :

Lube pos.14 Tightening torque

Coupling size Tightening Tightening
torque in Nm torque in lb-in
MTBR-145 25 200
MTBR-165 25 200
MTBR-185 25 200
MTBR-205 30 260
MTBR-230 35 300

The grease quantity at the gear mesh is as follows :

Coupling size Grease quantity Grease quantity

in kg in lb
MTBR-145 0.6 1.33
MTBR-165 1 2.22
MTBR-185 1.12 2.50
MTBR-205 1.64 3.64
MTBR-230 2 4.45
6
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

For “standard” conditions such as:
- Angular misalignment less than 35’.
- Coupling surface temperature lower than 70ºC ( ºF)
- Speed between 40-3000 rpm
- No big shock loads, No big reversing loads.
- Good sealing conditions. No severe environment

The following greases can be used :

- Coupling grease KP 0/1 K-30 from TEXACO
- Mobilgrease XTC from MOBIL
- Unirex RS 460 or Pen-0-Led from EXXON
- Hi-Speed coupling grease from EXXON
- Albida GC1 from SHELL

If such greases cannot be found , alternative greases should comply with the following :

- Base oil viscosity : Higher than 500CST at 40ºC (ºF) and higher than 40CST at
100ºC(ºF)
- Consistency following NLGI : between 0 and 1
- Thickener content ( Metallic soap ) : Less than 8%
- Drop point : Higher than 120ºC (ºF)
- Heavy additive: The less the better
- EP additive: Advisable
- Oxidation inhibitors: Required

If working conditions differ substantially from the conditions above please consult our
technical department

b) Lubrication of the bearings.

The purpose of lubricating the bearings is to have a good rotating surface whenever the
shear pins might break. Therefore the grease to be used in this area is minimum.

Grease shall be pumped at fitting item 20.

The type of grease to be used should be an EP-2 grease.

For grease quantities to be used please see below :

Coupling size Grease quantity Grease quantity

in kg in lb
MTBR-145 0.25 0.55
MTBR-165 0.5 1.10
MTBR-185 0.5 1.10

7
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

 MTBR-205 0.8 1.76
MTBR-230 0.8 1.76

5.- Final assembly.

Install the sleeves item 3, gaskets item 16 and tighten bolts item 18 to the specified
torque using a torque wrench :

Bolts item 8 Tightening torque

Coupling size Tightening torque Tightening torque
in Nm in lb-in
MTBR-145 108 930
MTBR-165 108 930
MTBR-185 328 2825
MTBR-205 328 2825
MTBR-230 328 2825

6.- Coupling removal

1.- In order to dismount the coupling proceed as mentioned in the installation

instruction refering to coupling preparation for assembly.

2.- Remove the hubs from their shafts using the pulling holes

7- Replacement of the shear pins

In case of a shear pin failure , the machine has to be inmediatelly stopped.

The metallic wire that joins the different pins has to be removed to allow the installation
of new pins.

The different pins in each coupling type are shown below :

- MNBR-150 = MTBR-145 = MTNBR-145

- MNBR-210 = MTBR-165 = MTNBR-165
- MNBR-325 = MTBR-185 = MTNBR-185
- MNBR-430 = MTBR-205 = MTNBR-205
- MNBR-600 = MTBR-230 = MTNBR-230

8
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

 13
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

8.- Maintenance

Every 4000 working hours or once a year:

- Add new grease , preferably removing the existing one in the gear meash.

Every 8000 hours :

- Before moving the sleeves , clean the hub surfaces near the seal rings of rust and dirt
as they might damage the seals.
- Remove the bolts item 18
- Inspect the gear meshes and seals
- Inspect alignment.
- Add new grease in the gearing and refill the one in the bearings.

9.- General Recommendations.

Before start up….For reasons of safety and to extend shaft coupling life, follow this
requirements.
Take the time to check your work.
1) Coupling guards protect personnel. All couplings must be covered with a guard, as
per OSHA requirements.
2) Recheck the alignment after all foundations bolts and mechanical connections are
tightened.
3) Use only the coupling manufacturer´s specified hardware. Make sure that all the
fasteners are properly torqued.
4) Make sure the coupling has been lubricated, and lubrication plugs are properly
torqued.
5) Do not allow contaminants to enter the coupling.
6) It is advisable to replace self-locking nuts after they have been assembled and
removed from the bolts FIVE (5) times.
7) For coupling dimensions, refer to specific drawing. For torque and lubrication
values refer to the values in this instruction sheets.
8) If further information is required , please contact :

JAURE SA
Ernio Bidea s/n
20150 Zizurkil
SPAIN
Tel. +34-943-690054
Fax. +34-943-690295
14
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

 e-mail : [email protected]
http: www.jaure.com

15
JAURE, S.A. ERNIO BIDEA, S/N 20150 ZIZURKIL (Guipúzcoa) - SPAIN
Tel: (+34) 943 690054 Fax: (+34) 943 690295
www.jaure.com

Blow torch installation-ME-03A-I

 Operating Manual
Drawings and Tables

7.3 Table of Lubricants

The selection of the proper lubricant depends on the corresponding technical details of the gearbox as
specified in the present operating manual.

Gear Oils on Mineral Oil Base

Viscosity Lubricant *
ISO - ** ARAL BP DEA ESSO Klüber MOBIL SHELL Tribol Castrol Optimol FUCHS
VG 680 Degol Energol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Optigear Renolin
BG 680 GR-XF CLP-680 EP 680 GEM XMP-680 Oil F 680 1100/680 BM 680 CLP 680
680 1-680 Plus
VG 460 Degol Energol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Optigear Renolin
BG 460 GR-XF CLP-460 EP 460 GEM XMP-460 Oil F 460 1100/460 BM 460 CLP 460
460 1-460 Plus
VG 320 Degol Energol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Alpha Optigear Renolin
BG 320 GR-XF CLP-320 EP 320 GEM XMP-320 Oil F 320 1100/320 MW 320 BM 320 CLP 320
320 1-320 Plus
VG 220 Degol Energol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Alpha Optigear Renolin
BG 220 GR-XF CLP-220 EP 220 GEM XMP-220 Oil F 220 1100/220 MW 220 BM 220 CLP 220
220 1-220 Plus
VG 150 Degol Energol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Alpha Optigear Renolin
BG 150 GR-XF CLP-150 EP 150 GEM XMP-150 Oil F 150 1100/150 MW 150 BM 150 CLP 150
150 1-150 Plus
VG 100 Degol Falcon SPARTAN Klüberoil Mobilgear Omala Tribol Alpha Optigear Renolin
BG 100 CLP-100 EP 100 GEM XMP-100 Oil F 100 1100/100 MW 100 BM 100 CLP 100
1-100 Plus
Greases for Gearboxes
Aralub Energrease Orona 00 Fibrax Microlube Mobilplex Alvania Molub- CLS- Longtime Calypsol
FD 00 HTO Orona EP 370 GB 00 44 GL 00 Alloy 00 Grease PD 00 SF7-047
FDP 00 HT 00 EP FG EP 0 00
Lithium Base Saponified Greases for Rolling Bearings
Aralub Energrease Glissando Beacon 3 Centoplex Mobilux 2 Alvania Molub- Spheerol Longtime
HL 2 LS 2 30 GLP 402 Mobilux 3 R2 Alloy AP2 PD 2
Glissando BRB 572 LZV-EP
20

(* designation acc. to DIN 51 502 ** acc. to DIN 51 519 at 40°C)

The above gear oils on CLP mineral oil base comply with the minimum requirements as specified in
DIN 51517 Part 3.
They contain additives for improving the oxidation, corrosion, foaming and wear protection properties
and are suited for operating temperatures ranging from –10°C to +100°C. Synthetic lubricants are
used where different operating temperatures are encountered.

G 046630X 19.12.2006 7–8

 Operating Manual
Drawings and Tables

7.4 Use of Loctite

Danger
As none of the Loctite products is LOBA approved, bolted connections secured with
Loctite 243 in a separable manner as set out in the following paragraph For Bolted
Connections, must in no case be used for components in deep mining application.

The Loctite products addressed in this operating manual are used where bolted
connections shall be secured against undesired separation (e.g. due to vibrations or
shock loads).

For Bolted Connections

Type of the Nominal Product Information Notes on the Drawing
Connection thread Ø
d
Separable, medium- Loctite Product 243
strength Colour: blue identification of the secured bolts by *
"LV" Breakaway torque DIN 54454, and the note:
M10 - bolts: 14-34 Nm secured as per GEN 6000812.06"LV“
(connection can be for a temperature range of: adjacent to the drawing title block
separated using - 55° to +150°C
standard tools)
Hardly separable ≤ 36 Loctite Product 262
high-strength Colour: red identification of the secured bolts by *
"SV" Breakaway torque DIN 54454, and the note
(connection that need M10 - bolts: 15-50 Nm secured as per GEN 6000812.06"SV“
not be separated later for a temperature range of: adjacent to the title block
on) - 55° to +150°C
Preparation of the Surface

Hint
The lightly oiled surfaces need not be cleaned.

Application of the Adhesive

 Apply the adhesive to one contact surface only (preferably to that of the bolt
thread). Be careful to treat the overall thread length.

For threaded blind holes:

 It is of paramount importance that the adhesive be applied to the bottom of the
threaded hole. The quantity of the adhesive shall be selected so that the
displaced adhesive fills the overall thread length after assembly.
 When screwing the bolt in, screw it back by a number of turns so that the
entrapped compressed air can escape.

G 046630X 19.12.2006 7–9

 Operating Manual
Annex

8 Annex

8.1 Service
Eickhoff Maschinenfabrik GmbH offer their customers a 24-hour hotline
at the following telephone number:

+ (2 34) 9 75 – 27 00

8.2 Company Address

Eickhoff Maschinenfabrik GmbH

Postfach 10 06 29

44706 Bochum

Hunscheidtstrasse 176

44789 Bochum

Telephone: + (2 34) 9 75 – 0

Telefax EAT: + (2 34) 9 75 – 25 79

E-Mail: [email protected]

G 046630X 19.12.2006 8–1

 Operating Manual
Annex

8.3 Agencies
Norddeutschland • North Germany USA und Mexiko · U.S.A. and Mexico
Wolfgang Henneberger Eickhoff Corporation
Marsenstrasse 64 200 Park West Drive
D-48429 Rheine Pittsburgh PA 15275, USA
Tel. (+ 49) 0 59 71 / 8 18 03 Tel. (+ 1) 04 12 / 7 88 - 14 00
Mobil (+ 49) 0172 / 2 80 33 85 Fax (+ 1) 04 12 / 7 88 - 41 00
Fax (+ 49) 0 59 71 / 8 19 38 E-Mail: [email protected]
E-Mail: [email protected]
Südafrika · South Africa
Süd- u. Südostdeutschland • South and Southeast Germany Eickhoff Pty. Ltd. Mining Machinery and Gearboxes
Dipl.-Ing. Sabine Hörling-Eckhard 12 Strauss Crescent, Wadeville Ext. 6
Eickhoff Maschinenfabrik GmbH P.O. Box 1 46 74, Wadeville 1422
Hunscheidtstrasse 176 Tel. (+ 27) 0 11 / 9 02-56 30
D-44789 Bochum Fax (+ 27) 0 11 / 9 02-58 30
Tel. (+ 49) 02 34 / 9 75-22 54 E-Mail: [email protected]
Fax (+ 49) 02 34 / 9 75-25 79
E-Mail: [email protected] Polen · Poland
West- u. Südwestdeutschland • West and Southwest Germany Eickhoff Polonia Ltd.
Podleska 72
Dipl.-Ing. Hans Bäcker
PL-43-190 Mikolow
Eickhoff Maschinenfabrik GmbH
Tel. (+ 48) 0 32 / 2 06 60 10
Hunscheidtstrasse 176
Fax (+ 48) 0 32 / 2 02 87 44
D-44789 Bochum
E-Mail: [email protected]
Tel. (+ 49) 02 34 / 9 75-25 01
Mobil (+ 49) 0172 / 2 82 85 93 V. R. China P. R. China
Fax (+ 49) 02 34 / 9 75-25 79 Eickhoff Office Beijing
E-Mail: [email protected] Room A0708, Huixin Plaza
Export No. 8 Beichen East Road
Dipl.-Ing. Klaus-Dieter Meyer Chaoyang District
Eickhoff Maschinenfabrik GmbH Beijing 100101
Hunscheidtstrasse 176 Tel. (+ 86) 10 51662022
D-44789 Bochum Fax (+ 86) 10 84982560
Tel. (+ 49) 02 34 / 9 75-23 62 E-Mail: [email protected]
Mobil (+ 49) 0172 / 2 84 30 81
Fax (+ 49) 02 34 / 9 75-25 79 Spanien · Spain
E-Mail: [email protected] Alfred Klöpp
c/ Dr. Robert, 7, 2°, 2a
Österreich • Austria E-08915 Badalona (Barcelona)
Dipl.-Ing. Sabine Hörling-Eckhard Tel. (+ 34) 0 93 / 3 99 35 62
Eickhoff Maschinenfabrik GmbH Mobil (+34) 0618 / 31 60 90
Hunscheidtstrasse 176 Fax (+ 34) 0 93 / 4 60 14 19
D-44789 Bochum E-Mail: [email protected]
Tel. (+ 49) 02 34 / 9 75-22 54
Fax (+ 49) 02 34 / 9 75-25 79 Schweden und Finnland · Sweden and Finland
E-Mail: [email protected] Injab Transmission AB
Ringvägen 99
Australien • Australia
SE-118 60 Stockholm
Eickhoff Australia Pty. Ltd.
Tel. (+ 46) 08 / 55 69 76 60
P.O. Box 4 06, 41 Prince William Drive
Fax (+ 46) 08 / 55 69 76 61
Seven Hills, N.S.W. 21 47
E-Mail: [email protected]
Tel. (+ 61) 02 / 96 74 67 33
Fax (+ 61) 02 / 96 74 65 81 Taiwan (R.O.C.)
E-Mail: [email protected] KCW Eternal Enterprise Co., Ltd.
Großbritannien • Great Britain No. 666, Yung-An St.,
Eickhoff (G.B.) Ltd. Tainan 702, Taiwan, R.O.C.
Darnall Works, Prince of Wales Road Tel. (+ 886) 06 / 2 96 53 96
Sheffield S9 4EX Fax (+ 886) 06 / 2 96 57 00
Tel. (+ 44) 870 122 1164 E-Mail: [email protected]
Fax (+ 44) 870 122 1165
E-Mail: [email protected]

G 046630X 19.12.2006 8–2

 Operating Manual
Annex

8.4 Manufacturer’s Declaration

Manufacturer's Declaration for Machinery that is Not Ready for

Use in the Sense of the EC Directive 98/37/EC, Annex II B

We hereby declare that the

Designation of the gearbox: 1 - stage helical gearbox

Part number: G 046630X

is designed for being installed in a machine and that its putting into operation is prohibited until it has
been ascertained on completion of the installation that the complete machine complies with the latest
issue of the EC Directive.

The existing Manufacturer's Declaration takes all Harmonized Standards into account - as far as they
are applicable to our products - published by the EC Commission in the Official Journal of the
European Community.

These are especially: EN 292/2

EN 563

Date / Place: 19.12.2006 / Bochum

Details of the Signatory: ppa. Dr.- Ing. R. Wittor

(Head of the Power Transmission Division)

G 046630X 19.12.2006 8–3