YILMAZ REDÜKTÖR T Series Operating Instructions Manual Download Page 2

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Contents. ...........................................................................................................................02

1 - How to Use This Manual .............................................................................................05

2 - Unit Designation ..........................................................................................................06

2.1- Detailed Unit Designation .......................................................................................

2.2- Nameplate, Unit Designation

....................................................................................

3. Standard Type Gearbox Parts Lists

..............................................................................

3.1- TT..00 type

...............................................................................................................

3.2- TT..00.K type ........................................................................................................09

3.3- TT..0S type............................................................................................................10

3.4- TT..0S.K type ........................................................................................................ 11

4- Things to Check Before the Gear Unit or Geared Motor is Installed ...................... 12

4.1- Safety notes for use in potentially explosive atmosphere ......................................

Intended use of Gearbox .......................................................................................

4.2- Transportation ........................................................................................................

4.3- Storage ...................................................................................................................

5 - Installing the Gear Unit ...............................................................................................14

5.1- Before You Start .....................................................................................................

5.2- Check Name Plate of the Gear Unit .......................................................................

5.3- Check the Ambient Conditions and Temperature ..................................................

5.4- Check Fitting Elements and the Shaft Dimensions to Fit ......................................

5.5- Check the Voltage Supply ......................................................................................

5.6- Check the Mounting Position..................................................................................

5.7- Usage of Breather Plug ..........................................................................................

5.8- Check the oil level ..................................................................................................

5.9- Check shaft ends and mounting faces ...................................................................

5.10- Cover abrasive ambients......................................................................................

5.11- Check accessibility to filling, breather and drain plugs .........................................

6- Mechanical Installation ................................................................................................18

6.1- Installing gear units in category II2G/D-II3G/D .......................................................

6.2- Installing Customer Shaft with Shoulder ................................................................

6.3- Installing Customer Shaft without Shoulder ...........................................................

6.4- Disassembling Customer Shaft with Shoulder .......................................................

6.5- Disassembling Customer Shaft without Shoulder ..................................................

6.6- Shaft Tightening Torques .......................................................................................

6.7- Recommended Shaft Dimensions and Mounting Washer Dimensions ..................

6.8- Assembling customer shaft with shrink disk ...........................................................

Operating Instructions

T Series

YILMAZ REDÜKTÖR

Contents

Summary of Contents for T Series

Page 1: ...YILMAZ REDÜKTÖR ISO 9001 YILMAZ REDÜKTÖR ISO 9001 T Series Gear Units Operating Instructions OITEX0500 0612 o ...

Page 2: ...Fitting Elements and the Shaft Dimensions to Fit 14 5 5 Check the Voltage Supply 16 5 6 Check the Mounting Position 16 5 7 Usage of Breather Plug 16 5 8 Check the oil level 17 5 9 Check shaft ends and mounting faces 17 5 10 Cover abrasive ambients 17 5 11 Check accessibility to filling breather and drain plugs 17 6 Mechanical Installation 18 6 1 Installing gear units in category II2G D II3G D 18 6...

Page 3: ...tion of input shaft elements 31 6 14 Fitting couplings 32 7 Maintenance and Inspections 33 8 Lubrication 34 8 1 Oil types 34 8 2 Changing the oil 35 8 3 Oil quantities lt 35 8 4 Oil plugs 36 8 5 Mounting Positions 37 9 Troubleshooting Guide 38 10 Appendix 10 1 Warranty Conditions 10 2 Warranty Decleration 10 3 Service Contact Points Operating Instructions T Series YILMAZ REDÜKTÖR Contents ...

Page 4: ...4 Operating Instructions T Series YILMAZ REDÜKTÖR ...

Page 5: ...ar units and is applicable only for these series If any different type of gear unit is used please ask YILMAZ REDUKTOR For special application and modified gear units ask YILMAZ REDUKTOR for validity The T series gear units are with input shaft and without motor The electric motor which will be con nected to the gear unit must also be in conformity with the ATEX 94 9 EC standards All the external ...

Page 6: ...0S Hollow shaft with shrink disc Backstop option K Backstop is avaliable Backtop is unavaliable Mounting Position M1 Gear unit is upright and input shaft is over output shaft M2 Input shaft is vertical to earth and input shaft points to sky M3 Gear unit is upright and input shaft is under output shaft M4 Input shaft is vertical to earth and input shaft points to earth M5 Input and output shaft is ...

Page 7: ...S ATATÜRK Mah Lozan Cad No 17 P K 34522 Esenyurt İstanbul TÜRKİYE TT57 00 K 2GD 100478985 11 1400 4850 85 42500 1500 37500 500 5 3 MINERAL VG320 M1 Abbreviations Type Type of gearbox S N Serial Number of gear unit IP Enclosure P Max Allowed Power M Output torque n Input speed n Output speed FR Max allowed radial load at output shaft FR Max allowed radial load at input shaft FA Max allowed axial lo...

Page 8: ...er 22 Gear 31 Bolt 40 Bolt 5 Cover Plate 14 Gear 23 Key 32 Input Shaft Cover 6 Plug 15 Output Hollow Shaft 24 Pinion 33 Bearing 7 Plug 16 Bearing 25 Bearing 34 Circlip 8 Circlip 17 Circlip 26 Shim 35 Key 9 Mounting Washer 18 Oil Seal 27 Washer 36 Input Pinion Shaft Standard TT 00 type basic part diagram Parts may differ for special applications Standard Part List Operating Instructions T Series YI...

Page 9: ... 5 Cover Plate 14 Gear 23 Key 32 Input Shaft Cover 41 Backstop Cover 6 Plug 15 Output Hollow Shaft 24 Pinion 33 Bearing 42 Bolt 7 Plug 16 Bearing 25 Bearing 34 Circlip 8 Circlip 17 Circlip 26 Shim 35 Key 9 Mounting Washer 18 Oil Seal 27 Washer 36 Input Pinion Shaft Standard TT 00 K type basic part diagram Parts may differ for special applications Standard Part List Operating Instructions T Series ...

Page 10: ... Oil Seal 40 Back Cover 5 Cover Plate 14 Washer 23 Gear 32 Bolt 41 Bolt 6 Plug 15 Gear 24 Key 33 Input Shaft Cover 7 Plug 16 Output Hollow Shaft 25 Pinion 34 Bearing 8 Bolt 17 Bearing 26 Bearing 35 Circlip 9 Shrink Disk Protec Cover 18 Circlip 27 Shim 36 Key Standard TT 0S type basic part diagram Parts may differ for special applications Standard Part List Operating Instructions T Series YILMAZ RE...

Page 11: ... Inner Bush 5 Cover Plate 14 Washer 23 Gear 32 Bolt 41 Backstop 6 Plug 15 Gear 24 Key 33 Input Shaft Cover 42 Backstop Cover 7 Plug 16 Output Hollow Shaft 25 Pinion 34 Bearing 43 Bolt 8 Bolt 17 Bearing 26 Bearing 35 Circlip 9 Shrink Disk Protec Cover 18 Circlip 27 Shim 36 Key Standard TT 0S K type basic part diagram Parts may differ for special applications Standard Part List Operating Instruction...

Page 12: ...e requirements of the directive 94 9 EC The gearbox is started up maintained and operated according this manual The gearbox is incorporated with 94 9 EC confirming parts machines A motor connected to the gear unit is only allowed to be operated in the frequency entries so that the data provided on nameplate of the gear unit is not exceeded and is accord ance with the nameplate The input speed rang...

Page 13: ...wrap and pack it in con tainer A moisture indicator should be placed around the container to observe the mois ture Relative atmospheric humidity should not exceed 50 The container should be kept under roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 years with regular check Without Packing Use protection oil for the output shaft and connection surface...

Page 14: ... oils acids gases vapors or radiated interference are present when the gear unit is being installed The ambient temperature must be in accordance with the oil tables given on the manual If it is different contact YILMAZ REDUKTOR for special solutions The ambient air temperature must not exceed 40 degrees celcius as mentioned on the nameplate The cooling air surrounding the gear unit must below 40 ...

Page 15: ...ance DIN 748 G7 Hollow Shaft Diameter with Shrink Disk Tolerance DIN 748 H7 Customer Shaft Diameter for Shrink Disk Tolerance DIN 748 h6 TT17 00 19 0 02 0 30 0 03 0 01 30 0 02 0 30 0 0 01 TT27 00 19 0 02 0 35 0 03 0 01 35 0 03 0 35 0 0 02 TT28 00 24 0 02 0 40 0 03 0 01 40 0 03 0 40 0 0 02 TT37 00 24 0 02 0 45 0 03 0 01 45 0 03 0 45 0 0 02 TT47 00 28 0 02 0 50 0 03 0 01 50 0 03 0 50 0 0 02 TT57 00 ...

Page 16: ...me plate If different please contact YILMAZ REDUKTOR for possibilities of using in a different mounting position then indicated on the name plate without informing YILMAZ REDUKTOR will cancel the ATEX conformity and YILMAZ does not take any responsibility Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit 5 7 Usage of Breather Plug Breather plugs are suppli...

Page 17: ...g available solvents on your market By using this do not touch sealing lips or painting of the housing 5 10 Cover abrasive ambient If the gear unit will be placed on a abrasive ambient be sure that the output seals are covered so that no abrasive material chemicals or water touches the seals Any pressure coming from outside over the seals can cause that the out staying sub stances to enter the gea...

Page 18: ...he following illustrations Only ATEX approved input and output elements are allowed to be used assuming the ele ments are subject to Directive 94 9 EC 6 1 Installing gear units in category II2G D II3G D Explosion proof gear units comply with the design requirements for unit group II catagory 2G 2D 3D 3G These units are intended for use in zones 1 and 21 The gear units in catagory II2D must be used...

Page 19: ...ten the bold as shown below 6 2 Installing Customer Shaft with Shoulder 6 2 1 Use anti seize assembling paste available on your market Use a brush to apply the paste 1 Bolt 2 Lock Washer 3 Circlip 4 Mounting Washer 5 Hollow Shaft 6 Customer Shaft Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 20: ...e anti seize mounting paste available on your market Use a brush to apply the paste 6 3 2 Fasten the bolt as shown below 1 Bolt 2 Lock Washer 3 Circlip 4 Mounting Washer 5 Hollow Shaft 6 Customer Shaft Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 21: ...the disassemble set from YILMAZ and fasten the bolt as shown below to take out the output shaft For disassemble sets look the following pages 1 Bolt 2 Lock Washer 3 Hollow Shaft 4 Customer Shaft 1 Bolt 2 Circlip 3 Mounting Washer 4 Hollow Shaft 5 Customer Shaft Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 22: ...e the disassemble set from YILMAZ and fasten the bolt as shown below to take out the output shaft For disassemble sets look the following pages 1 Bolt 2 Lock Washer 3 Hollow Shaft 4 Customer Shaft 1 Bolt 2 Circlip 3 Mounting Washer 4 Hollow Shaft 5 Customer Shaft Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 23: ...able for shaft tightening torques Type Bolt Tightening Torques Nm TT17 M10 36 TT27 M12 62 TT28 M16 153 TT37 M16 153 TT47 M16 153 TT57 M20 297 TT67 M20 297 TT77 M20 297 TT87 M24 513 TT97 M24 513 Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 24: ...0 35 2 55 38 45 M16 48 5 14 TT47 50 22 36 M8 14 50 49 5 136 45 40 3 60 38 45 M16 53 5 14 TT57 60 22 42 M12 16 60 59 5 171 50 45 3 75 44 53 M20 64 18 TT67 70 22 48 M16 18 70 69 5 189 55 50 4 85 44 53 M20 74 5 20 TT77 80 26 54 M20 20 80 79 5 222 60 55 4 100 44 53 M20 85 22 TT87 100 26 70 M20 20 100 99 5 263 65 60 5 120 52 63 M24 106 28 TT97 125 33 90 M24 20 125 124 5 288 70 65 5 150 52 63 M24 132 32...

Page 25: ...shrink disk 6 8 2 Use a solvent available in your market to clean all the dirt and oil from the shaft and shrink disk hole The surfaces must be free from oil or any dirt The solvent must be removed from the surfaces as well Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 26: ...of the gearbox 1 Customer Shaft 2 Bronze Ring 3 Hollow Shaft 4 Shrink Disk Type Bolt Tightening Torques Nm TT17 M8 30 TT27 M8 30 TT28 M8 30 TT37 M8 30 TT47 M8 30 TT57 M10 59 TT67 M10 59 TT77 M12 100 TT87 M14 160 TT97 M14 160 Note Tightening torques are according to DIN EN ISO 4017 10 9 and µ 0 1 Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 27: ...27 6 9 Disassembling customer shaft with shrink disk Loosen the bolts of the shrink disk and take out the shaft Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 28: ... of load and direction of rotation refer to one of the drawings below It is advised that the motor position is in a range of 15 degree as shown For uniform and moderate loads fs 1 6 If direction of output shaft is cw If direction of output shaft rotation is ccw Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 29: ...29 For uniform and moderate loads fs 1 6 If direction of output shaft rotation is cw If direction of output shaft rotation is ccw Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 30: ...s b1 Type a b b1 s TT17 132 118 16 10 TT27 160 138 20 12 TT28 174 152 20 14 TT37 200 170 24 16 TT47 232 205 26 18 TT57 288 254 30 22 TT67 332 292 34 24 TT77 378 344 38 26 TT87 442 395 42 28 TT97 496 462 46 32 Note All dimensions are in mm Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 31: ...ft End 2 Thrust Bearing 3 Coupling Hub 6 13 Correct position of input shaft elements The input shaft unit transmission elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit 1 Hub Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 32: ...ome clearance between the two elements 6 14 2 By fitting couplings be sure that there is no eccentricity between the two shaft axis 6 14 3 By fitting couplings be sure that the two shaft axis are not angular miss aligned Operating Instructions T Series YILMAZ REDÜKTÖR Installing ...

Page 33: ...k Replace Every 3000 Working Hours or Every 6 Months Every 4000 Working Hours Every 10000 Working Hours or Every 3 Years Every 25000 Working Hours Check for Oil Leakage x Check for Oil Level x Check for Oil Leakage from Seals x Check Bearing s Noise x Change if Necessary Change Mineral Oil x See Below for Details Change Synthetic PAO Oil x See Below for Details Change Sealing x Change Bearing Grea...

Page 34: ...Tivela S 320 30 30 0 30 220 Energsyn SG XP 220 Aphasyn PG 220 Klübersynth GH 6 220 Tivela S 220 35 20 5 20 150 Energsyn SG XP 150 Aphasyn PG 150 Klübersynth GH 6 150 Tivela S 150 40 10 8 10 100 Klübersynth GH 6 100 CLP HC 10 60 680 Klübersynth GEM4 680 N Mobilgear SHCXMP680 20 50 460 Enersyn EP XF 460 Alphasyn T 460 Klübersynth GEM4 460 N Mobilgear SHC XMP460 Omala HD 460 25 40 5 40 320 Enersyn EP...

Page 35: ...sive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin immediately Hot oil can cause scalding When changing oil protect yourself against contacting hot oil use protective gloves Type M1 M2 M3 M4 M5 M6 TT17 1 0 1 1 0 9 1 1 1 2 1 2 TT27 1 7 2 0 1 6 2 0 2 1 2 1 TT28 2 1 2 4 1 9 2 4 2 5 2 5 TT37 3 0 3 7 3 3 3 7 4 0 4 0 TT47 4 0 5 7 4 9 5 7 5 8 5 8 TT...

Page 36: ...36 Symbols Drain plug Oil level Oil Filling and Vent plug M6 M4 M3 M5 M2 M1 Operating Instructions T Series YILMAZ REDÜKTÖR Oil Plugs 8 4 Oil Plugs ...

Page 37: ...37 Mounting M6 M1 M5 M3 M2 M4 Operating Instructions T Series YILMAZ REDÜKTÖR 8 5 Mounting Positions ...

Page 38: ...ame problem the load may be too high for the chosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher motor power is needed For mono phase motors check the starting up condensator and running condensator as well If nothing helps go to ID 100 004 Gearbox Does Not Start Up You hear some noise but both motor shaft and gear box shaft is not t...

Page 39: ...irming check the oil type and oil quantity level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position go to ID 100 009 Gearbox is Heating Up too Much You are using Helical Gear Box Ambient temp is lower than 40 Cel sius Measure the surface temp using a temperature measuring device under full load If the temp is u...

Page 40: ... tion The plug may be not tight enough There are some parti cles under the plug rubber surface Clean and tighten the plug If still same problem go to ID 100 019 Oil is Leaking Oil Leakage from Housing Observe exactly where the oil is coming out It could be seal or plug point where it comes out and leaks over the housing If this is your case go to ID 018 019 If you are sure oil comes out from housi...

Page 41: ...g the correct diameter of chain drive and you are not exceeding max allowed ra dial load Check the position of your output element and re calculate your radial load and check if this fit to the maximum allowed radial load Go to ID 100 027 Gearbox is stopping too late You are using braked motor Please check the wiring diagram of the brake There are two different kind of brake wiring diagram The sta...

Page 42: ...Appendix ...

Page 43: ...the date which the company or representative was made aware of the problem and ends on the date of the re start up 4 If the product fails to operate because of a manufacturing or assembly failure during the warranty time the product will be repaired free of charge 5 If the product fails to operate because of a manufacturing or assembly failure during the warranty time and it is not possible to rep...

Page 44: ...The time for repair service will be added to the warranty time For detailed warranty conditions please refer the back side of this page Serial No Type Manufacturer Company YILMAZ REDUKTOR Sanayi ve Ticaret A S Address ATATÜRK Mah Lozan Cad No 17 P K 34522 Esenyurt Istanbul TURKIYE Telephone 90 0 212 886 90 01 8 line Fax 90 0 212 886 54 57 Stamp and Signature Supplier End User With signing this par...

Page 45: ...06 03 90 0 212 567 40 78 90 0 212 567 04 11 90 0 212 567 45 07 90 0 212 567 00 70 Fax 90 0 212 567 99 75 e mail yilmaz yr com tr web www yr com tr Factory Tel 90 0 212 886 90 01 8 line 90 0 212 886 50 43 90 0 212 886 50 44 90 0 212 886 52 82 Fax 90 0 212 886 54 57 e mail yilmaz yr com tr web www yr com tr Outside Turkey Please contact the main service point mentioned above You will be directed to ...

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