YILMAZ REDÜKTÖR D Series User manual

YILMAZ REDÜKTÖR ISO 9001 YILMAZ REDÜKTÖR ISO 9001
D Series Gear Units
Operating Instructions
OIDEX0104/1114
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3
Contents
1 How To Use This Manual .......................................................................................................... 05
2 Unit Designation........................................................................................................................ 06
2.1 Detailed unit designation ...................................................................................................... 06
2.2 Nameplate unit designation.................................................................................................. 07
3 Part List of Standard Type Gear Units...................................................................................... 08
3.1 D...00... Type ................................................................................................................... 08
3.2 D...01... Type ................................................................................................................... 09
3.3 D...02... Type. .................................................................................................................. 10
3.4 D...03... Type ................................................................................................................... 11
3.5 D...0S...Type.................................................................................................................... 12
3.6 D...0E... Types................................................................................................................. 13
3.7 D..4 Additional Stage....................................................................................................... 14
3.8 D..5 and D..6 Additional Stages ...................................................................................... 15
3.9 D Series Motor Flange for Direct Coupled Types............................................................ 16
3.10 DN..., DV...Types B5, B14 Motor Flange....................................................................... 16
3.11 DT... Types Input Bearing Housing with Solid Input Shaft ............................................. 17
4- Things to Check Before the Gear Unit or Geared Motor is Installed....................... 18
4.1- Safety notes for use in potentially explosive atmosphere ................................. 18
4.2- Transportation ...................................................................................................19
4.3- Storage..............................................................................................................19
5- Installing the Gear Unit................................................................................................ 20
5.1- Before you start.................................................................................................20
5.2- Check Nameplate of the Gear Unit ................................................................... 20
5.3- Check the Ambient Conditions and Temperature.............................................. 20
5.4- Check Fitting Elements and the Shaft Dimensions to Fit .................................. 20
5.5- Check the Voltage Supply ................................................................................. 22
5.6- Check the Mounting Position ............................................................................ 22
5.7- Usage of Breather Plug..................................................................................... 22
5.8- Check the oil level ............................................................................................. 23
5.9- Check shaft ends and mounting faces .............................................................. 23
5.10- Cover abrasive ambient .................................................................................. 23
5.11- Check accessibility to filling, breather and drain plugs .................................... 23
6- Mechanical Installation................................................................................................ 24
6.1- Installing gear units in category II2G/D-II3G/D.................................................. 24
6.2- Installing Customer Shaft with Shoulder ........................................................... 25
6.3- Disassembling Customer Shaft with Shoulder .................................................. 26
6.4- Fitting Output Shaft Elements ........................................................................... 27
6.5- Correct Position of Output Shaft Elements ....................................................... 27
6.6- Fitting Couplings ............................................................................................... 28
6.7- Shaft Tightening Torques .................................................................................. 29
6.8- Assembling customer shaft with shrink disk..................................................... 30
6.9- Disassembling customer shaft with shrink disk................................................ 32
6.10- Assembling Gear Unit with Torque Arm ......................................................... 33
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Contents

4
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Contents
7 Maintenance & Inspection .................................................................................36
8 Lubrication..........................................................................................................37
8.1 Oil types............................................................................................................37
8.2 Changing the oil................................................................................................37
8.3 Mounting Positions ...........................................................................................38
8.4 Oil Quantities ...............................................................................................39-41
9 Troubleshooting Guide ......................................................................................43
10 Appendix ...........................................................................................................48
Warranty conditions................................................................................................48
Warranty.................................................................................................................49
Service Contact Points ...........................................................................................50

5
1 - How to Use This Manual
Take attention to the following safety and warning signs for proper understanding and quick reference.
Electrical Hazard; Can cause severe or fatal injuries.
Mechanical Hazard; Can cause severe or fatal injuries.
Likely to be Hazardous; Can cause minor or fatal injuries
Damage Risk; Can damage the gearbox or environment
Important Information
Important information about explosion protection
The operating instructions contain important information to ensure ;
- Trouble-free operation
- Fulfilment of any rights to claim under guarantee
The operating instruction must be kept close to the gearbox and must be available in case it is
needed.
This operating instruction is written for D series gear 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 D 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 parts which will be assembled to the gear unit must conform ATEX (94/9/EC). The
product this declaration refers to must not be put into service until the machinery into which it is to be
incorporated has been declared in conformity with the provisions of the relevant European Directives.
If the gear unit is not operated as informed on this manual the gear unit is no longer ATEX conforming
and YILMAZ REDUKTOR does not take any responsibility.
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Operating Instructions
D Series
YILMAZ REDÜKTÖR
General Informations
7 Maintenance & Inspection .................................................................................36
8 Lubrication..........................................................................................................37
8.1 Oil types............................................................................................................37
8.2 Changing the oil................................................................................................37
8.3 Mounting Positions ...........................................................................................38
8.4 Oil Quantities ...............................................................................................39-41
9 Troubleshooting Guide ......................................................................................43
10 Appendix ...........................................................................................................48
Warranty conditions................................................................................................48
Warranty.................................................................................................................49
Service Contact Points ...........................................................................................50

6
2 - Unit Designation
2.1- Detailed Unit Designation
Detailed D Series gear units designation for ordering
(This Designation is different from the short nameplate designation)
Motor Size
Gearbox Type
D Serie
Input Type
R : With Motor
N:IEC B5 / B14 Flanged without Motor
V:IEC B5 / B14 Flanged with Motor
T:With Input Shaft
Housing Size
1...9
Revision Number
Output Shaft
00:Hollow Shaft output
01:Solid Shaft Output
02:Solid shaft output with IEC B5 /14 Flange
03:Flanged and Hollow Shaft output
0S:Shrink Disk Output
0E:Extruder Output
D R 4 7 4 . 02 - 90S / 4 - L05
Stage
2 Stages
3 Stages
4 Stages
5 Stages
6 Stages
Brake
L-220 V With Fan
P-24 V With Fan
S-220 V Without Fan
Z-24 V Without Fan
01-10 Nm
02-25 Nm
04-40 Nm
05-50 Nm
10-100 Nm
20-200 Nm
30-300 Nm
40-400 Nm
For DN Types
A06 : 63 B5 A09 : 90 B5 A13:132 B5 A25: 250 B5
B06 : 63 B14 B09 : 90 B14 B13:132 B14 A28: 280 B5
A07 : 71 B5 A10 :100 B5 A16:160 B5 A31: 315 B5
B07 : 71 B14 B10 :100 B14 A18:180 B5
A08 : 80 B5 A11 :112 B5 A20:200 B5
B08 : 80 B14 B11 :112 B14 A22:225 B5
90S / 4
Pole Number
Frame Lenght
Motor size
For DV Types
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Unit Designation

7
2.2- Nameplate, unit designation
Nameplate unit designation is a short abbreviation from the detailed designation
A sample name plate for D Series according to 94/9/EC
12
-20/+40
a
TºC
M.Pos.:
II 2GD IIB c k T4 / T120 ºC
FA1
N
FA2
Oil Qty:
R2
FR1
NF
N
lt.
N
Type:
M
kW
P
nrpm. n
2
S/N. :
Nm.
rpm.
:
:
:
:
:
:
:
:
:
:
IP65
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YILMAZ REDÜKTÖR A.S.
ATATÜRK Mah. Lozan Cad. No:17 P.K.34522
Esenyurt-İstanbul- TÜRKİYE
DT473.03
100524545
1.7
1400
1550
10
17000 1801
63781 1813
6.4
MINERAL VG220
M1
Abbreviations:
Type. : Type of gearbox
S/N: Serial Number of gear unit (Production Date can
be learnt from YILMAZ with this number.)
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 load at output shaft
FA :Max. allowed axial load at input shaft
Oil : Filled oil inside the gear unit
Qty. : Oil quantity
M.pos.: Mounting Position.
Ta : Ambient Temp.
Category of Gear Unit
(in acc. to 94/9/EC)
Intended use in Zones
(in acc. of 1999/92/EC)
2GD 1; 21; 2; 22
3GD 2; 22
1
2
2
1
2
1
2
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Unit Designation

8
3- Part List of Standard Type Gear Units
3.1- D..00... Types for 2 and 3 Staged Gear Units
1- Pin Screw 9- Bearing 17- Seal 25- Gear 33- Bearing
2- Housing 10- Hollow Shaft 18- Closing Cap 26- Spacer 34- Circlip
3- Plug 11- Key 19- Circlip 27- Bearing 35- Closing Cap
4- Cover Plate 12- Gear 20- Spacer 28- Spacer
5- Screw 13- Spacer 21- Spacer 29- Bearing
6- Oil Seal 14- Bearing 22- Bearing 30- Gear
7- Circlip 15- Spacer 23- Shaft Gear 31- Key
8- Spacer 16- Circlip 24- Key 32- Gear
Standard D...00... type basic part diagram. Parts may differ for special applications.
Standard Part List
30
24
11
3
3
3
1
2
3
5
29
31
32
33
34
35
18 19 20 21
22
23
25
26 2728
6
7
8
9
10
12
13
14
15
16
17
4
Only Valid For 3 Stages
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Part Designations

9
3.2- D..01... Types for 2 and 3 Staged Gear Units
1- Pin Screw 9- Bearing 17- Circlip 25- Key 33- Shaft Gear
2- Housing 10- Output Shaft 18- Oil Seal 26- Gear 34- Bearing
3- Plug 11- Key 19- Closing Cap 27- Spacer 35- Circlip
4- Cover Plate 12- Key 20- Circlip 28- Bearing 36- Closing Cap
5- Bolt 13- Gear 21- Spacer 29- Spacer
6- Oil Seal 14- Spacer 22- Spacer 30- Bearing
7- Circlip 15- Bearing 23- Bearing 31- Gear
8- Bearing 16- Spacer 24- Shaft Gear 32- Key
Standard D...01... type basic part diagram. Parts may differ for special applications.
Standard Part List
31
25
11
3
3
3
1
2
3
5
30
32
33
34
35
36
19 20 21 22
23
24
26
27 2829
6
7
8
9
10
13
14
15
16
17
18
4
12
Only Valid For 3 Stages
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Part Designations

10
3.3- D..02... Types For 2 and 3 Staged Gear Units
Standard D...02... type basic part diagram. Parts may differ for special applications.
Standard Part List
1- Pin Screw 10- Solid Shaft 19- Flange 28- Gear 37- Circlips
2- Housing 11- Key 20- Bolt 29- Spacer 38- Closing Cap
3- Plug 12- Key 21- Closing Cap 30- Bearing
4- Cover Plate 13- Gear 22- Circlip 31- Spacer
5- Bolt 14- Spacer 23- Spacer 32- Bearing
6- Oil Seal 15- Bearing 24- Spacer 33- Gear
7- Circlip 16- Spacer 25- Bearing 34- Key
8- Spacer 17- Circlip 26- Shaft Gear 35- Shaft Gear
9- Bearing 18- Seal 27- Key 36- Bearing
33
27
11
3
3
3
1
2
3
5
32
34
35
36
37
38
21 22 23 24
25
26
28
29 3031
6
7
8
9
10
13
14
15
16
17
18
4
12
19
20
Only Valid For 3 Stages
Operating Instructions
D Series
YILMAZ REDÜKTÖR
Part Designations