YILMAZ REDÜKTÖR T Series User manual

YILMAZ REDÜKTÖR ISO 9001 YILMAZ REDÜKTÖR ISO 9001
T Series Gear Units
Operating Instructions
OITEX0500/0612
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Contents............................................................................................................................02
1 - How to Use This Manual.............................................................................................05
2 - Unit Designation..........................................................................................................06
2.1- Detailed Unit Designation.......................................................................................06
2.2- Nameplate, Unit Designation ....................................................................................07
3. Standard Type Gearbox Parts Lists ..............................................................................08
3.1- TT..00 type ...............................................................................................................08
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 ...................................... 12
Intended use of Gearbox....................................................................................... 12
4.2- Transportation ........................................................................................................13
4.3- Storage...................................................................................................................13
5 - Installing the Gear Unit...............................................................................................14
5.1- Before You Start .....................................................................................................14
5.2- Check Name Plate of the Gear Unit ....................................................................... 14
5.3- Check the Ambient Conditions and Temperature .................................................. 14
5.4- Check 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
6.2- Installing Customer Shaft with Shoulder ................................................................ 19
6.3- Installing Customer Shaft without Shoulder ........................................................... 20
6.4- Disassembling Customer Shaft with Shoulder ....................................................... 21
6.5- Disassembling Customer Shaft without Shoulder .................................................. 22
6.6- Shaft Tightening Torques ....................................................................................... 23
6.7- Recommended Shaft Dimensions and Mounting Washer Dimensions.................. 24
6.8- Assembling customer shaft with shrink disk...........................................................25
Operating Instructions
T Series
YILMAZ REDÜKTÖR
Contents

3
6.9- Disassembling customer shaft with shrink disk...................................................... 27
6.10- Assembling Gear Unit with Tightening Arm..........................................................28
6.11- Fixing Holes Dimensions...................................................................................... 30
6.12- Fitting input shaft elements .................................................................................. 31
6.13- Correct position 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

4
Operating Instructions
T Series
YILMAZ REDÜKTÖR

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 T 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 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 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
T Series
YILMAZ REDÜKTÖR
General Informations

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2 - Unit Designation
2.1- Detailed Unit Designation
Detailed T series gear units designation for ordering
(This Designation is different from the short nameplate designation)
TT 57 . 00 . K - M1
Serie of gear unit
TT : Two stage helical gear unit
Gear unit size
Sizes from 17 to 97
Output hollow shaft diameter
00 : Standart hollow shaft diameter
0X : Special hollow shaft diameter
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 paralel to earth, input shaft is under
M6 : Input and output shaft is paralel to earth, input shaft is over
Operating Instructions
T 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 T Series according to 94/9/EC
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
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
YILMAZ REDÜKTÖR A.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 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.
Operating Instructions
T Series
YILMAZ REDÜKTÖR
Unit Designation

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3.1- TT...00 Types
3. Standard Type Gearbox Part Lists
1- Plug 10- Oil Seal 19- Key 28- Circlip 37- Bearing
2- Plug 11- Circlip 20- Closing Cap 29- Closing Cap 38- Circlip
3- Plug 12- Bearing 21- Bearing 30- Oil Seal 39- Back Cover
4- Bolt 13- Washer 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
YILMAZ REDÜKTÖR
Part Designations

9
3.2- TT...00.K Types
1- Plug 10- Oil Seal 19- Key 28- Circlip 37- Key
2- Plug 11- Circlip 20- Closing Cap 29- Closing Cap 38- Bearing
3- Plug 12- Bearing 21- Bearing 30- Oil Seal 39- Backtop Innner Bush
4- Bolt 13- Washer 22- Gear 31- Bolt 40- Backstop
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
YILMAZ REDÜKTÖR
Part Designations

10
3.3- TT...0S Types
1- Plug 10- Shrink Disk 19- Oil Seal 28- Washer 37- Input Pinion Shaft
2- Plug 11- Oil Seal 20- Key 29- Circlip 38- Bearing
3- Plug 12- Circlip 21- Closing Cap 30- Closing Cap 39- Circlip
4- Bolt 13- Bearing 22- Bearing 31- 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 REDÜKTÖR
Part Designations