Operating Instructions
Contents
1. T L M M 3 3 374 YILMAZ RED KT R 19 Operating Instructions TT Series Installing 20 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the name plate If different please contact YILMAZ REDUKTOR for possibilities of using in a different mounting position Refer to the mounting positions and oil guantities on this manual and adjust the oil level accordingly with the recommended oil types given on this manuel Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit 6 6 Use of breather plug Breather plugs are not needed for TT series under normal ambient and working conditions Up to 30 C ambient temperature and up to 8 hours per day If heavy ambient conditions and long time working hours then breather plug are recommended by YILMAZ REDUKTOR and delivered with the gearbox together Replace the breather plug with the most top plug according to your mounting position Some plug positions are not machined according mounting position If no mounting position is mentioned by ordering the standard M1 position plugs are machined 6 7 Check the oil level On the mounting position tables the oil level plug is shown Please refer to those tables and be sure that the oil level is correct according the mounting positio2. SH y 32 YILMAZ RED KT R 74 Operating Instructions TT Series Installing Fixing holes dimensions For the fixing holes refer to the following dimensions 74 YILMAZ RED KT R ap 33 Operating Instructions ao TT Series Installing n 7 10 Fitting outputshaft elements Use the following illustration to assemble output shaft units 1 2 1 Gear shaft end 2 Thrust bearing 3 Coupling hub e 7 11 Correct position of output shaft elements The Output 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 i Fyi Fyi N N 1 Hub 34 YILMAZ RED KT R b74 Operating Instructions TT Series Installing 7 12 Fitting Couplings ap 7 12 1 By fitting couplings be sure that there is some clearance between the two elements a ar 7 12 2 By fitting couplings be sure that there is no eccentric between the two shafts 7 12 3 By fitting couplings be sure that the t
3. 1 nn 31 7 10 Fitting output shaft E N N ES been anda di dee ea 34 7 11 Correct position of outputshaftelemenis nn 34 T A2 Fitting Coupling e MY e KR 35 8 Maintenance amp Inspection uuuuussnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnennnnnnannnn 36 9 Lubrication tee een reger 37 A MAY ole eu ee 37 92 Changing the Ol nee een ea ae na eeee 37 9 3 Mounting POS OT NS ee nee 38 IA IU icipated ieee taut ee ee es a e 39 10TroubleshootingGuide OUMM mm m gt m m gt gt gt m 40 11 e E ren n 43 AL EY Oil mi ii ii ae ilinin 43 11 2 Disposal ot Scale e EK ECER 43 11 3 DISDOSAL Gi IMG lal as asama a L E RA sl sak a a sa kia 43 12 ADDPENOIK ea ll yam m l and mak 44 122 Warranty COndilliOnS EA AM AE ASEE ER EE 45 12 3 MAMA ER ANAN RA er m 46 124 Service Contact PONS u ee 47 4 YILMAZ RED KT R 4 Operating Instructions TT Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference Electric 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 gearbox or environment H8 Dre Important Information EC Machinery Directive Within terms of the EC machinery directive 2006 42 EC the gearboxes are con
4. You are using braked motor too late livered from our factory is set to delayed braking For sudden braking check the wiring diagram For fast opening of big brakes over 100Nm you may need You are using braked motor shock transformators which is supplied by YILMAZ Goto ID 100 Gearbox is starting too late Please contact YILMAZ REDUKTOR Service point See on the back side of this manual Changing mechanical parts of gearbox can only be done by YILMAZ REDUKTOR or with information of YILMAZ REDUKTOR Any change without informing YILMAZ REDUKTOR will cancel the waranty manufacturer decleration and YILMAZ REDUKTOR will take no responsibility Service Reguired No self solution found 11 Disposal If your product is no longer of use and you wish to dispose of it refer to the instructions here If you have any questions regarding ecological disposal methods please consult our service points given on the backside of this manuel 11 1 Disposal of Oil Lubricants oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guid lines 11 2 Disposal of Sealings Remove the sealing rings from the gear reducer and clean them of oil and grease resudies Dispose of the sealings as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder of the gear reducer into ir
5. If nameplate mounting position does not fit the actual position goto ID 100 Gearbox is Heating Up too Much Ambient Temp is over 40 Celsius Standart Gearboxes are designed to work under 40 Celsius ambient temperature If ambient temp is higher than 40 Celsius special soluti ons gearboxes are required Please contact YILMAZ REDUKTOR Gearbox is noisy Noise is regular continious Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bea rings are defect Change bearings Goto ID 100 Gearbox is noisy Noise is random 374 YILMAZ RED KT R Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for small particles If metal particles are found the gearbox may have some demage Goto ID 100 41 Operating Instructions TT Series Troubleshooting Guide ID Problem Observation Remedy Check Your moving parts for noise Disassemble the gearbox and 013 Gearbox is noisy Regular nocking noise run without load If you still hear the noise one of the gears inside is defect Goto ID 100 Check the output shaft connection alements for runout Take out the 014 Gearbox is noisy Regular up and down noise output shaft element and run without load If you still hear the noise one of th
6. Part List sam 8 YILMAZ RED KT R 74 16 Bearing 26 Shim 36 Input Pinion Shaft Operating Instructions TT Series Part Designation 3 2 TT 00 K Types Standard TT 00 K type basic part diagram Parts may differ for special applications Standard Part List EE pnp Shah Cove cer baren 374 YILMAZ RED KT R 9 Operating Instructions TT Series Part Designation 3 3 TT 0S Types Standard TT 0S type basic part diagram Parts may differ for special applications Standard Part List 12 Circlip 23 Gear 34 Bearing 13 Bearing 24 Key 35 Circlip 14 Washer 25 Pinion 36 Key 15 Gear 26 Bearing 37 Input Pinion Shaft 5 Cover Plate 16 Output Hollow Shaft 27 Shim 38 Bearing 6 Plug 17 Bearing 28 Washer 39 Circlip 7 Plug 18 Circlip 29 Circlip 40 Back Cover 8 Bolt 19 Oil Seal 30 Closing Cap 41 Bolt 9 Shrink Disc Protec Cover 20 Key 31 Oil Seal 10 Shrink Disc 21 Closing Cap 32 Bolt 11 Oil Seal 22 Bearing 33 Input Shaft Cover 10 YILMAZ RED KT R 4 Operating Instructions TT Series Part Designation 3 4 TT 0S K Types e basic part diagram Parts may differ for special a lications Standard TT OS K t Standard Part List 12 Circlip 23 Gear 34 Bearing 13 Bearing 24 Key 35 Circlip 14 Washer 25 Pinion 36 Key
7. 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 Head Office Maltepe Gumussuyu Cad Bestekar Medeni Aziz Efendi Sok No 54 P K 34020 Topkapi lstanbul TURKEY Phone 90 0 212 567 93 82 83 Fax 90 0 212 567 99 75 Factory Ataturk Mah Lozan Cad No 17 P K 34522 K rac Esenyurt Istanbul TUR KEY Phone 90 0 212 886 90 00 PBX 10lines Fax 90 0 212 886 54 57 Stamp and Signature Supplier End User With signing this part and sending this back to our company your warranty period will be started and you are accepting that you have received the operating in struction of the product Name Billing Date Bill No Start Up Place Date Address Phone Fax Supplier End User Stamp and Signature Service Contact Points Main Service Point YILMAZ REDUKTOR A S Ataturk Mah Lozan Cad No 17 P K 34522 Esenyurt Istanbul TURKEY Head Office Tel 90 0 212 567 93 82 2 line 90 0 212 567 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 K Factory Tel 90 0 212 886 90 00 8 lines 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
8. the parts as shown 7 4 2 Use the disassembly set from YILMAZ and fasten the bold as shown bellow to take out the output shaft For disassembly sets look the following pages 1 Retaining Bolt 2 Circlip 3 Lock Washer 4 Washer 5 Hollow Shaft 6 Customer Shaft 74 YILMAZ RED KT R 25 Operating Instructions ao TT Series Installing n 7 5 Shaft tightening torques Use the following table for shaft tightening torques Tightening torque Nm 36 62 26 YILMAZ RED KT R 4 ar Operating Instructions TT Series Installing 7 6 Advised Shaft Dimensions and Accessiories D1 gt a el e el le EEE lee ENE FIFIFIFIFIFIF F Mounting Dismounting 6 Contour Bolt DIN ISO 4014 DIN ISO 4017 27 DIN ISO 8765 74 YILMAZ RED KT R Operating Instructions ao TT Series Installing n 7 7 Assembling customer shaft with shrink disk 7 7 1 Loosen the bolts of the shrink disk EZ 7 7 2 Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow The surfaces must be free from oil or any dirt The solvent must be removed from the surfaces as well 28 YILMAZ RED KT R b74 Operating Instructions ao TT Series Installing 7 7 3 Insert the shaft and tighten the bolts as shown Be sure that there is a clear ance b
9. 15 Gear 26 Bearing 37 Input Pinion Shaft 5 Cover Plate 16 Output Hollow Shaft 27 Shim 38 Key 6 Plug 17 Bearing 28 Washer 39 Bearing 18 Circlip 29 Circlip 40 Backstop Inner Bush 19 Oil Seal 30 Closing Cap 41 Backstop 20 Key 31 Oil Seal 42 Backstop Cover 21 Closing Cap 32 Bolt 43 Bolt 22 Bearing 374 YILMAZ RED KT R 33 Input Shaft Cover 11 Operating Instructions TT Series Safety N e e e bi 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important maxi mum permitted values are indicated on the nameplate of the product But the whole data can be found on our product catalogues Using the product out of the product catalogue nameplate s permitted ranges will cancel the warranty manufacturer declaration and YILMAZ will not take any responsibility The gear units are intended for industrial machines and may only be used in accordance with the information provided in this manual the product catalogue and the nameplate of the gearbox They comply with the applicable standards and regulations and meet the requirements of the directive 2006 42 EC The gearbox must be started up maintained and operated according this manual The gearbox most be incorporated with 2006
10. 42 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 cataloque of the gear unit is not exceeded and is ac cordance with the nameplate catalogue The speed range will be provided on the name plate if YILMAZ REDUKTOR is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this speed is allowed The electric motor and frequency inverter must be in accordance with 2006 42 EC If the gear units input is used with variable speed gear unit this must be informed to YILMAZ REDUKTOR before ordering and on the nameplate the allowed maximum and minimum speeds speed range will be provided If not mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed If the gear unit will be driven by belt coupling chain drive etc the gear unit is only allowed to be used according the nameplate catalogue entries Different speed higher motor power higher radial axial loads etc than nameplate catalogue is not allowed The ambient temperature must be between 5 40 C_and no abrasive media must attack the paint and seals If different working conditions this must be informed to YILMAZ before ordering The gearbox maintenance oil change check must be done according this manual 4 2 Improper Use Every usage whic
11. D 100 42 YILMAZ RED KT R M4 Operating Instructions TT Series Troubleshooting Guide Problem Observation Motor is running but Gearbox shaft does Scratchinh noise comes out Some part key gear may be defect inside gearbox Goto ID 10 not turn The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or oo BE the plate you assemble the gearbox is rigit enough Check if you Gearbox Housing is You are using chain drive or f _ are using the correct diameter of chain drive and you are not Defect pinion gear exceeding max allowed radial load Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radial load Goto ID 100 The radial load or poligon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or ae the plate you assemble the gearbox is rigit enough Check if you You are using chain drive or Output Shaft is Defect _ are using the correct diameter of chain drive and you are not inion gear E 2 exceeding max allowed radial load Check the position of your output element and re calculate your radyal load and check if this fit to the maximum allowed radial load Goto ID 100 Please check the wiring diagram of the brake There are two Gearbox is stopping different kind of brake wiring diagram The standart gearbox de
12. T R gt 4 Operating Instructions TT Series Installing 6 10 Check accessibility to filling breather and drain plugs The filling breather and drain plugs must be freely accessible for further checking and service 7 Mechanical Installation The gear unit can only be installed using the supplied connection points like foot and flange assembling points To install the gear unit without the supplied connection points can cause serious injuries b loosening or braking the gear unit Even the gear unit is installed totally correctly accordin this manual be sure that no one will be harmed by accidentally brake downs or loosening The mounting plate must be rigid enough not allowing torsions flat enough to prevent strains by tightening the bolts and stable enough not allowing vibrations By using chain drives this becomes much more important because of the polygon effect on chain drives According to your connection elements the maximal permitted radial and axial load of the gear unit must be in accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is overloaded by radial or axial loads it can cause serious damage to the gear unit Secure the gear unit using 8 8 or higher quality bolts Cover all the turning parts from human entering or touching Turning parts can cause severe or fatal injuries For different kind of basic installations refer to t
13. Turkey Please contact the main service point mentioned above You will be directed to our nearest service point to your location
14. YILMAZ RED KT R ISO 9001 YILMAZ RED KT R ISO 9001 v RED KT R TT Series Gear Units OITCE0101 1112 Operating Instructions Operating Instructions TT Series Contents Contents 1 How To Use This Milan g s dali 05 2 Unit D signation A EEE en 06 2 1 Detailed unit designalen eleme Ge ee 06 2 2 Nameplate unit designatlon 0 00040514040400 amaaa sana 07 3 Part List of Standard Type Gear Units unnnesssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnn 08 3 1 TL 00 Wesen ee den 08 A e 09 3 31 08 TYDeS e ee een ee Free 10 SATTE TS ee 11 A MA A ee ln 12 2 1 Intended Lee ana een ll t 12 4 2 p ope 343 ade n m aa lk dd E EE A 12 41 3 Salaly InSiruUclons e I HER eared 13 4 3 1 General Safety Instructions ccccccccceeseeseeeeeseeseetssececececeonenenenees 13 4 3 1 1 Working on the gearreducer 12 1110102 13 AREE oeoa A E m 13 4 3 1 3 Maintenance a 13 4 3 14 Lubricant e gayi e m nenne ips ele 18 4 3 1 5 Ambient Conditions eee inen ny a en 18 4 4 Tightening Torques nenne asa seli balla elime 14 4 5 S N R Ea Ri ae ilminde ila Babi e male e eae aa eda iaae 14 4 5 1 Suitable extinguishing agents protectiveeguipmenit 14 4 5 2 Unsuitable extinguishing agenis 20 1s 14 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed 15 5 1 Transportation m
15. al i el li are e E 15 2 SUNS AK ME EA EE PR A EMA 16 6 lnstalliingTheGearUnit MMMemememmemeMielll gt m m m m m nennen 17 8 1 Before YOU statt zn ae ee dil sab kia 17 6 2 Check the shaft dimensions to Til ana a lisenin mile silisli 17 6 3Checktheambienttemperature 17 6 4 Check the voltage SUpply u unten an 17 6 5 Check the mounting POSUMIOMN 256 25 ccc nee ae eneee 20 6 6 Use the ey de a en u ce 20 bl Check ING Ol NEV kb etme kerim idm ll a indi ie 20 6 8 Check shaft ends and mounting faces sise ns idi mekanlari Biri bisi 20 6 9 Cover abrasive ambient anne a nn 20 6 10 Check accessibility to filling breatheranddrainplugs 21 374 YILMAZ RED KT R Operating Instructions TT Series Contents T Mechanicallinstall ation res ss 22 7 1 Installing customer shaft with shoulder 22 7 2 Installing customer shaft without shoulder 2e nn en 23 7 3 Disassembling customer shaftwithshoulder 44a 24 7 4 Disassembling customer shaft without shoulder 25 1 5 Shaft tightening torques RAN ae 26 7 6 Recommended shaft dimensions and disassembling nutdimensions 27 7 7 Assembling customer shaft with Shrink disk 28 7 8 Disassembling customer shaft with shrink disk 30 7 9 Assembling gearunitwitihtorgucalm
16. 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 repair it the product will be changed with a new one according to the report from our service department mentioning that the hazard can not be repaired 6 Costumers must inform the manufacturer if there are some problems after the service and repair of the failed product 7 The extra costs like stopped plant physical or mental injuries etc by the costumer side are not covered by this warranty except the product itself YILMAZ REDUKTOR San ve Tic A S Head Office Maltepe Gumussuyu Cad Bestekar Medeni Aziz Efendi Sok No 54 P K 34020 Topkapi lstanbul TURKEY Phone 90 0 212 567 93 82 83 Fax 90 0 212 567 99 75 Factory Ataturk Mah Lozan Cad No 17 P K 34522 Esenyurt Istanbul TURKEY Phone 90 0 212 886 90 00 PBX 8lines Fax 90 0 212 886 54 57 YILMAZ RED KT R Warranty Decleration and Instruction Manual Receipt Form YILMAZ REDUKTOR products are warranted for 2 Two years covering all parts and materials used in products and their production errors unless they are started up and used according our service manual and is not modified or disassembled without an acknowledgement from our company The warranty covers all costs like repair service spare parts etc and no charge will be asked under any name The time for repair service will
17. e 5 1 Transportation When the goods arrive first check for any damage If some damage observed immediately contact the transport company and inform about the damage Contact YILMAZ for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the supplied eyebolts or lifting holes for lifting up the gear unit The eyebolts are capable to carry the weight of gearboxes only Do not hang additional loads Use suitable hoisting equipment which is capable to hold the gear units weight Refer to the catalogue for various types weights See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting equipment which may cause serious injuries by fallin down objects accidental movements unexpected accidents Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of your gear unit Ensure that the load is slowly and carefully handled and placed gt 74 YILMAZ RED KT R pp 15 Operating Instructions TT Series Checking 5 2 Storage If the geared unit or geared motor will be stored up to 3 years refer to the following in structions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange sur face or foot assembling surface Seal the unit in a plastic wrap and pack it in container A moisture indicator should be placed ar
18. e gear unit housing For connecting elements refer to the mechani cal installation part Tightenning Torque Nm 23 43 ir 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthetic or min eral gear oil Please observe the following if the gear reducer is situated in a burning environment 4 5 1 Suitable extinguishing agents Protective equipment Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit High temperature produce irritating steam Use a protective breathing apparatuses 4 5 2 Unsuitable extinguishing agents Do not spray with water gt gt 14 YILMAZ RED KT R 4 Operating Instructions TT Series Safety gt 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed If geared motors are used please also refer to the manual of the motor manufacturer Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage Points to take into consideration before you start to install the unit You have received the correct operation manual of the your product The gearbox and all its parts are transported without damage The gearbox is stored correctly according the instructions in this manual You have the latest product catalogue or you have access to our web pag
19. e gears has runout problem Goto ID 100 Gearbox is with braked motor Low randomly clicking noise may come from the brake disk which is 015 Gearbox is noisy and noise is comming from the normal If noise level is disturbing the brake may be defect or brake brake side randomly clearance is not adjusted Goto ID 100 f The frequency inverter parameters are not optimized for the frequ You are using frequency inver i i N ency range or motor you are using Observe the frequency inverters 016 Gearbox is noisy ter and the noise level is chan f manual If still same problem change the ratio of gearbox Goto ID ging according your speed 100 If ambient Temp is over 40 Celsious or none stop work over 16 Er hours please change the top plug with a breather plug Observe this 017 Oil is Leaking Oil Leakage from Seal i u manual for using breather plug If this is not your case the seal could be damaged Goto ID 100 If you are using breather plug be sure it is in the correct place This is the most top plug position according your mounting position The 018 Oil is Leaking Oil Leakage from Plug plug may be not tight enough There are some particles under the plug rubber surface Clean and tifgten the plug If still same problem goto ID 100 Observe exactly where the oil is comming out It could be seal or Er il plug point where it comes out and leakes over the housing If this is 019 Oil is Leaking Oil Leakage from Housing your case go
20. e is opening If you hear no noise the brake or rectifier is defect If you hear the clicking noise the brake is working You should this clicking noise by your normal electric connection as well By supplying direct supply to the brake you hear the click ing noise and at same time you supply the motor with direct voltage according to its name plate and still same problem the load may be too high for the choosen motor Goto ID 003 YILMAZ RED KT R b74 Operating Instructions TT Series Troubleshooting Guide Problem Observation Remedy Gearbox Does Not Work in Low Speeds frequencies You are using frequency inverter For very low speeds the frequency inverters frequency is lowering down For very low frequencies the inverter parameter and motor parameter must be optimized Also for low speeds the efficiency of the gearbox may varry too much Specially for worm gearboxes The recomended frequ ency range is 20 70 Hz for worm gearboxes and 10 70 Hz for Helical Gear Boxes Use Higher motor power and Frequency inverter or change ratio of gearbox to work inside the reccomended range Gearbox Does Not Start Mornings or Af ter Long Time Stop Ambient Temperature is below 5 Celsius The oil is not in accordance with your working conditions Change to lo wer viscosity oils Observe this manuel for using the correct oil Working in higher ambient temperatures is an other solution if possible If still same problem yo
21. ear unit is upright and input shaft is under output shaft Input shaft is vertical to earth and input shaft points to earth Input and output shaft is paralel to earth input shaft is under Input and output shaft is paralel to earth input shaft is over Backstop option K Backstop is avaliable Backtop is unavaliable Output Type 00 Standart hollow shaft diameter 0X Special hollow shaft diameter 0S Hollow shaft with shrink disc Gear unit size Sizes from 17 to 97 Serie of gear unit TT Two stage helical gear unit YILMAZ RED KT R 4 Operating Instructions TT Series Type Designation 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for TT Series RED KT R 374 YILMAZ RED KT R YILMAZ www yr com tr MADE IN TURKEY CE Type TT37 00 K Serial N 104837 Power 3 0 kW Ratio 19 53 Speed 46 rpm M Pos M5 Oil VG320 Mineral Oil Qty 4 It Abreviations Serial N Serial Number M Pos Mounting Position Type Designation Serial Number Designation 10 4837 Year of manufacturing Order Number 374 YILMAZ RED KT R Operating Instructions TT Series Part Designation 3 Part List of Standard Type Gear Units 3 1 TT 00 Types Standard TT 00 type basic part diagram Parts may differ for special applications Standard
22. electric motor or environment The following wiring diagram is for standard 230 400 V 50 Hz AC electric motors For dif ferent voltages please contact YILMAZ REDUKTOR For gear units supplied without motor refer to the motor manufacturers user manual The electric connection must be done by experienced electric technician The gearbox the motor and the brake must be grounded to prevent potential differences of earth and gearbox motor Nominal Powers at 400V 50Hz 230V D 400V Y 400V D Pole Number Starting Principle Direct or Y D Basic motor connection wiring diagram L1 L2 L3 L1 L2 L3 4 U no U Le Ut U 230V 230V 400V 400V U U J 230V 400V ny 12 13 18 YILMAZ RED KT R d4 Operating Instructions TT Series Installing Standard type brakes basic wiring diagram The electric connection must be done by experienced electric technician The gearbox and the motor must be grounded to prevent potential differences of earth and gearbox motor Delayed Running Brake 220 V Sudden Brake 220 V RST RSTN OOO RAA gt gt moo G M M 3 Delayed Running Brake 24 V Sudden Brake 24 V RSTN RSTN 5666 Le 55o
23. etween the shrink disk shoulder and the hollow shaft shoulder of the gearbox 1 Customer Shaft 2 Bronze Ring 3 Hollow Shaft 4 Shrink Disk Tightening Torque Nm 74 YILMAZ RED KT R 29 Operating Instructions ao TT Series Installing n 7 8 Disassembling customer shaft with shrink disk 7 8 1 Loosen the bolts of the shrink disk and take out the shaft 30 YILMAZ RED KT R 4 Operating Instructions ao TT Series Installing G 7 9 Assembling Gear Unit with Torque Arm 7 9 1 Use the torque arm connection according the following drawing The advised mounting positions are shown below According to the nature of load and direction For uniform and moderate loads fs lt 1 6 If direction of output shaft rotation is cw on I m Ral Tin hal m Iren PLN A2 lt N g0 pe BEN RIG a BSE If direction of output shaft rotation is ccw N 74 YILMAZ RED KT R 31 Operating Instructions ao TT Series Installing For heavy loads fs gt 1 6 If direction of output shaft rotation is cw UN N 90 If direction of output shaft rotation is ccw ZA W 2
24. h exceeds the limits stated above the nameplate and catalogue of the product especially higher torques and speeds is not compliant with the regulations and thus prohibited The operation of the gear reducer is prohibited if It was not mounted installed according to regulations and this manual The gear reducer is very soiled It is operated without lubricant It is operated out of the permitted values provided on catalogues and or nameplate YILMAZ RED KT R 4 Operating Instructions TT Series Safety PEPPER ERP PE 4 3 Safety Instructions 4 3 1 General Safety Instructions 4 3 1 1 Working on the gear reducer Inappropriately executed work can lead to injury or damage Make sure that the gear reducer is only installed maintained and dismantled by trained technicians Foreign bodies spinning through the air can cause grave injury Before putting the gear reducer into operation check that there are no foreign bodies or tools near the gear reducer 4 3 1 2 Operation Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suitable safety equipment like gloves Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A1 EN13857 4 3 1 3 Maintenance An unintentional start of the machine during maintenance wor
25. he following illustrations gt 74 YILMAZ RED KT R a Operating Instructions ao TT Series Installing n 7 1 Installing customer shaft with shoulder 7 1 1 Use anti seize assembling paste available on your market Use a brush to apply the paste 7 1 2 Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft 22 YILMAZ RED KT R b74 Operating Instructions ao TT Series Installing G 7 2 Installing customer shaft without shoulder 7 2 1 Use anti seize mounting paste available on your market Use a brush to apply the paste 7 2 2 Fasten the bold as shown below 1 Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft 74 YILMAZ RED KT R 23 Operating Instructions ao TT Series Installing n 7 3 Disassembling customer shaft with shoulder 7 3 1 Disassemble the bolt and take out the parts as shown gt KE 7 3 2 Use the disassemble set from YILMAZ and fasten the bold as shown bellow to take out the output shaft For disassemble sets look the following pages 1 Retaining Bolt 2 Circlip 3 Lock Washer 4 Washer 5 Hollow Shaft 6 Customer Shaft 24 YILMAZ RED KT R 4 Operating Instructions ao TT Series Installing G 7 4 Disassembling customer shaft without shoulder 7 4 1 Disassembly the bolt and take out
26. k can lead to serious accidents Make sure no one can start the machine while you are working on it Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating Make sure that all safety devices are mounted and active 4 3 1 4 Lubricant Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroughly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 4 3 1 5 Ambient Conditions Standard gearboxes are allowed to work in ambient temperatures between 5 to 40 C unless differently specified on the nameplate Using the gear unit out of this range can cause damage to the gear unit or environment Over 40 C ambient conditions the gear unit surface temp could be so high causing burns when touched If the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust Entering substances inside the gear unit from seals can damage the ear unit Observe the safety instructions for outdoor use EN12100 2010 74 YILMAZ RED KT R 13 Operating Instructions TT Series Safety 4 4 Tightening Torques All screwed connections for which a tightening torque is specified must on principle be tightened with a calibrated torque wrench and checked Use the following torques for the threaded bores over th
27. n by screwing half way out the level plug and see if oil comes out from that plug If oil comes out tighten the plug again If no oil comes out take out the filling plug and add oil until oil comes out from the level plug and tighten both plugs after finish Be sure you are using the correct oil mentioned on the oil tables on this manual Do not mix synthetic oils with mineral which can cause serious damage on the gear unit 6 8 Check shaft ends and mounting faces Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or painting of the housing 6 9 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 substances to enter the gearbox and cause serious damage to the gear unit If pressure or abrasive material can not be prevented from coming over the sealing contact YILMAZ REDUKTOR for solutions Abrasive material chemicals water positive or negative pressure exceeding 0 2 bar can affect or damage the sealing lip or output shaft Inside entering substances from the seals can cause serious damage to the gear unit YILMAZ RED K
28. ng Guide All the operations bellow must be done by authorized and skilled mechanician electrician Inform YILMAZ REDUKTOR before making any change to the gearbox Only oil change is allowed to change without information Do not make any think if you are not sure what you are doing and contact YILMAZ Any change or operation done without the information of YILMAZ REDUKTOR is in your own risk and responsibility and YILMAZ REDUKTOR does not take any responsibility Problem Observation Remedy Start Up Gearbox Does Not You hear no noise and shaft is not turning You are not using any driver or frequency inverter Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still does not work go to ID 100 Start Up Gearbox Does Not You hear no noise and shaft is not turning You are using frequency inverter or driver Please observe the frequency incerter driver manual Chech the motor by supplying direct voltage to see ifthe problem is on your driver frequency inverter Still does not work go to ID 001 Start Up Gearbox Does Not You hear some noise but both motor shaft and gearbox shaft is not turning You are not using any driver frequency in verter or braked motor Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate
29. nits refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres 6 2 Check the shaft dimensions to fit ollow Hollow Shaft Customer Input Shaft 2 Shaft j Tolerance Shaft Tolerance Diameter Tolerance _ Tolerance Diameter Diameter for Diameter with Shrink Shrink Disc Disc 19 N 30 30 N 30 19 35 35 35 24 40 40 40 24 45 45 45 28 50 50 50 38 60 60 60 42 70 70 70 48 80 80 80 55 100 55 6 3 Check the ambient temperature The ambient temperature must be between 5 C to 40 C for standard type gear units If different contact YILMAZ REDUKTOR for special solutions 6 4 Check the voltage supply The standard geared motors are supplied with 230 400 V 50 60 Hz up to 3 kW including 3 kW and 400 690 V 50 60 Hz over 3 kW and is indicated on the motors name plate unless it is differentiy ordered 374 YILMAZ RED KT R 17 Operating Instructions TT Series Installing In case of only gear unit is supplied from YILMAZ REDUKTOR please observe the name plate of the electric motor and the instructions of the supplier Check the basic electric con nection diagrams below Use experienced electric technician STOP Using wrong connection or voltage can damage the
30. of the motor Observe motor manufacturers start up manual Still same problem the load may be too high for the choosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher mo tor power is needed For monophaze motors check the star ting up condansator and running condansator as well If notting helps go to ID 100 Start Up Gearbox Does Not You hear some noise but both motor shaft and gearbox shaft is not turning You are using driver or frequency inverter Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver frequency inverter and make direct voltage sup ply to the motor according the motors nameplate Still does not work go to ID 100 Start Up 40 Gearbox Does Not You hear some noise but both motor shaft and gearbox shaft is not turning You are using braked motor Please Check the voltage supply and frequency of your electric connection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Be sure that the brake is working Observe the brake manufactur ers manuel If brake is supplied from YILMAZ observe this ma nuel for correct brake wiring diagram If still not work supply the brake with voltage according its nameplate directly For exam ple 198V DC You will hear a clicking noise explaining that the brak
31. oil change must be done by using the filling draining and level plugs according the mounting position_illustrated in section 9 4 Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thorough gt Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 74 YILMAZ RED KT R 37 Operating Instructions TT Series Lubrication 9 3 Mounting Positions M2 M4 Oil Plugs M1 M2 M4 Symbols Drain plug E 38 M6 Oil Filling and Vent plug V Oillevel V YILMAZ RED KT R b74 Operating Instructions TT Series Lubrication 9 4 Oil Plugs and Oil Quantities TT Series Oil Level Plugs 74 YILMAZ RED KT R 39 Operating Instructions TT Series Troubleshooting Guide 10 Troubleshooti
32. on aluminium non ferrous havy metal if possible Dispose of it according to the valid national guidelines b4 YILMAZ RK a3 Appendix v YILMAZ RED KT R Warranty Conditions 1 The geared motors and gear units are warranted for two year except the electric motor For motor warranty please refer to the manual of the electric motor manufacturer or the war ranty document of the motor manufacturer This warranty is valid only if the gearbox is as sembled and started up according our operating instructions and is used under the allowed conditions for the appropriate gearbox type in our catalogue Special Gearbox parts made according to customer request are not covered by this warranty 2 The warranty time starts from the start up time written on the warranty document and last for two years If the start up time is more then three months after the billing time the total warranty time is limited to 27 months starting from billing time If the warranty document is not send to our company after start up the total warranty time will be limited to 24 months after the billing time 3 Any time during the warranty for maintenance repair or change will be added to the war ranty time This time starts from 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
33. ound the container to observe the moisture Rela tive 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 year with regular check The ambient temperature should be between 5 to 60 C Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be between 5 to 60 C The gearbox must be kept under enclosed roof with constant temperature and constant humidity not exceeding 50 The storage should be free of dust and dirt and ventilated with filter If the gearbox is stored without packing it is recommended not to store more than 2 years and regular check dur ing this time is recommended If stored in open protect against insect damage YILMAZ RED KT R b74 Operating Instructions TT Series Checking 6 Installing The Gear Unit 6 1 Before you start Observe the gear unit for damages of storage or transportation If any damage please contact YILMAZ REDUKTOR Be sure that you have all the equipment necessary for installing like Spanners torque wrench shims and distance rings fixing devices for input and output elements lubricant bolt adhesive etc This manual is not for 94 9 EC ATEX conforming gear units For 94 9 EC conformin gear u
34. sidered as not autonomous machine but as a component to install in machines Operation is prohibited within the area of validity of the EC directive until it has been determined that the machine in which this product is installed corresponds to the regula tions within this directive 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 TT Series gear units and is applicable only for TT series If any different type of gearbox is used please ask YILMAZ REDUKTOR for the operating instructions of that type This instruction can be used only for standard type geared units of YILMAZ REDUKTOR For special application and modified gear units ask YILMAZ REDUKTOR for validity This manual does not cover 94 9 EC compatible gearboxes For 94 9 EC contact YILMAZ REDUKTOR W4 YILMAZ RED KT R pi 5 Operating Instructions TT Series Type Designation 2 Unit Designation 2 1 Detailed unit designation Detailed TT Series gear units designation for ordering This Designation is different from the short nameplate designation TT 57 00 K M1 Mounting Position M1 Gear unit is upright and input shaft is over output shaft Input shaft is vertical to earth and input shaft points to sky G
35. ties refer to the following table 36 YILMAZ RED KT R 4 Operating Instructions TT Series Lubrication 9 Lubrication 9 1 Oil Types Beyond Kl ber Ambient Temp FC icati Wlan Temp POJ Petroleum Castrol Lubrication Lubricant DIN 51517 3 bp Dip Lubrication ie 4 7 M ii obil i KLUBER LUBRICATION Energol Kl beroil Mobilgear GR XP 680 GEM 1 680 N XMP 680 Energol Kl beroil Mobilgear GR XP 460 GEM 1 460 N XMP 460 E Energol Kl beroil Mobilgear Mineral Oil GR XP 320 GEM 1 320 N XMP 320 Energol Kl beroil Mobilgear GR XP 220 GEM 1 220 N XMP 220 Energol Kl beroil Mobilgear GR XP 150 GEM 1 150 N XMP 150 Energol Kl beroil GR XP 100 GEM 1 100 N Kl beroil Mobil Cassida Nevastane Food Grade Oil gar 4 UH1 320 N SHC Fluid SL 320 Cibus 320 GL 320 Biodegradable Oil Tribol BioTop Kl bersynth Carter E 1418 320 GEM 2 320 Bio 320 Energrease Spheerol Centoplex Mobilux Alvania Multis Mineral Grease 20 120 Working Temperature C LS 3 AP3 2 EP EP 3 RL3 Complex EP 2 Energrease Petamo Mobiltemp Cassida Multis Synthetic Grease 30 100 Working Temperature C SY 2202 GHY 133 N SHC 100 RLS2 Complex SHD 220 9 2 Changing the oil Refer to the nameplate to find out the correct oil filled inside the gearbox Do not mix synthetic oils with mineral oils which will cause serious damage to the gear unit The
36. to ID 018 019 If you are sure oil comes out from hou sing than housing has some micro split crack Goto ID 100 The sealing liquit under cover is split defect Disassemle the cover 020 Oil is Leaking Oil Leakage from Cover and put new sealing liquit Assemle the cover and tighten the bolts If still same problem goto ID 100 Gearbox is The movement of gear box is because of the runout of the shaft 021 moving regularly i it i You are using Torque Arm which you assemle the gearbox This has no bad affect or harm to on its mountin Int gt the gearbox and is normal unless you are using torque arm poin The movement of gear box is because of the runout and clearance Gearbox is r i of the shaft which you assemle the gearbox Check the clearance of 022 moving randomly j i i You are using Torque Arm the assemling shaft and the clearances on your machine This has on its mountin a z no bad affect or harm to the gearbox unless you are using torque oin 4 arm 023 Motor is heating Motor is running over its The motor power is not enough or some overload to the motor is up nominal current possible The motor may be defect Goto ID 100 Check the motor Fan Hub and rips They must be free of dust If you 023 Motor is heating are using forced external fan check if it is working If you are using up Ambient is dusty frequency inverter in low speeds and you do not have forced exter nal fan you may need forced external fan Goto I
37. u need higher motor power Gearbox is Heating Up too Much You are using Worm Gear Box and ambient tenp is lower than 40 Celsius Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes and standart worm gearboxes are designed to work under max 120 Cel sius If higher than 120 Celsius and using ATEX conforming gear box immidiately stop the system and contact YILMAZ REDUKTOR Go to ID 100 If not ATEX confirming check the oil type and oil quantitiy level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position goto ID 100 Gearbox is Heating Up too Much You are using Helical Gear Box Ambient temp is lower than 40 Celsius Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes are designed to work under max 120 Celsius If higher than 120 Celsi us and using ATEX conforming gear box immidiately stop the system and contact YILMAZ REDUKTOR If not ATEX gearbox the gearbox is designed to work under max 80 Celsious If higher than 80 Celsius check the oil type and oil quantitiy level according your mounting positi on and check the nameplate mounting position
38. wo shafts are not angular miss aligned 374 YILMAZ RED KT R 35 Operating Instructions ao TT Series Maintenance and Inspections 9 8 Maintenance and Inspections Under normal ambient and working conditions the gear unit should be checked according the follow ing intervals For definition of normal working conditions refer to the product catalogue Selecting Gearbox section Every 10 000 working hours or every 3 years Item to check replace Every 3 000 working hours Every 4 000 working or every 6 months hours Every 25 000 working hours Check for oil leakage Check for oil level Check oil leakage from seal Check Rubber buffer x Change if necessary Check Bearings Noise x Change if necessary x See Below for Change Mineral Oil details Change Synthetic PAO x See Below for Oil details Change Sealing Change Bearing Grease Change Bearings Check for noise Changes 45000 40000 35000 30000 25000 20000 15000 10000 5000 Mineral Synthetic PAO Synthetic PG Oil change interval Hours 70 80 90 100 110 120 130 140 150 160 Oil bath temperature Celcius il For normal ambient conditions 70 C oil bath temperature should be taken as reference For TT series mineral oil is used unless it is differently ordered For oil type and quanti
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