1

ASSEMBLY
AND OPERATION MANUAL
Geared Motor, type TP
 1

1. TECHNICAL DESCRIPTION AND DESIGNATION

The geared motors we offer find wide application in the machine building industry. They are used
to transfer power by reduction of the rotation frequency and increase of the moment of rotation. The
geared motors are made by modern technology which gives a guarantee for reliable and noiseless
operation. The two parts of the casing (body and cover) are made of cast iron. The gear wheels have
pitched teeth. The wheels operate in oil bath with reliable sealing. The easy assembly to the transmission
and the fixing by elastic bumpers to the bracket give a guarantee for reliability. The connection between
the electric motor and the gear unit is achieved by transitional cast iron flange and elastic clutch.
The geared motors are supplied for normal climatic conditions provided there is no special
requirement of the customer.
The geared motors are available in four sizes: TP1160; TP1200; TP1250 and TP1315.
Designation of the geared motors:

Type Size Gear ratio Electric motor

TP 1200 35 T80B - 12/4R BRII

2. GEAR RATIO VALUES

Table 1
TP 1160 TP 1200 TP 1250 TP 1315
Actual Rated Actual Rated Actual Rated Actual Rated
79.08 79 84.40 84 87.52 88 86.03 86
69.89 70 69.56 70 72.29 72 77.85 78
63.72 64 69.51 69 65.82 66 70.56 70
57.88 58 57.29 57 60.87 61 59.83 60
56.31 56 53.74 54 54.36 54 59.46 59
49.12 49 49.65 50 51.98 52 54.14 54
48.69 48 44.29 44 48.24 48 49.96 50
46.63 47 42.70 43 45.77 46 44.97 45
44.87 45 40.92 41 39.09 39 41.35 41
43.41 43 39.72 40 36.28 36 35.31 35
39.23 39 35.19 35 26.60 27 29.60 30
35.95 36 32.73 33 20.88 21 26.78 27
35.57 35 32.27 32 20.00 20 22.84 23
33.04 33 26.60 27 15.70 16 20.45 20
30.25 30 24.82 25
28.66 29 21.84 22
27.87 28 20.46 20
26.62 27 18.00 18
22.09 22
20.52 21
20.19 20
16.26 16
12.54 13
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3. TECHNICAL DATA

The geared motors are equipped with three phase, asynchronous electric motors series T with
height of the rotation axis 71, 80, 90, 100 and 112, and built in brake type BRII.
3.1. Electric motors designation
T 80 A 12/4 R BR 10

Type designation
Size
Number of poles
Rotor with increased resistance
Electromagnetic brake
Brake moment

3.2. Main characteristics of the electric motors

- voltage 220, 380, 400, 440 V

- current frequency 50Hz and 60Hz
- stage of protection IP 54
- insulation class B or F
- mode of operation - single speed with 2p = 2; 4; 6 and 8 - 60%
- double speed 2 = 4/2; 8/4; 8/2 and 12/4 - 20/40%
- normal and tropical climate

3. 3. Technical data for electric motor with rotor with increased resistance
-1 -1
380V; 50Hz; 1500min ; 60%; 180 h
Table 2
Starting Starting Maximum
current moment moment Brake
Rotation Current
Power moment Inertia
fre- at Direct start as multiplicity of
factor moment
Output Type quency 380V rated Weight
current moment small large

n IH cos IN/IH MN/MH MM/MH MBR J

-1
kW HP - min A - - Nm kg.m2 kg

0.25 0.34 T71A-4R BRII 1320 0.86 0.71 2.5 2.2 2.1 2.5 5 0.00121 8.5

0.37 0.5 T71B-4R BRII 1330 1.19 0.73 2.7 2.2 2.1 2.5 5 0.00134 10

0.55 0.75 T80A-4R BRII 1370 1.75 0.75 2.8 2.0 2.1 4 10 0.00287 12

0.75 1.0 T80B-4R BRII 1370 2.38 0.71 3.0 2.4 2.5 4 10 0.00313 13.5

1.1 1.5 T90S-4R BRII 1380 3.0 0.79 4.0 2.4 2.4 10 20 0.00457 17.5

1.5 2.0 T90L-4R BRII 1370 3.9 0.81 4.2 2.6 2.6 10 20 0.00480 19.5

2.2 3.0 T100LA-4R BRII 1380 5.6 0.83 4.9 2.4 2.6 15 40 0.01020 26

3.0 4.0 T100LB-4R BRII 1380 7.5 0.83 4.9 2.6 2.6 15 40 0.01138 29

4.0 5.5 T112M-4R BRII 1390 9.54 0.83 5.2 3.0 2.9 15 50 0.01213 36

5.5 7.5 T112MB-4R BRII 1370 12.44 0.84 5.5 3.0 3.0 15 50 0.01523 40
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-1 -1
380V; 50Hz; 500/1500min ; 20/40%; 180 h
Table 3
Starting Starting Maximum
current moment moment Brake
Rotation fre- Current Power moment
quency at 380V factor Direct start as multiplicity of rated
Output Type Weight
current moment small large

n IH cos IN/IH MN/MH MM/MH MBR

-1
kW - min A - - Nm kg

0.08/0.25 T80A-12/4R BRII 450/1440 1.3/1.2 0.72/0.65 1.1/2.7 1.5/1.5 1.9/2.6 4 10 11.5

0.12/0.37 T80B-12/4R BRII 450/1440 1.8/1.5 0.70/0.66 1.1/2.7 1.5/1.7 2.1/2.5 4 10 12.5

0.18/0.55 T90S-12/4R BRII 450/1400 2.0/1.7 0.63/0.75 1.8/4.7 2.0/2.1 2.5/2.8 10 20 17.3

0.25/0.75 T90L-12/4R BRII 450/1420 2.5/2.2 0.61/0.77 1.6/4.8 2.0/2.2 2.1/2.7 10 20 20.8

0.37/1.1 T100LA-12/4R BRII 400/1400 3.1/2.8 0.63/0.83 1.7/4.3 1.6/1.8 1.6/2.5 15 40 26.0

0.55/1.5 T100LB-12/4R BRII 420/1400 4.0/3.8 0.65/0.82 1.7/4.3 1.6/1.8 1.6/2.5 15 40 29.0

0.75/2.2 T112M-12/4R BRII 440/1400 4.4/5.0 0.68/0.90 2.2/4.9 1.2/1.3 1.4/1.7 15 50 34.6

The variety of gear units and electric motors gives a possibility through correct choice to reach the
required outlet parameters - revolutions and turning moment most oftenly used in their application -
materials handling machines, crane gear units, transport lines and general machine building, etc.

4. SERVICE FACTOR - shown in Tables 5, 6, 7 and 8

It shows the loading of the gear unit during operation: type of loading, number of switchings per
hour, operating duration, dynamic loading, etc.
The service factor is determined by the following relation:
Mtmax
fs =
Mtu
Mtmax - maximum turning moment, the gear unit is made for
Mtu - outlet moment for each separate case. It corresponds to the applied power, the number of
revolutions and the gear ratio of the gear unit.
The following condition must be observed for each separate case:
Mtmax ≥ Mtu

We recommend you to observe the following condition when chosing a geared motor:

Mmax
fs = ≥ 1,75
Mu
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5. MAIN PARAMETERS

5.1. Geared motors

Fig. 1

Table 4
Type a b c dH7 d1 F h h1 h2 k m n s t v

T80A-12/4R 492 124

TP 1160 T80B-12/4R 70 510 97 30 16 4 100 236 167 132 124 8 12 33.3 72

T90S-12/4R 530 132

T80B-12/4R 524 124

TP 1200 T90S-12/4R 72 544 106 35 16 2 125 280 178 152 132 10 14 38.3 80

T90L-12/4R 584 132

T90S-12/4R 548 132

T90L-12/4R 568 132

TP 1250 78 118 40 18 2 145 323 207 180 12 14 43.3 96
T100LA-12/4R 604 132

T100LB-12/4R 638 136

T100LB-12/4R 568
TP 1315 98 142 50 22 2 174 383 244 210 14 16 54 106
T112M-12/4R 584

5.2. Elastic bumpers

TP1160 TP1200 TP1250 TP1315

A 14 14 14 17

B 32 41 50 50

C 30 30 40 40
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-1
6. DATA FOR THE GEARED MOTORS WITH ELECTRIC MOTORS 500/1500 min

6.1. TP 1160; Mmax = 250 Nm; 50 Hz

Table 5
Outlet turning
Outlet revolutions Service factor
Kw i moment
-1
min Nm fS
0.08/0.25 79 5.69/18.21 128/125 1.95/2.00
0.08/0.25 70 6.44/20.60 113/100 2.21/2.27
0.08/0.25 64 7.06/22.60 103/100 2.43/2.50
0.12/0.37 58 7.77/24.86 140/135 1.79/1.85
0.12/0.37 56 7.99/25.57 136/131 1.84/1.91
0.12/0.37 49 9.16/29.31 119/115 2.10/2.19
0.12/0.37 48 9.24/29.57 118/114 2.12/2.20
0.12/0.37 47 9.65/30.88 113/109 2.21/2.29
0.12/0.37 45 10.02/32.06 109/105 2.29/2.38
0.12/0.37 43 10.36/33.15 105/101 2.38/2.48
0.18/0.55 39 11.47/35.68 142/140 1.76/1.79
0.18/0.55 36 12.51/38.92 130/128 1.92/1.95
0.18/0.55 35 12.65/39.36 129/127 1.94/1.97
0.18/0.55 33 13.62/42.38 120/118 2.08/2.12
0.18/0.55 30 14.88/46.29 110/108 2.27/2.31
0.25/0.75 29 15.70/49.54 144/137 1.74/1.82
0.25/0.75 28 16.15/50.96 140/134 1.79/1.87
0.25/0.75 27 16.90/53.33 134/128 1.87/1.95
0.25/0.75 22 20.37/64.28 111/106 2.25/2.36
0.25/0.75 21 21.93/69.20 103/98 2.43/2.55
0.25/0.75 20 19.81/69.34 102/97 2.45/2.58
0.37/1.1 16 24.60/86.10 136/116 1.84/2.16
0.55/1.5 13 34.49/114.96 149/122 1.68/2.05

6.2. TP 1200; Mmax = 500 Nm; 50 Hz

Table 6
Outlet turning
Outlet revolutions Service factor
Kw i moment
-1
min Nm fS
0.12/0.37 84 5.33/17.06 204/197 2.45/2.54
0.18/0.55 70 6.47/20.13 252/241 1.98/2.07
0.18/0.55 69 6.48/20.14 252/241 1.98/2.07
0.25/0.75 57 7.85/24.77 289/284 1.73/1.82
0.25/0.75 54 8.37/26.42 271/257 1.85/1.95
0.25/0.75 50 9.06/28.60 250/238 2.00/2.09
0.25/0.75 44 10.16/32.06 223/212 2.24/2.36
0.25/0.75 43 10.54/33.26 215/205 2.36/2.44
0.25/0.75 41 11.00/34.70 206/196 2.43/2.55
0.25/0.75 40 10.07/35.25 200/190 2.50/2.63
0.37/1.10 35 11.37/39.78 295/251 1.70/1.99
0.37/1.1 33 12.22/42.77 275/233 1.83/2.15
0.37/1.1 32 12.40/43.38 271/230 1.85/2.17
0.37/1.1 27 15.79/52.63 223/190 2.24/2.63
0.55/1.5 25 16.92/56.41 295/241 1.70/2.01
0.55/1.5 22 19.23/64.10 259/212 1.93/2.36
0.55/1.5 20 21.50/68.42 243/198 2.05/2.53
0.75/2.2 18 24.44/77.78 278/257 1.80/1.95
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6.3. TP 1250; Mmax = 800 Nm; 50 Hz

Table 7
Outlet turning
Outlet revolutions Service factor
Kw i moment
-1
min Nm fS
0.25/0.75 88 5.14/16.22 441/419 1.81/1.91
0.25/0.75 72 6.22/19.64 364/346 2.19/2.31
0.25/0.75 66 6.84/21.57 332/315 2.41/2.54
0.25/0.75 61 6.57/23.00 307/292 2.60/2.74
0.37/1.1 54 7.36/25.75 456/387 1.75/2.07
0.37/1.1 52 7.70/26.93 436/370 1.83/2.16
0.37/1.1 48 8.29/29.02 405/344 1.98/2.33
0.37/1.1 46 9.18/30.59 384/326 2.08/2.45
0.55/1.5 39 10.74/35.81 464/380 1.73/2.10
0.55/1.5 36 11.58/38.59 431/352 1.86/2.27
0.75/2.2 27 16.54/52.63 411/379 1.95/2.11
0.75/2.2 21 21.07/67.05 323/298 2.47/2.68
0.75/2.2 20 22.00/63.64 309/285 2.59/2.80
0.75/2.2 16 28.03/89.17 242/224 3.30/3.57

6.4. TP 1315; Mmax = 1200 Nm; 50 Hz

Table 8
Outlet turning
Outlet revolutions Service factor
Kw i moment
-1
min Nm fS
0.37/1.1 86 4.65/16.27 722/614 1.66/1.95
0.37/1.1 78 5.13/17.98 653/555 1.84/2.16
0.37/1.1 70 5.67/19.84 592/503 2.03/239
0.55/1.5 60 7.02/23.40 711/582 1.69/2.06
0.55/1.5 59 7.06/23.55 706/578 1.70/2.08
0.55/1.5 54 7.76/25.86 643/526 1.87/2.28
0.55/1.5 50 8.41/28.02 594/486 2.02/2.47
0.75/2.2 45 9.78/31.13 695/641 1.73/1.87
0.75/2.2 41 10.64/33.86 639/589 1.88/2.04
0.75/2.2 35 12.46/39.65 546/503 2.20/2.39
0.75/2.2 30 14.86/47.30 458/422 2.62/2.84
0.75/2.2 27 16.43/52.28 414/382 2.90/3.14
0.75/2.2 23 19.26/61.26 353/326 3.40/3.68
0.75/2.2 20 21.52/68.46 316/292 3.80/4.10
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7. ASSEMBLY AND COMMISSIONING

Check the geared motor before assembly for eventual damages caused during transportation.
The assembly is made upon choice of the end user in one of the stated versions, Fig. 2. Depending on
the chosen version, the place of the tap-air drain is fixed. Clean the same if necessary.

Fig. 2

Remark: If the gear unit has a name plate "not filled with oil", use suitable oil:
SHELL OMALA 320; SHELL OMALA 460; SHELL OMALA 680; MOBILE CERD 632; ULITA EP90
or their analogue, in the following quantities:

TP 1160 TP 1200 TP 1250 TP 1315

0.5l 0.8l 1.0l 2.0l

The geared motor must be placed in the shaft of the driving unit and fixed by safety ring at the
front side. Avoid shocks and force on the shaft of the driving unit during assembly. This may lead to
improper operation of the gear unit. The two elastic bumpers should be placed on the bracket axle to
absorb the eventual vibrations and shocks that may pass through the gears, bearings and the body. To
avoid all problems in case of disassembly, we recommend you to oil very carefully the joints /shaft of the
driving unit - gear unit/ with anticorrosion lubricant.
Take care of the sealings in case of painting.
Change the oil after 2000 working hours or once a year.
Remove the sealing taps and drain the oil. Fill with petrol or similar product in double quantity of
the oil quantity marked on the gear unit and clean it. After draining the liquid fill the gear unit with the
prescribed oil.
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8. SPARE PARTS

State the following data for prompt delivry of spare parts:

- gear unit designation (overall dimensions)
- position number (Fig. 3)
- part denomination
Positions 12 and 23 and 13 and 15 are supplied complete and you have to state the gear ratio in
this case.

Fig. 3
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Table 9
Description TP 1160 TP 1200 TP 1250 TP 1315

1 Clutch 71-80-90 71-80-90-100 80-90-100 90-100

2 Flange /mm/ dia.160-200 dia.160-200 dia.200-250 dia.200-250

3 Key DIN 6885 4x4x18 5x5x20 5x5x25 6x6x20

4 Shaft seal DIN 3760 12x24x7 15x28x7 17x30x7 20x32x7

5 Bearing DIN 625 6201 6202 6203 6004

6 Body G25 TP160 TP200 TP250 TP315

7 Gasket TP160 TP200 TP250 TP315

8 Cover G25 TP160 TP200 TP250 TP315

9 Inlet shaft Z11… Z11… Z11… Z11…

10 Bearing DIN 625 6001 6202 6202 6202

11 Bearing DIN 625 6201 6302 6204 6304

12 Mediate shaft – gear wheel Z21… Z21… Z21… Z21…

13 Mediate shaft – gear wheel Z22… Z22… Z22… Z22…

14 Bearing DIN 625 6201 6302 6304 6305

15 Shaft-gear wheel Z13… Z12… Z12… Z12…

16 Outlet shaft Z63… Z55… Z55… Z53…

17 Shaft seal DIN 3760 45x60x7 50x65x8 60x80x10 70x90x10

18 Bearing DIN 625 16009 16010 16012 16014

19 Screw 8.8 DIN 912 M8x50 M8x55 M8x55 M8x70

20 Oil plug DIN 7604 M18x1,5 M18x1,5 M18x1,5 M18x1,5

21 Pin DIN 7 8x30 8x30 8x30 8x30

22 Bearing DIN 625 6202 6204 6304 6305

23 Gear wheel Z12… Z12… Z12… Z12…

24 Bearing DIN 625 6001 6202 6203 6204

25 Screw 8,8 DIN 912 M8x25 M8x25 M8x25 M8x35

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9. TROUBLERSHOOTING

Table 10
Problem Possible cause Troubleshooting steps

1 The motor does not The brake is stuck Switch off the motor, remove the seal and
run when switched push the shaft.
on
The motor is blocked Dismount and repair the motor

2 The motor drones The motor operates at two Check the supply voltage
and when loaded phases
does not run
Voltage is lower than normal Check the supply voltage

Terminal end bolts or other Clean and tighten the terminal ends and
cable ends are loosen bolts

Gear teeth are broken Change the broken gears

3 Safety fuses fail and Earthing rupture Check the insulation with meqaohmmeter
the motor does not
run Phase rupture Check the insulation between phases

4 The motor The motor is overloaded, Keep the recommended torque

overheats hence the torque Is hiqh

Supply voltage is asymmetric Switch off the motor until the supply
voltage Is normal

Voltage is lower than normal Keep the recommended voltage

The duty cycle exceeds the Keep the recommended duty cycle
nominal

The brake is not adjusted Adjust the brake following the instructions
correctly

5 The gearbox emits The bearings are worn out Chanqe the bearinqs
unusual sounds
There Is not enough oil in the Add oil to the needed level
gear box

6 Oil leaks from the The sealing is bad Change the sealing
gear box
Air-holes are blocked up Clear the air-holes
 11

10. LUBRICATING

The geared motor is delivered wilhout oil.

Attention!
Regular and correct greasing is of prime importance for every gear operating in oil bath
It is convenient to attach a label "NO OIL" to the machine. After mounting it should be filled with
appropriate oil and lubricated according to the following scheme (seeTable 11)
Schedule for geared motor lubricating
Table 11

 Before the initial starting

 After 3 months or 100 hours of operation

 After 12 months of operation

 Afier each period of 12 months

 After each period of 36 months

Gear box   Check the oil level and add oil if necessary

Gear box    Change the oil

Motor  Change the lubricant

11. STORAGE AND TRANSPORT

11.1. The geared motors should be stored in dry and covered places, wrapped in nylon and
packed in wooden cases.
11.2. The geared motors should be transposed in closed trucks.
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CONTENTS

1. TECHNICAL DESCRIPTION AND DESIGNATION 1

2. GEAR RATIO VALUES 1

3. TECHNICAL DATA 2

4. SERVICE FACTOR 3

5. MAIN PARAMETERS 4
-1
6. DATA FOR THE GEARED MOTORS WITH ELECTRIC MOTORS 500/1500 min 5

7. ASSEMBLY AND COMMISSIONING 7

8. SPARE PARTS 8

9. TROUBLERSHOOTING 10

10. LUBRICATING 11

11. STORAGE AND TRANSPORT 11

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BALKANCARPODEM Ltd
1040 Sofia, Bulgaria
18, Kliment Ohridsky Boul.
Tel. (+359 2) 975 33 95
Fax (+359 2) 975 30 89
e-mail: mail@bcp.bg
http://www.bcp.bg