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Operating Instructions

1. Oil Quantities It M1 AIB M2 AIB M3 AIB M4 A B M5 A B M6 A B 1 8 0 4 2 0 0 6 1 2 0 5 1 6 0 6 1 9 0 5 1 6 0 5 1 8 0 35 2 0 0 5 1 2 0 5 1 6 0 55 1 9 0 4 1 6 0 4 2 0 0 4 2 8 0 6 1 8 0 5 2 1 0 6 2 4 0 5 2205 2 0 0 35 2 8 0 5 1 8 0 5 2 1 0 5 2 4 0 4 2 2 0 4 3 2 0 4 3 7 0 6 2 0 0 5 3 5 0 6 3 9 0 5 3 3 0 5 3 2 0 35 3 7 0 5 2 0 0 5 3 5 0 5 3 5 0 4 3 3 0 4 6 4 0 65 8 4 0 95 9 9 0 7 5 0 0 95 7 3 0 7 U2 OU 6 4 0 6 8 4 0 8 5 5 0 7 5 0 0 8 7 3 0 65 7 210 65 Nhe lo 12 4 2 1 7 412 az 11 35 1 4 11 5 1 4 11 2 1 1 12 4 2 7 411 9 9 6 2 11 35 1 3 11 5 1 3 18 0 1 2 18 0 2 1 14 0 2 15 0 2 1 16 1 4 15 0 1 4 18 0 1 1 18 0 2 14 0 1 9
2. 374 YILMAZ RED KT R 25 Operating Instructions D Series Installing 26 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 quantities 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 D 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 position by screwing half way out the level plug and s
3. 7 12 3 By fitting couplings be sure that the two shafts are not angular miss aligned 374 YILMAZ RED KT R 41 Operating Instructions ao D 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
4. 1 Bolt 4 Rubber Buffer 7 Bolt 3 Washer Ring 6 Fixing Plate 38 YILMAZ RED KT R 4 Operating Instructions ao D Series Installing 6 7 9 3 For the fixing bold position refer to the following dimensions h1 74 YILMAZ RED KT R 39 Operating Instructions ao D 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 40 YILMAZ RED KT R 4 Operating Instructions D 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
5. 15 0 2 16 1 3 15 0 1 3 BUY 28 0 3 4 20 0 3 1 22 5 3 4 24 0 2 8 22 0 2 8 27 2 1 9 28 0 3 3 20 0 3 22 5 3 3 24 0 2 6 22 0 2 6 43 0 2 45 0 3 4 32 0 3 1 36 0 3 4 42 0 2 8 40 0 2 8 43 0 1 9 45 0 3 3 32 0 3 0 36 0 3 3 42 0 2 6 40 0 2 6 73 0 4 5 76 0 8 0 54 0 7 5 61 0 8 0 73 0 5 5 70 0 5 5 Symbols 73 0 4 0 yg Drain plug 374 YILMAZ RED KT R 76 0 7 6 54 0 7 0 V Oil Filling and Vent plug 61 0 7 6 73 0 5 0 70 0 5 0 V Oillevel 47 Operating Instructions D Series Troubleshooting Guide 10 Troubleshooting 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 Gearbox Does Not Start Up 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
6. For D series mineral oil is used unless it is differently ordered For oil type and quantities refer to the following table 42 YILMAZ RED KT R 4 Operating Instructions D Series Lubrication 9 Lubrication 9 1 Oil Types Beyond Kl ber Ambient Temp FC icati mbient Temp C Petroleum C strol ubrication 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 ei 1418 320 GEM 2 320 Bio 320 Energrease Spheerol Centoplex Mobilux Alvania Multis Mineral Grease 20 120 Working Temperature C LS3 AP3 2EP EP3 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
7. 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 the following illustrations W4 YILMAZ RED KT
8. 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 13 Gear 21 Spacer 29 Spacer 14 Spacer 22 Spacer 30 Bearing 15 Bearing 23 Bearing 31 Gear 16 Spacer 24 Shaft Gear 32 Key 374 YILMAZ RED KT R 9 Operating Instructions D Series Part Designation 3 3 D 02 Types For 2 and 3 Staged Gear Units Only Valid For 3 Stages Standard D 02 type basic part diagram Parts may differ for special applications Standard Part List 3 Plug 14 Spacer 23 Spacer 32 Bearing 5 Bolt 16 Spacer 25 Bearing 34 Key 17 Circlip 26 Shaft Gear 35 Shaft Gear 18 Seal 27 Key 36 Bearing 10 YILMAZ RED KT R gt 4 Operating Instructions D Series Part Designation Only Valid For 3 Stages Standard D 03 t 3 4 D 03 Types For 2 and 3 Staged Gear Units e basic part diagram Parts may differ for special a lications Standard Part List 1 Pin Screw 9 Bearing 17 Oil Seal 25 Shaft Gear 33 Key 2 Housing 10 Hollow Output Shaft 18 Flange 26 Key 34 Gear 3 Plug 11 Key 19 Bolt 2 Gear 35 Bearing 12 Gear 20 Closing Cap 28 Spacer 36 Circlip 13 Spacer 21 Circlip 29 Bearing 37 Closing C
9. R eee Operating Instructions ao D Series Installing 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 28 YILMAZ RED KT R 4 Operating Instructions ao D Series Installing 6 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 374 YILMAZ RED KT R 29 Operating Instructions ao D Series Installing n 7 3 Disassembling customer shaft with shoulder 7 3 1 Disassemble the bolt and take out the parts as shown 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 30 YILMAZ RED KT R 4 Operating Instructions ao D Series Installing 6 7 4 Disassembling customer shaft without
10. Tightening TONE nee ee ee ee 20 AS SASS S bl 0 iklim T 20 4 5 1 Suitable extinguishing agents protectiveeguipmenit 20 4 5 2 Unsuitableextinguishingagenis 20 5 Thinks to Check Before the Gear Unit or Geared Motor is Installed 21 z ep AR PE A AR ZEY EK 21 SA EO RE PA A A PE a ON een Te mum ET en 22 6 Installing The Gear Ui salise silinmez a a elalem bele balsa lliekedemie 23 6 1 R e e ylmy ee si ec 23 6 2 Checkihesh ftdimensionstofit 1 nan 23 6 3Checktheambienttemperature nr nr rrn rreeeen 23 6 4 Check the voltage supply nennen 26 6 5 Check the mounting POSINON RA ERA 26 6 6 Use the breather PlU u e une ann 26 6 Check Heaven ee 26 6 8 Check shaft ends and mounting faces cccccceseeeeeeeeecececeeeeeeeeeeeeeenenenenees 26 6 9 Cover abrasive ambiente 26 6 10 Check accessibility to filling breatheranddrainplugs 27 374 YILMAZ RED KT R Operating Instructions D Series Contents T Mechanicallinstall ation ses 27 7 1 Installing customer shaft with shoulder 28 7 2 Installing customer shaft without shoulder 4 sn 29 7 3 Disassembling customer shaftwithshoulder RR 30 7 4 Disassembling customer shaft without shoulder 31 1 5 Shaft tightening torques RAN ae 32 7 6 Recom
11. shoulder 7 4 1 Disassembly the bolt and take out 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 31 Operating Instructions D Series Installing 7 5 Shaft tightening torques Use the following table for shaft tightening torques ay Tightining Torque Type Bolt Nm D 172 173 M10 20 D 272 273 M12 20 D 282 283 M16 40 D 372 373 M16 40 D 472 473 M16 40 D 572 573 M20 80 D 672 673 M20 80 D 772 773 M24 200 D 872 873 M24 200 D 972 973 M24 200 32 YILMAZ RED KT R gt 4 Operating Instructions ao D Series We Installing 7 6 Advised Shaft Dimensions and Accessiories t1 e1 g DIN 332 Dismounting Mounting ie _ UUU ENER 7 Z Vl 6 Contour Bolt DIN ISO 4014 DIN ISO 4017 DIN ISO 8765 74 YILMA
12. 0 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 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 Dat
13. Observe motor manufacturers start up manual Still does not work go to ID 100 Gearbox Does Not Start Up 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 Gearbox Does Not Start Up 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 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 Gearbox Does Not Start Up 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 S
14. YILMAZ RED KT R ISO 9001 YILMAZ RED KT R ISO 9001 v RED KT R D Series Gear Units OIDCE0201 0814 Operating Instructions Operating Instructions D Series Contents Contents 1 How To Use This Mila ern g ya 04 2 Unit Designation A EEE ne 05 2 1 Detailed unit designalen eleme Ge ee 05 2 2 Nameplate unit deSignation c ccccccssessseesecececeeeceececccececeeneeeeceeeeseneeeennesenee 06 3 Part List of Standard Type Gear Units nnnnsesssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnn 07 3 1D 00 po see ee eng 07 32 D 0l TYPE ceases ee ie 08 93 D aa VDO ee ee Eee 19 OR ten 10 A DE e nee see gen E 11 3 6 D DE TYPES vnesie innesa ee ee 12 3 7 D 4 Additional bolie O ZA en E ee EE Ee 13 3 8 D 5 and D 6 Additional SEGA ee 15 3 9 D Series Motor FlangeforDirecCtCouplediypes 15 3 10 DN DV Types B5 B14 Motor Flange san een a 15 3 11 DT Types Input Bearing Housing with Solid Input Shaft 16 a SUG A A MM RA AN SEAN 18 4 1 intended L mg ajan kalan adan kli ny 18 4 2 Improper USE elenme el Selene lanl aaa melanet ii ehren 18 4 3 Safety pg A A ee 19 4 3 1 General Safety InstrucliorB uses seen 19 4 3 1 1 Workingonthegearreducer 2 2 19 2 3 12 D EN NE S ae 19 4 3 1 3 NDE ia nel l in a aa ms anilan 19 43 14 e e i GR MY EM DV 19 4 3 1 5 Ambient Gonditions nn 19 4 4
15. Z RED KT R 33 Operating Instructions ao D Series Installing n 7 7 Assembling customer shaft with shrink disk 7 7 1 Loosen the bolts of the shrink disk 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 34 YILMAZ RED KT R 4 Operating Instructions ao D Series Installing n 7 7 3 Insert the shaft and tighten the bolts as shown Be sure that there is a clear ance between 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 35 Operating Instructions ao D 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 36 YILMAZ RED KT R 4 Operating Instructions D Series Installing 7 9 Assembling Gear Unit with Torque Arm 7 9 1 Use the torque arm connection according the following drawing 74 YILMAZ RED KT R ap 37 Operating Instructions ao D Series Installing n 7 9 2 Assemble the parts as shown bellow
16. a 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 cataloque 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 which exceeds the limits stated above the nameplate and catalogue of the product especially higher torques and speeds is not compliant with the
17. ap 14 Bearing 22 Spacer 30 Spacer 15 Spacer 23 Spacer 31 Bearing 16 Circlip 374 YILMAZ RED KT R 24 Bearing 32 Gear 11 Operating Instructions D Series Part Designation 3 5 D 0S Types For 2 and 3 Staged Gear Units Only Valid For 3 Stages Standard D 0S type basic part diagram Parts may differ for special applications Standard Part List 1 Pin Screw 9 Spacer 17 Circlip 25 Key 33 Shaft Gear 2 Shrink Disk 10 Bearing 18 Oil Seal 26 Gear 34 Bearing 3 Housing 11 Output shaft 19 Closing Cap 27 Spacer 35 Circlip 12 Key 20 Circlip 28 Bearing 36 Closing Cap 13 Gear 21 Spacer 29 Spacer 14 Spacer 22 Spacer 30 Bearing 15 Bearing 23 Bearing 31 Gear 16 Spacer 24 Shaft Gear 32 Key 12 YILMAZ RED KT R b74 Operating Instructions D Series Part Designation 3 6 D 0E Types For 3 Staged Gear Units Standard D 0E type basic part diagram Parts may differ for special a Standard Part List 5 Extruder Neck 9 Key 6 Bolt 10 Hollow Shaft Output 7 Seal 11 Spacer 8 Bearing 374 YILMAZ RED KT R 12 Seal 13 Operating Instructions D Series Part Designation 3 7 D 4 Series Additional Stage for 4 Stage Types Standard D 4 type additional stage basic part diagram Parts may differ for spec
18. d 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 iron aluminium non ferrous havy metal if possible Dispose of it according to the valid national guidelines 4 YILMAZ RED KT R CO 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 warranty document of the motor manufacturer This warranty is valid only if the gearbox is assembled 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 customer request are not covered by this warranty 2 The warranty time starts from the start up time written on the warranty
19. derstanding 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 considered 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 D series gear units and is applicable only for D 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 gt 74 YILMAZ RED KT R pi 5 Operating Instruct
20. 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 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 9
21. e 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 Turkey Please contact the main service point mentioned above You will be directed to our nearest service point to your location
22. ee 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 KT R gt 4 Operating Instructions D Series
23. ey 16 YILMAZ RED KT R gt 4 Operating Instructions D Series 3 11 DT Types Input Bearing Housing with Solid Input Shaft Parts List 7 Circlips Nut 8 Gear Flange 9 Circlips Shaft 10 Key Bearing 11 Key Bearing 74 YILMAZ RED KT R 17 Operating Instructions D Series Safety x 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 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 dat
24. he 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 Output Shaft Flange Centering Shoulder Hollow Shaft Hollow Shaft Output Shaft Tolerance DIN748 Type Centering Shoulder Tolerance Diameter Tolerance H8 Diameter Up to 50mm k6 Diameter Over 50mm m6 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 30 35 40 45 50 70 110 20 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 differently ordered 374 YILMAZ RED KT R 23 Operating Instructions D 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 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 m
25. ial applications Parts List 1 Circlips 6 Circlips 11 Key 2 Bearing 7 Shaft 12 Key 3 Gear 8 Seal 13 Bolt 4 Oil plug 9 Gear 14 Additional Housing 5 Bearing 10 Circlips 15 Screw Pin 14 YILMAZ RED KT R gt 4 Operating Instructions D Series Part Designation 3 8 D Series 5 6 Stages Types N Type 2 and 3 stages are additional housing of D series 5 stages and 6 stages of gear units Only Valid For 6 Stages 14 Standard N type 3 stages basic part diagram Parts may differ for special applications Parts List Housing 9 Gear Key Cover Oil plug Oil plug Bearing Seal Circlips Bolt Circlips Circlips Circlips Bearing Eye bolt Bearing Cover Bearing Gear Oil plug Spacer Output Flange Spacer Key Top side cover Gear Bolt Gear Gear Screw Pin Bearing Key Bearing Bearing Key Output Shaft Circlips Circlips 374 YILMAZ RED KT R 15 Operating Instructions D Series Part Designation 3 9 D Series Motor Flange for Direct Coupled Types Parts List Shaft 6 Key Circlips 7 Gear Bearing 8 Circlips Circlips 9 Nut Flange 10 Key 3 10 DN DV Types B5 B14 Motor Flange Parts List Shaft 6 Seal Circlips 7 Gear Bearing 8 Circlips Circlips 9 Nut B5 B14 Flange 10 K
26. ions D Series Type Designation 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 DR47 4 02 90S 4 L05 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 Motor Size For DV Types 90S 4 Number Frame Lenght Motor size Output Shaft 00 Hollow Shaft output 01 Solid Shaft Output 10 100 Nm 20 200 Nm 30 300 Nm 40 400 Nm For DN Types 763 BS 763 B14 71 BS 71 B14 80 BS 80 B14 A06 B06 A07 B07 A08 B08 02 Solid shaft output with IEC B5 14 Flange 03 Flanged and Hollow Shaft output 0S Shrink Disk Output 0E Extruder Output Stage 2 Stages 5 Stages 3 Stages 6 Stages 4 Stages Revision Number Housing Size 1 9 Input Type R With Motor N IEC B5 B14 Flanged without Motor V IEC B5 B14 Flanged with Motor T With Input Shaft Gearbox Type D Serie A09 90 B5 A13 132 B5 A25 250 BS B09 90 B14 B13 132 B14 A28 280 BS A10 100 B5 A16 160 B5 A31 315 B5 B10 100 B14 A18 180 B5 A11 112 B5 A20 200 BS B11 112 B14 A22 225 B5 YILMAZ RED KT R 4 Operating Instructions D Series Type Designation 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for D Series YILMAZ REDUKTOR ww
27. lling and Vent plug W Oil level 374 YILMAZ RED KT R 45 Operating Instructions D Series Lubrication Oil Plugs and Oil Quantities D Series 4 Stages Oil Level Plugs Oil Quantities It M1 A B M2 A B M3 A B M4 A B M5 A B M6 A B 6 4 0 7 6 5 0 7 4 3 0 7 5 0 0 7 7 0 0 7 7 0 0 7 11 2 1 5 12 4 1 5 7 411 5 9 6 1 5 11 5 1 5 11 5 1 5 18 0 4 0 18 0 4 0 14 0 4 0 15 0 4 0 16 5 4 0 17 0 4 0 27 214 0 28 0 4 0 20 0 4 0 22 5 4 0 27 0 4 0 27 0 4 0 43 0 6 0 45 0 6 0 32 0 6 0 36 0 6 0 43 0 6 0 43 0 6 0 Symbols 46 73 0 4 0 76 5 4 0 m Drain plug 54 0 4 0 V Oil Filling and Vent plug 61 0 4 0 73 0 4 0 73 0 4 0 V Oillevel YILMAZ RED KT R b74 Operating Instructions D Series Lubrication Oil Plugs and Oil Quantities D Series 5 6 Stages Oil Level Plugs
28. mended shaft dimensions and disassembling nutdimensions 33 7 7 Assemblingcustomershaftwithshrinkdisk nennen 34 7 8 Disassembling customer shaftwithshrinkdisk 36 7 9 Assembling gearunitwitihtorgucalm 1 nn 37 7 10 Fitting output shaft elemente ee 40 7 11 Correct position of outputshaftelemenis 40 7212 Fitting Coupling e a e ARM 41 8 Maintenance amp Inspection unuussnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnennnnnnannn 42 9 Lubrication lee RR MN ARAL EE RM PA EN 43 EA EE Ee ERE 43 92 Changing Ne Ol ee een ea ae nano 43 9 3 Mounting POSIHONS ee a ee mes 44 DF OQ cpa nee ee a tee ace ala ts eeu i 45 10TroubleshootingGuide OUMnmnnnnnmmmm gt m gt e gt gt gt L Z m 48 TT e E ME nen 51 111 EY mei di ii ale izli 51 11 2 Disposal ot sealing ae a een ee 51 11 3 DISDOSAL Gi IMG lal as casinceicncearcidasnadsnessailecreasatndabdarmdesindacuasdtondarcadecniddcnbndasvarawesadaladeaste 51 12 AY o e fe GE P NE YAZ ennenen EE EA eana eiae EN EGM YY REN 52 122 Warranty CondilliOns eu ee ee SARERA EES 53 12 gt Warner ee Re ee 54 12 4 Servic Contact FOR nenne aan ee ee 55 4 YILMAZ RED KT R 4 Operating Instructions D Series General Informations 1 How To Use This Manual Take attention to the following safety and warning signs for proper un
29. ne 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 19 Operating Instructions D 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 the gear unit housing For connecting elements refer to the mechani cal installation part Tightenning Torque Nm 23 43 i
30. not mix synthetic oils with mineral oils which will cause serious damage to the gear unit The 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 43 Operating Instructions D Series Lubrication 9 3 Mounting Positions Figured mounting positions of M1 to M6 are de termined as reference of directional position of the gearbox Mounting surfaces are not binding YILMAZ RED KT R b74 as reference of directional position of the gearbox Mount Figured mounting positions of M1 to M6 are determined ing surfaces are not binding 44 Operating Instructions D Series Lubrication 9 4 Oil Plugs and Oil Quantities D Series 2 3 Stage Oil Level Plugs Oil Quantities It Symbols M Drain plug W Oil Fi
31. ntainer 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 D 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 ear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and t
32. ny 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 374 YILMAZ RED KT R 21 Operating Instructions D Series Checking 22 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 around the container to observe the moisture Rela tive atmospheric humidity should not exceed 50 The co
33. omly 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 ID 100 50 YILMAZ RED KT R 4 Operating Instructions D 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 G
34. oto 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 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 Required No self solution found 11 Disposal If your product is no longer of use an
35. otor 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 e U Le Ut U 230V 230V 400V 400V U U J 230V 400V ny 12 13 24 YILMAZ RED KT R b74 Operating Instructions D Series Installing Standard type brakes basic wiring diagram The gearbox and the motor must be grounded to prevent potential differences of earth A The electric connection must be done by experienced electric technician and gearbox motor Gecikmeli Frenleme Delayed Running Brake Versp tete Bremsung Ani Frenleme Sudden Brake Pl tzliche Bremsung 220 V 220 V RST RSTN OOO RAA gt gt moo G Fren Bobini Fren Bobini M M Ce su Gecikmeli Frenleme Delayed Running Brake Verspatete Bremsung Ani Frenleme Sudden Brake Pl tzliche Bremsung 24 V 24 V RSTN Fren Bobini RSTN Fren Bobini ey ch es LZ 55o
36. otor 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 you 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 Gearbo
37. 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 goto 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 rand
38. r 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 20 YILMAZ RED KT R 4 Operating Instructions D Series Safety as A D 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 page 5 1 Transportation When the goods arrive first check for any damage If some damage observed immediately contact the transport compa
39. 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 D Series Safety PEPPER ERP BP D 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 work 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 machi
40. se 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 49 Operating Instructions D 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 the 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
41. till does not work go to ID 100 48 Gearbox Does Not Start Up 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 brake 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 D 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 m
42. w yr com tr C MADE IN TURKEY Type DR473 03 90L 4 Serial N 100524545 Power 15 kW Ratio 116 6 Speed 12 rpm M Pos M1 Ol ineo Oil Qty 64 It Abreviations Serial N Serial Number M Pos Mounting Position Type Designation DR473 100L 4 Type Motor Size DR With motor DT With input shaft DV With Motor and IEC Flange DN EC Flange without Motor 374 YILMAZ RED KT R Operating Instructions D Series Part Designation 3 Part List of Standard Type Gear Units 3 1 D 00 Types for 2 and 3 Staged Gear Units Only Valid For 3 Stages Standard D 00 type basic part diagram Parts may differ for special applications Standard Part List 9 Bearing 17 Seal 25 Gear 33 Bearing 10 Hollow Shaft 18 Closing Cap 26 Spacer 34 Circlip 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 14 Bearing 22 Bearing 30 Gear 15 Spacer 23 Shaft Gear 31 Key 16 Circlip 24 Key 32 Gear 8 YILMAZ RED KT R b74 Operating Instructions D Series Part Designation 3 2 D 01 Types for 2 and 3 Staged Gear Units Only Valid For 3 Stages Standard D 01 type basic part diagram Parts may differ for special applications Standard Part List 1 Pin Screw 9 Bearing 17 Circlip 25
43. x 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 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 noi

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